Pathfinder™ Air Cooled Chillers

Pathfinder™ Air Cooled Chillers
Installation Manual
Pathfinder™ Air Cooled Chillers
IM 1002
Group: Chillers
Part Number: 10000199902
Date: June 11, 2009
Models AWS 280ADS to AWS 300ADS (Standard Efficiency)
Models AWS 300ADH to AWS 360ADH (High Efficiency)
280 to 350 Tons, 985 to 1230 kW
R-134a
50 Hz
© 2009 McQuay International
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation and Startup . . . . . . . . . . . . . . . . . . . . . 4
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Service Access . . . . . . . . . . . . . . . . . . . . . . . . 4
Clearance Requirements . . . . . . . . . . . . . . . . 5
Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . 6
Chilled Water. . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Water Volume . . . . . . . . . . . . . . . . . . 9
Variable Speed Pumping . . . . . . . . . . . . . . . . 9
Evaporator Freeze Protection . . . . . . . . . . . . 10
Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Adjustment Factors . . . . . . . . . .
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting & Mounting Weights . . . . . . . . . . . . . . . . .
Lifting and Mounting Locations . . . . . . . . . . . . .
Isolator Locations and Kit Numbers . . . . . . . . . .
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . .
10
11
13
15
20
21
24
26
30
33
Hazard Identification
DANGER
Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.
WARNING
Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not
avoided.
CAUTION
Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.
Modbus
Document:
Issue Date:
Revision Date:
Replaces:
IM 1002
June 2009
June 11, 2009
June 1, 2009
©2009 McQuay International. Illustrations and data cover the McQuay International product at the time of publication and we reserve the right to make changes in
design and construction at anytime without notice. ™® The following are trademarks or registered trademarks of their respective companies: BACnet from ASHRAE;
LONMARK, LonTalk, LONWORKS, and the LONMARK logo are managed, granted and used by LONMARK International under a license granted by Echelon
Corporation; ElectroFin from AST ElectroFin Inc.; Modbus from Schneider Electric; FanTrol, MicroTech III, Open Choices, and SpeedTrol from McQuay International
Introduction
Introduction
Figure 1: Model Nomenclature
A W S XXX A D S
Air-Cooled
World Product
Screw Compressor
Nominal Tons
S = Standard Efficiency
H = High Efficiency
Dual Compressor
Design Vintage
General Description
Daikin McQuay Pathfinder™ air-cooled chillers are complete,
self-contained chillers that include the latest in engineered
components arranged to provide a compact and efficient unit.
Each unit is completely assembled, factory wired, evacuated,
charged, tested and comes complete and ready for installation.
Each of two circuits consists of an air-cooled condenser
section with an integral subcooler section, a semi-hermetic,
single-screw compressor with starter, a multi-circuit, shelland-tube, direct expansion evaporator, an economizer and
complete refrigerant piping. Each compressor has an
independent refrigeration circuit. Liquid line components
included are a manual liquid line shutoff valve, charging port,
filter-drier, sight-glass/moisture indicator, and electronic
expansion valve. A combination discharge check and shutoff
valve is included and a compressor suction shutoff valve is
optional. Other features include compressor heaters,
evaporator heaters for freeze protection, automatic, one-time
pumpdown of each refrigerant circuit upon circuit shutdown,
and an advanced fully integrated microprocessor control
system.
A high ambient option is required for operation in ambient
temperatures above 105F (40.6C) and up to 125F (51.7C)
and when the VFD low ambient option is selected.
Information on the operation of the unit MicroTechIII
controller is in the OM 998 manual.
Inspection
When the equipment is received, carefully check all items
against the bill of lading to verify for a complete shipment.
Check all units for damage upon arrival. All shipping damage
must be reported to the carrier and a claim must be filed with
the carrier. Check the unit’s serial plate before unloading the
unit to be sure that it agrees with the power supply available.
Physical damage to a unit after shipment is not McQuay
International’s responsibility.
Note: Unit shipping and operating weights are shown in the
Physical Data Tables beginning on page 13.
Pathfinder units are available as standard efficiency (ADS) or
high efficiency (ADH)
Table 1: Operating Limits
Maximum standby ambient temperature
Maximum operating ambient temperature
with optional high ambient package (see detailed information on page 3
130°F (55°C)
105°F (40.6°C)
125°F (52°C)
Minimum operating ambient temperature (standard control)
35°F (2°C)
Minimum operating ambient temperature (with optional low-ambient control)
0°F (-18°C)
Leaving chilled water temperature
Leaving chilled fluid temperatures (with anti-freeze) - Unloading is not permitted with fluid leaving
temperatures below 30°F (-1°C).
Operating chilled water delta-T range
40°F to 60°F (4.4°C to 15.6°C)
20°F to 60°F (-7°C to 16°C)
6 to 18°F (-14 to -8°C)
Maximum evaporator operating inlet fluid temperature
76°F (24°C)
Maximum evaporator non-operating inlet fluid temperature
100°F (38°C)
IM 1002
3
Installation and Startup
Installation and Startup
Installation and maintenance are to be performed only by
qualified personnel who are familiar with local codes and
regulations, and experienced with this type of equipment.
WARNING
Sharp edges and coil surfaces are a potential injury hazard.
Avoid contact with them.
Start-up by McQuay Factory Service is included on all
Pathfinder units sold for installation within the U.S. and
Canada and must be performed by them to initiate the standard
Limited Product Warranty. Start-up by any party other than
McQuay Factory Service or a McQuay Authorized Service
Representative will void the Limited Product Warranty. Twoweek prior notification of start-up is required. The contractor
should obtain a copy of the Start-up Scheduled Request Form
from the sales representative or from the nearest McQuay
Factory Service office.
For pad-mounted units, it is recommended that the unit be
raised a few inches with suitable supports such as neoprene
waffle vibration pads, located at least under the mounting
locations. This will allow water to drain from under the unit
and facilitate cleaning under it.
Figure 2: Required Lifting Method
WARNING
Escaping refrigerant can displace air and cause suffocation.
Immediately evacuate and ventilate the equipment area. If the
unit is damaged, follow Environmental Protection Agency
(EPA) requirements. Do not expose sparks, arcing equipment,
open flame or other ignition source to the refrigerant.
Handling
DANGER
Improper lifting or moving of a unit can result in property
damage, severe personal injury or death. Follow rigging and
moving instructions carefully.
Avoid rough handling shock due to impact or dropping the
unit. Do not push or pull the unit. Never allow any part of the
unit to fall during unloading or moving, as this can result in
serious damage.
To lift the unit, lifting tabs with 3" (76 mm) diameter holes are
provided on the base of the unit. All lifting holes must be used
when lifting the unit. Spreader bars and cables should be
arranged to prevent damage to the condenser coils or unit
cabinet (see Figure 2).
Location
Locate the unit carefully to provide proper airflow to the
condenser. (SeeFigure 4, page 5 for required clearances.)Using
less clearance than shown in Figure 4can cause discharge air
recirculation to the condenser and could have a significant
detrimental effect on unit performance.
Due to the shape of the condenser coils on the Pathfinder
chillers, it is recommended that the unit be oriented so that
prevailing winds blow parallel to the unit length, thus
minimizing the wind effect on condensing pressure and
performance. If low ambient temperature operation is
expected, optional louvers should be installed if the unit has no
protection against prevailing winds.
4
NOTES:
1. Unit with 8 lifting points illustrated above; the number of
condenser sections, fans, and lifting points can vary from
this diagram.see lifting/mounting drawings beginning on
page page 41 to identfy the number of lifting points for a
specific unit.
2. All rigging points must be used. See weights at lifting
points beginning on page 39 for each specific size unit.
3. Crosswise and lengthwise spreader bars must be used to
avoid damage to unit.
Service Access
Compressors, filter-driers, and manual liquid line shutoff
valves are accessible on each side or end of the unit. The
evaporator heater is located on the barrel.
The control panels are located on the end of the chiller. The
left-hand control box contains the unit and circuit
microprocessors as well as transformers, fuses and terminal.
The right-hand panel contains a circuit breaker. A minimum of
four feet of clearance is required in front of the panels. The
side clearance required for airflow provides sufficient service
clearance.
IM 1002
Installation and Startup
g
On all Pathfinder units, the condenser fans and motors can be
removed from the top of the unit. The complete fan/motor
assembly can be removed for service. The fan blade must be
removed for access to wiring terminals at the top of the motor.
,
,
g
Single Point Disconnect Switch
Compressor #2
Circuit Breaker
Compressor #1
Circuit Breaker
DANGER
Disconnect, lockout and tag all power to the unit before
servicing condenser fan motors or compressors. Failure to do
so can cause bodily injury or death.
Do not block access to the sides or ends of the unit with piping
or conduit. These areas must be open for service access. Do
not block access to the control panels with field-mounted
disconnect switches.
Figure 3: Control and Power Panel Component Location
Alarm & Limit
Extension
Module
Controller
Fuse
Emergency
Switch
Relay
Clearance Requirements
Notes:
1 Minimum side clearance between two units is 12 feet
(3.7 meters).
2 Unit must not be installed in a pit or enclosure that is
MicroTech III
Main
Controller
Control
Circuit
Breaker
Optional
115V
Outlet
Unit On/Off
Switch
Cir #1 & #2
Fan Control
Extension
Module
Circuit #1
Pumpdown
Switch
Circuit #2
Pumpdown
Switch
deeper or taller than the height of the unit unless extra
clearance is provided per note 4.
3 Minimum clearance on each side is 8 feet (2.4 meters)
when installed in a pit no deeper than the unit height.
4 Minimum side clearance to a side wall or building taller
than the unit height is 6 feet (1.8 meters), provided no
solid wall above 6 feet (1.8 meters) is closer than 12 feet
(3.7 meters) to the opposite side of the unit.
5 Do not mount electrical conduits where they can block
service access to compressor controls, refrigerant driers
or valves.
NOTES:
1. The Emergency Switch Relay de-energizes circuit #1 and #2 control power when activated,
causing an immediate compressor and fan shutdown. The red emergency button switch is
located on the bottom front of the control panel door.
2. The control power transformer is located in the power panel adjacent to the control panel.
3. Additional extension (aka extension) modules are located elsewhere on the chiller.
6 There must be no obstruction of the fan discharge.
7 Field installed switches must not interfere with service
access or airflow.
Figure 4: Clearance Requirements
Fan Contactors, 1 per Fan
Circuit #1
Phase/Voltage
Monitor
No obstructions.
Recommended area
required for unit
operation, air flow
and maintenance
access.
Cir# 1, Fan Circuit Breaker
5ft (1.5m) if open fence or 50% open wall
6ft (1.8m) if solid wall (see note 3 for pit)
4ft (1.2m)
For electric
panel access
Fan Contactors
1 per Fan, Circuit #2
120/24V
Transformer
5ft (1.5m) if open fence or 50% open wall
6ft (1.8m) if solid wall (see note 3 for pit)
3ft (1m) for service
Line/120V
Transformer
See notes 2 & 4
concerning wall
height at unit sides.
Air Flow
No obstructions allowed
above unit at any height
See Note 5
Wall or
Fence
IM 1002
5
Installation and Startup
Restricted Air Flow
General
The clearances required for design operation of Pathfinder aircooled chillers are described in the previous section.
Occasionally, these clearances cannot be maintained due to site
restrictions such as units being too close together or a fence or
wall restricting airflow, or both. Pathfinder chillers have
several features that may help mitigate the penalties
attributable to restricted airflow.
"The condenser section is "W" shaped, as shown below. This
allows inlet air for these coils to come in from both sides and
the bottom. All the coils in one "V" section serve one
compressor. Each compressor has its own independent
refrigerant circuit.
The existence of a screening wall or the wall of a building in
close proximity to an air-cooled chiller is common in both
rooftop and ground level applications. Hot air recirculation on
the coils adjoining the wall will increase compressor discharge
pressure, decreasing capacity and increasing power
consumption.
When close to a wall, it is desirable to place chillers on the
north or east side of them. It is also desirable to have
prevailing winds blowing parallel to the unit's long axis. The
worst case is to have wind blowing hot discharge air into the
wall.
Figure 5: Unit Adjacent to Wall - Adjustment Factors
H
D
Building
"The MicroTech III control is proactive in response to "offdesign conditions". In the case of single or compounded
influences restricting airflow to the unit, the microprocessor
will act to keep the unit running (at reduced capacity), rather
than allowing a shut-off on high discharge pressure.
Case 1: Building or Wall on One Side of One Unit
Full Load Capacity Adjustment Factor
D=4 ft (1.2m)
Capacity Reduction (%)
1.00
0.75
0.50
D=5 ft (1.5m)
0.25
D=6 ft (1.8m)
0.00
8
(2.4)
16
(4.8)
24
(7.2)
H - Height of Wall or Building in ft. (m)
Full Load Power Adjustment Factor
D=4 ft (1.2m)
2.00
Power Increase (%)
1.50
1.00
D=5 ft (1.5m)
0.50
D=6 ft (1.8m)
0.00
8
(2.4)
16
(4.8)
24
(7.2)
H - Height of Wall or Building in ft. (m)
6
IM 1002
Installation and Startup
Case 2: Two Units Side By Side
Case 3: Three or More Units Side By Side
Two or more units sited side by side are common. If spaced
closer than 12 feet (3.7 meters) it is necessary to adjust the
performance of each unit; circuits adjoining each other are
affected. If one of the two units also has a wall adjoining it, see
Case 1. Add the two adjustment factors together and apply to
the unit located between the wall and the other unit.
When three or more units are side by side, the outside chillers
(1 and 3 in this case) are influenced by the middle unit only on
their inside circuits. Their adjustment factors will be the same
as Case 2. All inside units (only number 2 in this case) are
influenced on both sides and must be adjusted by the factors
shown below.
Mounting units end to end will not necessitate adjusting
performance.
Figure 7: Three or More Units - Adjustment Factor
Do not use pit or solid wall surrounds where the ambient air
temperature exceeds 105F (40C).
Figure 6: Two Units Side by Side - Adjustment Factors
Full Load Capacity Adjustment Factor
Full Load Capacity Adjustment Factor
Capacity Reduction (%)
1.50
Capacity Reduction (%)
3.00
2.00
1.00
1.00
0.00
8
(2.4)
0.50
12
(3.6)
16
(4.8)
20
(6.1)
Distance Between Units in ft. (m)
0.00
6
(1.8)
8
(2.4)
10
(3.0)
Full Load Power Adjustment Factor
12
(3.6)
6.00
Distance Between Units in ft. (m)
Power Increase (%)
Full Load Power Adjustment Factor
3.00
Power Increase (%)
2.50
4.00
2.00
2.00
0.00
1.50
8
(2.4)
12
(3.6)
16
(4.8)
20
(6.1)
1.00
Distance Between Units in ft. (m)
0.50
0.00
6
(1.8)
8
(2.4)
10
(3.0)
12
(3.6)
Distance Between Units in ft. (m)
IM 1002
7
Installation and Startup
Case 4: Open Screening Walls
Case 5, Pit/Solid Wall Installation
Decorative screening walls are often used to help conceal a
unit either on grade or on a rooftop. Design these walls such
that the combination of their open area and distance from the
unit do not require performance adjustment. It is assumed that
the wall height is equal to or less than the unit height when
mounted on its base support. This is usually satisfactory for
concealment. If the wall height is greater than the unit height,
see Case 5, Pit Installation.
Pit installations can cause operating problems. Use care if they
are to be used on an installation. Recirculation and restriction
can both occur. A solid wall surrounding a unit is substantially
the same as a pit and the data presented here should be used.
The distance from the sides of the unit to the side walls must
be sufficient for service, such as opening control panel doors.
If each side wall is a different distance from the unit, the
distances can be averaged providing either wall is not less than
8 feet (2.4 meters) from the unit. For example, do not average
4 feet and 20 feet to equal 12 feet (1 meter and 5 meters to
equal 3 meters).
Steel grating is sometimes used to cover a pit to prevent
accidental falls or trips into the pit. The grating material and
installation design must be strong enough to prevent such
accidents, yet provide abundant open area or serious
recirculation problems will occur. Have any pit installation
reviewed by the McQuay sales representative prior to
installation to make sure it has sufficient air-flow
characteristics. The installation design engineer must approve
the work to avoid an unreasonable risk of accident.
Figure 8: Open Screening Walls - Adjustment Factors
Figure 9: Pit Installation - Adjustment Factors
Fu ll Load P owe r Ad justme nt F ac tor
Wall Fre e Are a vs D istance
8 .00
D= 8 ft (2 .4 m )
8 .0 0
6 .00
6 .0 0
Power Increase (%)
D - Distance from Wall to Unit in Ft. (m)
D =6 ft (1 .8 m )
4 .00
D= 1 0 ft
(3 .1 m )
4 .0 0
2 .0 0
2 .00
0 .0 0
0 .00
0
10
20
30
40
50
8
(2 .4 )
10
(3 .1 )
12
(3 .7 )
14
(4 .3 )
% Ope n Wall Ar e a
H - He ig ht of W a ll or Building in ft. ( m )
8
IM 1002
Installation and Startup
Chilled Water
It is recommended that the chilled water pumps' starters be
wired to, and controlled by, the chiller's microprocessor. The
controller will energize the pump whenever at least one circuit
on the chiller is enabled to run, whether there is a call for
cooling or not. The control will also start the pump when
freezing temperatures are approached. Wiring connection
points are shown in Figure 23, page 30.
Water Piping
Due to the variety of piping practices, follow the
recommendations of local authorities. They can supply the
installer with the proper building and safety codes required for
a proper installation.
Design the piping with a minimum number of bends and
changes in elevation to keep system cost down and
performance up. It should contain:
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 and drains at the low parts in the system. The
evaporator should not be the highest point in the piping
system.
4 Some means of maintaining adequate system water
pressure (i.e., expansion tank or regulating valve).
5 Water temperature and pressure indicators located at the
evaporator inlet and outlet to aid in unit servicing. Any
connections should be made prior to filling the system
with water.
6 A strainer to remove 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 help maintain high
system performance levels. Note: A 20-mesh strainer
must also be placed in the supply water line just prior to
the inlet of the evaporator. This will aid in preventing
foreign material from entering the evaporator and
causing damage or decreasing its performance. Care
must also be exercised if welding pipe or flanges to the
evaporator connections to prevent any weld slag from
entering the vessel.
7 Any water piping to the unit must be protected to prevent
freeze-up if below freezing temperatures are expected.
8 If the unit is used as a replacement chiller on a
previously existing piping system, flush the system
thoroughly prior to unit installation. Perform regular
chilled water analysis and chemical water treatment
immediately at equipment start-up.
9 In the event glycol is added to the water system as a late
addition for freeze protection, recognize that the
IM 1002
refrigerant suction pressure will be lower, cooling
performance less, and water side pressure drop greater. If
the percentage of glycol is large, or if propylene is
employed in lieu of ethylene glycol, the added pressure
drop and loss of performance could be substantial.
10 For ice making or low temperature glycol operation, a
different freezestat pressure value is usually required.
The freezestat setting can be manually changed through
the MicroTech III controller.
Make a preliminary leak check prior to insulating the water
piping and filling the system.
Include a vapor barrier with the piping insulation to prevent
moisture condensation and possible damage to the building
structure. It is important to have the vapor barrier on the
outside of the insulation to prevent condensation within the
insulation on the cold surface of the pipe.
System Water Volume
All chilled water systems need adequate time to recognize a
load change, respond to that load change and stabilize, without
undesirable short cycling of the compressors or loss of control.
In air conditioning systems, the potential for short cycling
usually exists when the building load falls below the minimum
chiller plant capacity or on close-coupled systems with very
small water volumes.
Some of the things the designer should consider when looking
at water volume are the minimum cooling load, the minimum
chiller plant capacity during the low load period and the
desired cycle time for the compressors.
Assuming that there are no sudden load changes and that the
chiller plant has reasonable turndown, a rule of thumb of
"gallons of water volume equal to two to three times the
chilled water gpm flow rate" is often used.
A properly designed storage tank should be added if the
system components do not provide sufficient water volume.
Variable Speed Pumping
Variable water flow involves reducing the water flow through
the evaporator as the load decreases. McQuay chillers are
designed for this duty, provided that the rate of change in water
flow is slow, and the minimum and maximum flow rates for
the vessel are not exceeded.
The recommended maximum change in water flow is 10
percent of the change per minute. For example, if the
maximum (design) flow is 200 gpm and the flow is reduced to
a minimum of 140 gpm, the change in flow is 60 gpm, so the
maximum change per minute would be 10% of 60, or 6 gpm
per minute. It would take ten minutes to change the flow
through the entire range.
The water flow through the vessel must remain between the
minimum and maximum values listed on page 19. If flow
drops below the minimum allowable, large reductions in heat
9
Installation and Startup
transfer can occur. If the flow exceeds the maximum rate,
excessive pressure drop and tube erosion can occur.
Evaporator Freeze Protection
Pathfinder chillers are equipped with thermostatically
controlled evaporator heaters that help protect against freezeup down to -20°F (-28°C). For additional protection, at least
one of the followingprocedures should be used during periods
of sub-freezing temperatures:
1 Adding of a concentration of a glycol anti-freeze with a
freeze point 10°F. below the lowest expected
temperature. This will result in decreased capacity and
increased pressure drop.
Note: Do not use automotive grade antifreezes as they contain
inhibitors harmful to chilled water systems. Use only
glycols specifically designated for use in building cooling
systems.
Flow Switch
A flow switch must be included in the chilled water system to
prove that there is adequate water flow before the unit can
start. It also serves to shut down the unit in the event that water
flow is interrupted in order to guard against evaporator freezeup.
A factory-mounted, solid state, thermal dispersion flow switch
is available as an option. A field-installed version is also
available as a kit (Accessory part number 332688401).
A paddle-type flow switch for field mounting and wiring is
also available as a kit (Accessory part number 017503300). It
is adaptable to pipe sizes from 1" (25mm) to 8" (203mm).
Certain minimum flow rates are required to close the switch
and are listed in Table 3. Installation should be as shown in
Figure 10.
2 Draining the water from outdoor equipment and piping
Flow direction marked
Flow
marked
on
s witdirection
ch
on switch
1" (25mm) NPT flow
1" (25mm)
NPT flow
switch
connection
switch connection
and blowing the chiller tubes dry from the chiller. Do not
energize the chiller heater when water is drained from
the vessel.
3 Providing operation of the chilled water pump,
circulating water through the chilled water system and
through the evaporator
Note: The heaters come from the factory connected to the
control power circuit. The control power can be rewired
in the field to a separate 115V supply (do not wire directly
to the heater). See the field wiring diagram on page 30. If
this is done, it should power the entire control circuit.
Mark the disconnect switch clearly to avoid accidental
deactivation of the heater during freezing temperatures.
Exposed chilled water piping also requires protection. If
the evaporator is drained for winter freeze protection, the
heaters must be de-energized to prevent heater
burnout..
Table 2: Freeze Protection
% Volume Glycol Concentration Required
Temp.
For Freeze Protection For Burst Protection
F (C)
Ethylene Propylene Ethylene Propylene
Glycol
Glycol
Glycol
Glycol
20 (6.7)
10 (-12.2)
0 (-17.8)
-10 (-23.3)
-20 (-28.9)
-30 (-34.4)
-40 (-40.0)
-50 (-45.6)
-60 (-51.1)
Note:
Note:
Note:
10
16
25
33
39
44
48
52
56
60
18
29
36
42
46
50
54
57
60
11
17
22
26
30
30
30
30
30
12
20
24
28
30
33
35
35
35
Tee
Tee
1 1/4" (32mm) pipe
1 1/4"
pipe
dia.
min.(32mm)
after switch
dia. min. after switch
1 1/4" (32mm) pipe
1 1/4"
pipe
dia.
min. (32mm)
before switch
dia. min. before switch
Electrical connections in the unit control center should be
made at terminals 60 and 67 from switch terminals Y and R.
The normally open contacts of the flow switch should be wired
between these two terminals. Flow switch contact quality must
be suitable for 24 VAC, low current (16ma). Flow switch wire
must be in separate conduit from any high voltage conductors
(115 VAC and higher) and have an insulation rating of 600
volts.
“Freeze protection” maintains the solution ina pumpable, usable
liquid state. “Burst protection” prevents pipes from rupturing, but
solution may be in a gel state and not pumpable. In most
applications, “burst” protection is sufficient; concentrations over 30%
Ethylene Glycol or 35% Propylene Glycol will result in efficiency and
capacity losses with negligible protection increases
These figures are examples only and cannot be appropriate to every
situation. Generally, for an extended margin of protection, select a
temperature at least 15°F lower than the expected lowest ambient
temperature. Inhibitor levels should be adjusted for solutions less
than 25% glycol.
Glycol of less than 25% concentration is not recommended because
of the potential for bacterial growth and loss of efficiency.
IM 1002
Installation and Startup
Table 3: Paddle Type Flow Switch Flow Rates
Pipe Size
inch
1 1/4
1 1/2
2
2 1/2
3
4
5
6
8
mm
32
38
51
63
76
102
127
153
204
(4)
(4)
(4)
(5)
18.0
27.5
65.0
125.0
190.0
205.0
(NOTE)
Flow
Min.
Adjst.
No Flow
Flow
Max.
Adjst.
No Flow
Note:
1
Note:
2Flow
Note:
3
Note:
4Flow
Note:
5
-
(2)
(2)
gpm
5.8
7.5
13.7
(3)
Lpm
1.3
1.7
3.1
4.1
6.2
14.8
28.4
43.2
46.6
gpm
3.7
5.0
9.5
12.5
19.0
50.0
101.0
158.0
170.0
Lpm
0.8
1.1
2.2
2.8
4.3
11.4
22.9
35.9
38.6
gpm
13.3
19.2
29.0
34.5
53.0
128.0
245.0
375.0
415.0
Lpm
3.0
4.4
6.6
7.8
12.0
29.1
55.6
85.2
94.3
gpm
12.5
18.0
27.0
32.0
50.0
122.0
235.0
360.0
400.0
Lpm
2.8
4.1
6.1
7.3
11.4
27.7
53.4
81.8
90.8
A segmented 3-inch paddle (1, 2, and 3 inches) is furnished mounted, plus a 6-inch paddle loose.
rates for a 2-inch paddle trimmed to fit the pipe.
Flow rates for a 3-inch paddle trimmed to fit the pipe.
rates for a 3-inch paddle.
Flow rates for a 6-inch paddle.
Figure 10: Typical Field Water Piping
2 Flow - To determine flow (or Delta-T) knowing Delta-T
(or flow) and capacity:
Suction
In
Vibration
Valved Eliminator
Pressure
Gauge
Out
Liquid
Drain
GPM 
Water
Strainer
Vent
Flow
Gate
Valve
Protect All Field Piping
Against Freezing
Flow
Vibration Flow
Balancing Gate
Eliminator Switch
Valve Valve
Note: Connections for vent and drain fittings are located on the
top and bottom of the evaporator.
Note: Piping must be supported to avoid putting strain on the
evaporator nozzles.
Refrigerant Charge
All packaged units are designed for use with R-134a and are
shipped with a full operating charge. The operating charge for
each unit is shown in the Physical Data Tables beginning on
page 13.
Glycol Solutions
When using glycol anti-freeze solutions, the chiller's capacity,
glycol solution flow rate, and pressure drop through the
evaporator can be calculated using the following formulas and
tables.
Note: The procedure below does not specify the type of
glycol. Use the derate factors found in Table 4 or Table 5
forcorrections when using glycol.
1 Capacity - Cooling capacity is reduced from that with
plain water. To find the reduced value, multiply the
chiller’s water system tonnage by the capacity correction
factor to find the chiller’s capacity when using glycol.
IM 1002
24 tons   flow
factor 
Delta  T
3 Pressure drop - To determine pressure drop through the
evaporator when using glycol, enter the water pressure
drop curve at the water flow rate. Multiply the water
pressure drop found there by the "PD" factor to obtain
corrected glycol pressure drop.
4 Power - To determine glycol system kW, multiply the
water system kW by the factor designated "Power".
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, the supplier normally
recommends that a minimum of 25% solution by weight be
used for protection against corrosion or that additional
inhibitors should be employed.
Note: Do not use automotive grade antifreeze. Industrial grade glycols
must be used. Automotive antifreeze contains inhibitors that will
cause plating on the copper tubes within the chiller evaporator.
The type and handling of glycol used must be consistent with
local codes.
Performance Adjustment Factors
Ethylene and Propylene Glycol Factors
Pathfinder chiller units are designed to operate with leaving
chilled fluid temperatures of 20.0°F to 60.0°F (-6.7°C to
15.6°C). Consult the local McQuay sales office for
performance outside these temperatures. Leaving chilled fluid
temperatures below 40°F (4.4°C) result in evaporating
temperatures at or below the freezing point of water and a
glycol solution is required. MicroTech III control inhibits
compressor unloading at leaving fluid temperatures below
30°F (-1°C)
11
Installation and Startup
.
Table 4: Ethylene Glycol Correction Factors
% E.G
Freeze Point
Table 7: Electric Power Connection Option
Capacity
Power
Flow
PD
0.991
0.996
1.013
1.070
0.982
0.992
1.040
1.129
-13.9
0.972
0.986
1.074
1.181
-7
-21.7
0.961
0.976
1.121
1.263
-28
-33.3
0.946
0.966
1.178
1.308
o
10
F
26
o
C
-3.3
20
18
-7.8
30
7
40
50
Table 5: Propylene Glycol Correction Factors
% P.G
Freeze Point
Capacity
Power
Flow
PD
1.120
oF
oC
10
26
-3.3
0.985
0.993
1.017
20
19
-7.2
0.964
0.983
1.032
1.272
30
9
-12.8
0.932
0.969
1.056
1.496
40
-5
-20.6
0.889
0.948
1.092
1.792
50
-27
-32.8
0.846
0.929
1.139
2.128
Multi-Point
Power Connection
Single-Point
Power Connection
Standard:
Disconnect switch per circuit, no
compressor isolation circuit breakers
Optional:
one power block, compressor
isolation circuit breakers
Optional:
High interrupt rated disconnect
switches, no compressor isolation
circuit breakers
Optional:
One disconnect switch replacing
the power block, compressor
isolation circuit breakers
Optional:
High short circuit current rated
panel, high interrupt disconnect
switches, no compressor isolation
circuit breakers
Optional:
One high interrupt rated
disconnect switch, compressor
isolation circuit breakers
Optional:
High short circuit current rated
panel, one high interrupt
disconnect switch, compressor
isolation circuit breakers
Note:
Table 6: Ambient Freeze Protection
Temperature
F (C)
20 (6.7)
10 (-12.2)
0 (-17.8)
-10 (-23.3)
-20 (-28.9)
-30 (-34.4)
-40 (-40.0)
-50 (-45.6)
-60 (-51.1)
Note:
Note:
Note:
Percent Volume Glycol Concentration Required
For Freeze Protection
For Burst Protection
Ethylene
Propylene
Ethylene
Propylene
Glycol
Glycol
Glycol
Glycol
16
18
11
12
25
29
17
20
33
36
22
24
39
42
26
28
44
46
30
30
48
50
30
33
52
54
30
35
56
57
30
35
60
60
30
35
In most applications, “burst” protection is sufficient; concentrations
over 30% Ethylene Glycol or 35% Propylene Glycol will result in
efficiency and capacity losses with negligible protection increases.
These figures are examples only and may not be appropriate to
every situation. Generally, for an extended margin of protection,
select a temperature at least 10°F (-12°C) lower than the expected
lowest ambient temperature. Adjust inhibitor levels for solutions
less than 25% glycol
Glycol of less than 25% concentration is not recommended because
of the potential for bacterial growth and subsequent loss of heat
transfer efficiency. Additional inhibitors may be required.
Electrical Connections
All wiring must be done in accordance with applicable local
and national codes. Pathfinder units can be ordered with either
standard multi-point power or optional single point power
connections and with various disconnect and circuit breaker
options. Wiring within the unit is sized in accordance with the
U.S.A. National Electrical Code. Field-supplied disconnect
switches are required if not factory-supplied with the unit.
12
Note:
Note:
Note:
Note:
Disconnect switches are molded case construction with lockable
through-the-door handles. They can be used to remove the unit/
circuit from the power system.
The individual compressor isolation circuit breakers for each circuit
isolate the compressor and do not have through-the-door handles.
They are operable only after the panel doors are opened.
The high short circuit rated panel means that a short circuit current
up to the ratings shown in Table 8, Interrupt Ratings (kAmps)will be
contained in the panel. There is a short period of time when the
circuit breaker will short circuit before opening a circuit that can
damage downstream components. In other words, the enclosure is
stronger than a standard enclosure. It has a high interrupt rated
disconnect switch.
The factory-mounted control power transformer is protected by fuses.
Condenser fans are protected and isolated by circuit breakers.
Table 8: Interrupt Ratings (kAmps)
VOLTAGE
460
STANDARD
SHORT
CIRCUIT
PANEL
RATING
35 kA
HIGH
INTERRUPT
DISCONNECT
SWITCH
HIGH SHORT
CIRCUIT
RATED
PANEL
35 kA
65 kA
Disconnecting means are addressed by Article 440 of the
U.S.A. National Electrical Code (NEC), which requires
“disconnecting means capable of disconnecting air
conditioning and refrigerating equipment including motorcompressors, and controllers from the circuit feeder.” Select
and locate the disconnect switch per the NEC guidelines.
Maximum recommended fuse sizes are given in the electrical
data tables of this catalog for help in sizing the disconnect.
Terminals are provided in a unit control panel for optional field
hookup of the control circuit to a separate fused 115-volt
power supply in lieu of the standard factory installed control
transformer.
IM 1002
Physical Data
Physical Data
Table 9: Physical Data, Standard Efficiency 50 Hz
Pathfinder Chiller Model Numbers
DATA
AWS280ADS Std Eff
CIRCUIT 1
CIRCUIT 2
AWS300ADS Std Eff
CIRCUIT 1
CIRCUIT 2
BASIC DATA
Unit Cap. @ AHRI tons (kW)
273.4 (961.6)
185 (84)
185 (84)
294.1 (1034.4)
185 (84)
185 (84)
316 x 88 x 101
(8027 x 2235 x 2565)
316 x 88 x 101
(8027 x 2235 x 2565)
Unit Operating Weight, lbs. (kg)
17434 (7908)
17434 (7908)
Unit Shipping Weight, lbs (kg)
16567 (7515)
16567 (7515)
Weight-Add for Copper Fins
2372
2372
Weight-Add for Louvered Panels
1034
1034
Weight-Add for Sound Enclosures
477
477
Unit Operating Charge lbs (kg)
Unit Dimensions
L x W x H, in. (mm)
COMPRESSORS, SCREW, SEMI-HERMETIC
Nominal Capacity, tons (kW)
150 (528)
125 (140)
Oil charge per circuit , gallons (liters)
150 (528)
150 (528)
15
Minimum Capacity (% of Full Load)
15
6.6 (25)
6.6 (25)
6.6 (25)
6.6 (25)
CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER
Pumpdown Capacity, lbs (kg)
Coil Inlet Face Area, sq. ft. (sq m.)
Rows Deep/Fins Per Inch
370 (168)
370 (168)
370 (168)
370 (168)
196.9 (18.3)
196.9 (18.3)
196.9 (18.3)
196.9 (18.3)
3 / 16
3 / 16
3 / 16
3 / 16
8
8
CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE
Number of Fans per Circuit
Fan Diameter: 31.5 in. (800 mm)
Fan Motor hp (kW)
Fan & Motor RPM, 50Hz
8
8
1.4 (1.05)
1.4 (1.05)
850
850
EVAPORATOR, DIRECT EXPANSION SHELL AND TUBE
Shell Dia.-Tube Length, in.(mm)
Water Volume, gallons (liters)
20 x 108 / (508 x 2750)
20 x 108 / (508 x 2750)
103.9 (393.3)
103.9 (393.3)
8 (203)
8 (203)
Max. Water Pressure, psi (kPa)
152 (1048)
152 (1048)
Max. Refrigerant Press., psi (kPa)
325 (2241)
325 (2241)
Victaulic inlet/outlet conn. in. (mm)
IM 1002
13
Physical Data
Table 10: Physical Data, High Efficiency 50 Hz
Pathfinder Chiller Model Numbers
DATA
AWS300ADH High Eff
CIRCUIT 1
CIRCUIT 2
AWS320ADH High Eff
CIRCUIT 1
CIRCUIT 2
AWS350ADH High Eff
CIRCUIT 1
CIRCUIT 2
BASIC DATA
Unit Cap. @ AHRI tons (kW)
Unit Operating Charge lbs (kg)
287.4 (1010.8)
200 (91)
314.8 (1107.2)
200 (91)
237 (107)
341.6 (1201.4)
237 (107)
237 (107)
237 (107)
316 x 88 x 101
(8027 x 2235 x 2565)
387 x 88 x 101
(9830 x 2235 x 2565)
387 x 88 x 101
(9830 x 2235 x 2565)
Unit Operating Weight, lbs. (kg)
17724 (8040)
19656 (8916)
19656 (8916)
Unit Shipping Weight, lbs (kg)
16857 (7646)
18789 (8523)
18789 (8523)
Weight-Add for Copper Fins
2372
2968
2968
Weight-Add for Louvered Panels
1034
1262
1262
Weight-Add for Sound Enclosures
477
477
477
Unit Dimensions
L x W x H, in. (mm)
COMPRESSORS, SCREW, SEMI-HERMETIC
Nominal Capacity, tons (kW)
150 (528)
150 (528)
Oil charge per circuit , gallons (liters)
175 (615)
150 (528)
15
Minimum Capacity (% of Full Load)
175 (615)
175 (615)
15
6.6 (25)
6.6 (25)
15
6.6 (25)
6.6 (25)
6.6 (25)
6.6 (25)
CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER
Pumpdown Capacity, lbs (kg)
Coil Inlet Face Area, sq. ft. (sq m.)
Rows Deep/Fins Per Inch
370 (168)
370 (168)
462 (210)
462 (210)
462 (210)
462 (210)
196.9 (18.3)
196.9 (18.3)
246.1 (22.8)
246.1 (22.8)
246.1 (22.8)
246.1 (22.8)
3 / 16
3 / 16
3 / 16
3 / 16
3 / 16
3 / 16
10
10
10
10
CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE
Number of Fans per Circuit
Fan Diameter: 31.5 in. (800 mm)
Fan Motor hp (kW)
8
8
1.4 (1.05)
1.4 (1.05)
1.4 (1.05)
850
850
850
20 x 108 / (508 x 2750)
20 x 108 / (508 x 2750)
20 x 108 / (508 x 2750)
103.9 (393.3)
103.9 (393.3)
103.9 (393.3)
8 (203)
8 (203)
8 (203)
Max. Water Pressure, psi (kPa)
152 (1048)
152 (1048)
152 (1048)
Max. Refrigerant Press., psi (kPa)
325 (2241)
325 (2241)
325 (2241)
Fan & Motor RPM, 50Hz
EVAPORATOR, DIRECT EXPANSION SHELL AND TUBE
Shell Dia.-Tube Length, in.(mm)
Water Volume, gallons (liters)
Victaulic inlet/outlet conn. in. (mm)
14
IM 1002
7.1
89.1
21.3
IM 1002
92.9
8" NOMINAL PIPE
CONNECTION
OUTLET
INLET
315.8
118.0
109.2
VENT - FOR UNITS WITH
AMBIENT ABOVE 105
°F
11.4
15.8
4.7
REF
42.3
9.1
92.7
11.1 REF.
FIELD CONTROL
CONNECTIONS
(3) .88 K.O.'S IN
BOTTOM OF C-BOX
23.6 REF.
POWER ENTRY
IN BOTTOM OF C-BOX
REMOVEABLE COVER
9 X 12.5 OPENING
87.6
DOES NOT INCLUDE
LIFTING LUGS
29.9
EVAP IN/OUT
42.6
AWS280ADS 50HZ 400V 10000199824C0300
40.4
100.3
Dimensions
Dimensions
Figure 11: Physical Dimensions - AWS280 Standard Efficiency, 50 Hz
Note: All dimensions in decimal inches. Allow 1-inch manufacturing tolerance on all dimensions
15
7.1
89.1
21.3
16
92.9
8" NOMINAL PIPE
CONNECTION
OUTLET
INLET
315.8
118.0
109.2
VENT - FOR UNITS WITH
AMBIENT ABOVE 105
°F
11.4
15.8
4.7
REF
42.3
9.1
92.7
11.1 REF.
FIELD CONTROL
CONNECTIONS
(3) .88 K.O.'S IN
BOTTOM OF C-BOX
23.6 REF.
POWER ENTRY
IN BOTTOM OF C-BOX
REMOVEABLE COVER
9 X 12.5 OPENING
87.6
DOES NOT INCLUDE
LIFTING LUGS
29.9
EVAP IN/OUT
42.6
AWS300ADS 50HZ 400V 10000199824C0300
40.4
100.3
Dimensions
Figure 12: Physical Dimensions - AWS300 Standard Efficiency, 50 Hz
Note: All dimensions in decimal inches. Allow 1-inch manufacturing tolerance on all dimensions
IM 1002
7.1
89.1
21.3
IM 1002
92.9
8" NOMINAL PIPE
CONNECTION
OUTLET
INLET
315.8
118.0
108.5
VENT - FOR UNITS WITH
AMBIENT ABOVE 105
°F
11.4
15.8
4.7
REF
42.3
9.1
74.0
11.1 REF.
FIELD CONTROL
CONNECTIONS
(3) .88 K.O.'S IN
BOTTOM OF C-BOX
23.6 REF.
POWER ENTRY
IN BOTTOM OF C-BOX
REMOVEABLE COVER
9 X 12.5 OPENING
87.6
DOES NOT INCLUDE
LIFTING LUGS
29.9
EVAP IN/OUT
42.7
39.7
AWS300ADH 50HZ 400V 10000199824C0100
100.3
Dimensions
Figure 13: Physical Dimensions - AWS300 High Efficiency, 50 Hz
Note: All dimensions in decimal inches. Allow 1-inch manufacturing tolerance on all dimensions
17
18
7.1
7.1
160.0
160.0
21.3
21.3
92.9
8" NOMINAL PIPE
8" NOMINAL
PIPE
CONNECTION
CONNECTION
92.9
OUTLET
INLET
OUTLET
INLET
386.7 386.7
118.0
118.0
128.2
128.2
VENT VENT
- FOR-UNITS
WITHWITH
FOR UNITS
AMBIENT
ABOVE
105 105
AMBIENT
ABOVE
°F °F
11.411.4
15.8
15.8
4.7 4.7
REFREF
42.3
42.3
92.792.7
9.1 9.1
11.111.1 REF.REF.
FIELD
FIELDCONTROL
CONTROL
CONNECTIONS
CONNECTIONS
(3)(3).88.88K.O.K.O.
'S 'INS IN
BOTTOMOFOFC-BOX
C-BOX
BOTTOM
23.623.6 REF.REF.
POWER
POWERENTRY
ENTRY
IN IN
BOTTOM
BOTTOMOFOFC-BOX
C-BOX
REMOVEABLE
REMOVEABLECOVER
COVER
9 X912.5
X 12.5OPENING
OPENING
87.6
87.6
DOES NOT INCLUDE
DOES NOT
INCLUDE
LIFTING
LUGS
LIFTING LUGS
29.9
29.9
EVAPIN/OUT
IN/OUT
EVAP
43.2
43.2
42.3
42.3
100.3
100.3
AWS320ADH
AWS320ADH400V
400V50HZ
50HZ10000199826C010B
10000199826C010B
Dimensions
Figure 14: Physical Dimensions - AWS320 High Efficiency, 50 Hz
Note: All dimensions in decimal inches. Allow 1-inch manufacturing tolerance on all dimensions
IM 1002
IM 1002
7.1
160.0
21.3
8" NOMINAL PIPE
CONNECTION
OUTLET
386.7
92.9
INLET
118.0
128.2
VENT - FOR UNITS WITH
AMBIENT ABOVE 105
°F
11.4
15.8
4.7
REF
42.3
9.1
92.7
11.1 REF.
FIELD CONTROL
CONNECTIONS
(3) .88 K.O.'S IN
BOTTOM OF C-BOX
23.6 REF.
POWER ENTRY
IN BOTTOM OF C-BOX
REMOVEABLE COVER
9 X 12.5 OPENING
87.6
DOES NOT INCLUDE
LIFTING LUGS
29.9
EVAP IN/OUT
43.2
42.3
100.3
AWS350ADH 400V 50HZ 10000199826C010B
Dimensions
Figure 15: Physical Dimensions - AWS350 High Efficiency, 50 Hz
Note: All dimensions in decimal inches. Allow 1-inch manufacturing tolerance on all dimensions
19
Lifting & Mounting Weights
Lifting & Mounting Weights
Table 11: Lifting and Mounting Weights (I-P Units)
UNIT SIZE
VOLT
Hz
M10
3092 2920 2500 2361 1768 1670 1161 1097 3240 3061 2758 2605 1854 1751 1114 1052
-
-
16
3092 2920 2500 2361 1768 1670 1161 1097 3240 3061 2758 2605 1854 1751 1114 1052
-
-
50
16
3154 3003 2541 2420 1784 1699 1156 1101 3300 3143 2802 2669 1870 1781 1107 1054
-
-
400
50
20
3379 3284 2875 2795 1950 1895 1324 1287 3269 3177 2941 2859 2327 2262 1431 1391
-
-
400
50
20
3379 3284 2875 2795 1950 1895 1324 1287 3269 3177 2941 2859 2327 2262 1431 1391
-
-
400
50
16
AWS300
Std Eff
400
50
AWS300
High Eff
400
AWS320
High Eff
AWS350
High Eff
L1
L2
L3
L4
L5
L6
L7
MOUNTING LOADS FOR EACH POINT (LBS)
M9
AWS280
Std Eff
Note:
Note:
LIFTING WEIGHT FOR EACH POINT (LBS)
# OF
FANS
L8
M1
M2
M3
M4
M5
M6
M7
M8
Lifting and Mounting locations begin onpage 21
See Physical Data Tables, beginning on page 13, for Shipping and Operating Weights, and weight adjustments for accessories and options.
Table 12: Lifting and Mounting Weights (SI Units)
UNIT SIZE
VOLT
Hz
# OF
FANS
LIFTING WEIGHT FOR EACH POINT (KG)
L5
L6
L7
L8
1403 1325 1134 1071
802
758
527
16
1403 1325 1134 1071
802
758
50
16
1431 1362 1153 1098
809
400
50
20
1533 1490 1304 1268
400
50
20
1533 1490 1304 1268
AWS280
Std Eff
400
50
16
AWS300
Std Eff
400
50
AWS300
High Eff
400
AWS320
High Eff
AWS350
High Eff
L1
L2
L3
L4
MOUNTING LOADS FOR EACH POINT (KG)
M1
M2
M3
M4
M5
M6
M7
M8
M9
M10
498
1470 1388 1251 1182
841
794
505
477
-
-
527
498
1470 1388 1251 1182
841
794
505
477
-
-
771
524
499
1497 1426 1271 1211
848
808
502
478
-
-
885
860
601
584
1483 1441 1334 1297 1056 1026
649
631
-
-
885
860
601
584
1483 1441 1334 1297 1056 1026
649
631
-
-
Lifting and Mounting locations begin onpage 21
See Physical Data Tables, beginning on page 13, for Shipping and Operating Weights, and weight adjustments for accessories and options.
20
IM 1002
Lifting and Mounting Locations
Lifting and Mounting Locations
Figure 16: Lifting & Mounting Locations - AWS280 Standard Efficiency, 50Hz
-
.
-
-
.
.
-
$0/530-#09
.
.
-
.
-
-
.
.
-
Figure 17: Lifting & Mounting Locations - AWS300 Standard Efficiency, 50Hz
-
.
-
-
.
.
-
$0/530-#09
.
.
IM 1002
-
.
-
-
.
.
-
21
Lifting and Mounting Locations
Figure 18: Lifting & Mounting Locations - AWS300 High Efficiency, 50Hz
-
.
-
-
.
.
-
$0/530-#09
.
.
-
.
-
-
.
.
-
Figure 19: Lifting & Mounting Locations - AWS320 High Efficiency, 50Hz
-
-
-
-
.
-
.
-
.
.
-
$0/530-#09
.
.
.
.
-
22
IM 1002
Lifting and Mounting Locations
Figure 20: Lifting & Mounting Locations - AWS350 High Efficiency, 50Hz
-
-
-
-
.
-
.
-
.
.
-
$0/530-#09
.
.
.
.
-
IM 1002
23
Isolator Locations and Kit Numbers
Isolator Locations and Kit Numbers
Transfer the unit as indicated under Handling on page 4. In all
cases, set the unit in place and level with a spirit level. When
spring-type isolators are required, install springs running under
the main unit supports.
Figure 21: Spring Isolators - CP-4
The unit should be set initially on shims or blocks at the listed
spring free height. When all piping, wiring, flushing, charging,
etc., is completed, the springs are adjusted upward to loosen
the blocks or shims that are then removed.
A rubber anti-skid pad should be used under isolators if holddown bolts are not used.
Installation of spring isolators requires flexible piping
connections and at least three feet of flexible electrical conduit
to avoid straining the piping and transmitting vibration and
noise.
Figure 22: Neoprene-in-Shear Isolators - RP-4
6.25
5.00
3.75
3.00
ø .500-13NC-2B
R4
VM&C
.56 TYP.
VM&C
4.63
3.87
R.28
TYP.
R4
R.250 TYP.
RECESSED
GRIP RIBS
DURULENE
MATERIAL
R.750 TYP.
1.13 ± .25
APPROX.
1.63
.38
NOTES:
1.
24
RAISED GRIP RIBS
MOUNT MATERIAL TO BE DURULENE RUBBER.
2.
MOLDED STEEL AND ELASTOMER MOUNT FOR
OUTDOOR SERVICE CONDITIONS.
3.
RP-4 MOUNT VERSION WITH STUD IN PLACE.
DRAWING NUMBER 3314814
ALL DIMENSIONS ARE IN DECIMAL INCHES
IM 1002
Isolator Locations and Kit Numbers
Table 13: Spring Isolators (for Units with Aluminum Fin Condensers)
UNIT SIZE VOLT Hz # OF FANS
Kit P/N
M1
M2
M3
M4
M5
M6
M7
M8
M9
M10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
M9
M10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
M9
M10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
M9
M10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
332620800 332620800 332620800 332620800 332620600 332620600 332620400 332620400
AWS280
Std Eff
400 50
AWS300
Std Eff
400 50
AWS300
High Eff
400 50
AWS320
High Eff
400 50
AWS350
High Eff
400 50
16
332320801
Dk. Green Dk. Green Dk. Green Dk. Green Dk. Purple Dk. Purple
Red
Red
332620800 332620800 332620800 332620800 332620600 332620600 332620400 332620400
16
332320801
Dk. Green Dk. Green Dk. Green Dk. Green Dk. Purple Dk. Purple
Red
Red
332620800 332620800 332620800 332620800 332620600 332620600 332620400 332620400
16
332320801
Dk. Green Dk. Green Dk. Green Dk. Green Dk. Purple Dk. Purple
Red
Red
332620900 332620900 332620900 332620900 332620800 332620800 332620500 332620500
20
332320802
Gray
Gray
Gray
Gray
Dk. Green Dk. Green
Black
Black
332620900 332620900 332620900 332620900 332620800 332620800 332620500 332620500
20
332320802
Gray
Gray
Gray
Gray
Dk. Green Dk. Green
Black
Black
M7
M8
Table 14: Spring Isolators (for Units with Copper Fin Condensers)
UNIT SIZE VOLT Hz # OF FANS
Kit P/N
M1
M2
M3
M4
M5
M6
332620900 332620900 332620900 332620900 332620800 332620800 332620500 332620500
AWS280
Std Eff
400 50
AWS300
Std Eff
400 50
AWS300
High Eff
400 50
AWS320
High Eff
400 50
AWS350
High Eff
400 50
16
332320802
Gray
Gray
Gray
Gray
Dk. Green Dk. Green
Black
Black
332620900 332620900 332620900 332620900 332620800 332620800 332620500 332620500
16
332320802
Gray
Gray
Gray
Gray
Dk. Green Dk. Green
Black
Black
332620900 332620900 332620900 332620900 332620800 332620800 332620500 332620500
16
332320802
Gray
Gray
Gray
Gray
Dk. Green Dk. Green
Black
Black
332620900 332620900 332620900 332620900 332620800 332620800 332620600 332620600
20
332320803
Gray
Gray
Gray
Gray
Dk. Green Dk. Green Dk. Purple Dk. Purple
332620900 332620900 332620900 332620900 332620800 332620800 332620600 332620600
20
332320803
Gray
Gray
Gray
Gray
Dk. Green Dk. Green Dk. Purple Dk. Purple
Table 15: Neoprene-in-shear Isolators (for Units with Aluminum Fin Condensers)
UNIT SIZE VOLT Hz # OF FANS
Kit P/N
M1
M2
M3
M4
M5
M6
M7
M8
331481404 331481404 331481403 331481403 331481403 331481403 331481401 331481401
AWS280
Std Eff
400 50
AWS300
Std Eff
400 50
AWS300
High Eff
400 50
AWS320
High Eff
400 50
AWS350
High Eff
400 50
16
332325801
Gray
Gray
Green
Green
Green
Green
Brown
Brown
331481404 331481404 331481403 331481403 331481403 331481403 331481401 331481401
16
332325801
Gray
Gray
Green
Green
Green
Green
Brown
Brown
331481404 331481404 331481403 331481403 331481403 331481403 331481401 331481401
16
332325801
Gray
Gray
Green
Green
Green
Green
Brown
Brown
331481404 331481404 331481403 331481403 331481403 331481403 331481401 331481401
20
332325801
Gray
Gray
Green
Green
Green
Green
Brown
Brown
331481404 331481404 331481403 331481403 331481403 331481403 331481401 331481401
20
332325801
Gray
Gray
Green
Green
Green
Green
Brown
Brown
M6
M7
M8
Table 16: Neoprene-in-shear Isolators (for Units with Copper Fin Condensers)
UNIT SIZE VOLT Hz # OF FANS
M1
M2
M3
M4
M5
331481404 331481404 331481404 331481404 331481402 331481402 331481402 331481402
AWS280
Std Eff
400 50
AWS300
Std Eff
400 50
AWS300
High Eff
400 50
AWS320
High Eff
400 50
AWS350
High Eff
400 50
IM 1002
Kit P/N
16
332325803
Gray
Gray
Gray
Gray
Red
Red
Red
Red
331481404 331481404 331481404 331481404 331481402 331481402 331481402 331481402
16
332325803
Gray
Gray
Gray
Gray
Red
Red
Red
Red
331481404 331481404 331481404 331481404 331481402 331481402 331481402 331481402
16
332325803
Gray
Gray
Gray
Gray
Red
Red
Red
Red
331481404 331481404 331481404 331481404 331481403 331481403 331481403 331481403
20
332325802
Gray
Gray
Gray
Gray
Green
Green
Green
Green
331481404 331481404 331481404 331481404 331481403 331481403 331481403 331481403
20
332325802
Gray
Gray
Gray
Gray
Green
Green
Green
Green
25
Electrical Data
Electrical Data
Field Wiring
Wiring must comply with all applicable codes and ordinances.
Warranty does not cover damage to the equipment caused by
wiring not complying with specifications.
An open fuse indicates a short, ground, or overload. Before
replacing a fuse or restarting a compressor or fan motor, the
trouble must be found and corrected.
Copper wire is required for all power lead terminations at the
unit, and copper must be used for all other wiring to the unit.
Pathfinder chillers can be ordered with main power wiring for
either multi-point power connection (standard) or single-point
connection (optional).
If the optional single-point power connection is ordered, a
single power connection is made to a power block (or optional
disconnect switch) in the unit power panel. A separate
disconnect is required if the optional factory-mounted
disconnect is not ordered. Factory-mounted isolation circuit
breakers for each circuit are included as standard on all singlepoint connection options.
.
CAUTION
If a separate disconnect is used for the 120V supply to the unit,
it must power the entire control circuit. It must be clearly
marked so that it is not accidentally shut off during freezing
temperatures, thereby de-energizing the evaporator heaters.
Freeze damage to the evaporator could result. If the
evaporator is drained for winter freeze protection, the heaters
must be de-energized to prevent heater burnout.
CAUTION
Pathfinder unit compressors are single-direction rotation
compressors and can be damaged if rotated in the wrong
direction. For this reason, proper phasing of electrical power is
important. Electrical phasing must be A, B, C for electrical
phases 1, 2 and 3 (A=L1, B=L2, C=L3) for single or multiple
point wiring arrangements. The solid-state starters contain
phase reversal protection. DO NOT ALTER THE WIRING TO
THE STARTERS.
If the standard multiple-point power wiring is ordered, two
power connections are required. They are made to factorymounted disconnect switches in the power panel. See the
dimension drawings beginning on page 15 for entry locations.
It can be desirable to have the unit evaporator heaters on a
separate disconnect switch from the main unit power supply so
that the unit power can be shut down without defeating the
freeze protection provided by the evaporator heaters. See the
field wiring diagram on page 30 for connection details.
The 120-volt control transformer is factory mounted and
wired.
26
IM 1002
Electrical Data
Table 17: Multi-Point Electrical Data
Model
HZ
Voltage
# of
Fans
Multiple Point Field Data - Circuit #1
(Wire 75C for SP Power Block / Disconnect Sw. - 90C for SP HSCCR)
MCA
Recommended
Fuse Size
Maximum
Fuse Size
# of Leads
Wire Size
# of Hubs
Hub Size
280 Std Eff
50
400V
8
362
500
600
3
500 MCM
1
3
300 Std Eff
50
400V
8
402
600
600
6
4/0 AWG
2
2
300 High Eff
50
400V
8
390
600
600
6
3/0 AWG
2
2
320 High Eff
50
400V
10
398
600
600
6
3/0 AWG
2
2
350 High Eff
50
400V
10
435
600
700
6
4/0 AWG
2
2
# of Hubs
Hub Size
Multiple Point Field Data - Circuit #2
Maximum
# of Leads
Wire Size
Fuse Size
600
6
4/0 AWG
Model
HZ
Voltage
280 Std Eff
50
400V
# of
Fans
8
402
Recommended
Fuse Size
600
2
2
300 Std Eff
50
400V
8
402
600
600
6
4/0 AWG
2
2
300 High Eff
50
400V
8
390
600
600
6
3/0 AWG
2
2
320 High Eff
50
400V
10
435
600
700
6
3/0 AWG
2
2
350 High Eff
50
400V
10
435
600
700
6
4/0 AWG
2
2
Note:
MCA
400A and larger circuit breakers are 100% rated; 250A and smaller are 80% rated.
Table 18: Multipoint Electrical Data
Model
HZ
Compressor
Rated Load Amps
Fan
# of
Voltage
Motors
Fans
FLA
CIRC 1 CIRC 2 CIRC 3
Fan
Motor
LRA
Inrush Amps
LRA (ATL)
Inrush Amps
LRA (SS)
Inrush Amps
LRA (YD)
Cir.
1
Cir.
1
Cir.
3
Cir.
1
Cir.
2
Cir.
3
Cir.
2
Cir.
3
Cir.
2
280 Std Eff
50
400V
264
296
--
16
4.0
15
1724 2014
-
1000 1168
-
576
673
-
300 Std Eff
50
400V
296
296
--
16
4.0
15
2014 2014
-
1168 1168
-
673
673
-
300 High Eff
50
400V
286
286
--
16
4.0
15
1724 1724
-
1000 1000
-
576
576
-
320 High Eff
50
400V
286
316
--
20
4.0
15
1724 2014
-
1000 1168
-
576
673
-
350 High Eff
50
400V
316
316
--
20
4.0
15
2014 2014
-
1168 1168
-
673
673
-
IM 1002
27
Electrical Data
Table 19: Multi-Point Field Wiring Information
Circuit #1
Model
HZ
Voltage
# of Fans
280 Std Eff
50
400V
8
Size
380A
Std Lug Size
(1/PH) #4 - 500
Size
400A
Std Lug Size
(2/PH) 3/0 - 500 kcmil
High Short Circuit Current Rating
Circuit Breaker (note 1)
Size
Std Lug Size
600A
(2/PH) 3/0 - 500 kcmil
300 Std Eff
50
400V
8
760A
(2/PH) #2 - 500 kcmil
400A
(2/PH) 3/0 - 500 kcmil
600A
(2/PH) 3/0 - 500 kcmil
300 High Eff
50
400V
8
760A
(2/PH) #2 - 500 kcmil
400A
(2/PH) 3/0 - 500 kcmil
600A
(2/PH) 3/0 - 500 kcmil
320 High Eff
50
400V
10
760A
(2/PH) #2 - 500 kcmil
400A
(2/PH) 3/0 - 500 kcmil
600A
(2/PH) 3/0 - 500 kcmil
350 High Eff
50
400V
10
760A
(2/PH) #2 - 500 kcmil
600A
(2/PH) 3/0 - 500 kcmil
600A
(2/PH) 3/0 - 500 kcmil
Power Block
Disconnect Switch
Circuit #2
Model
HZ
Voltage
# of Fans
280 Std Eff
50
400V
8
Size
760A
(2/PH) #2 - 500 kcmil
Size
400A
Std Lug Size
(2/PH) 3/0 - 500 kcmil
High Short Circuit Current Rating
Circuit Breaker (note 1)
Size
Std Lug Size
600A
(2/PH) 3/0 - 500 kcmil
Power Block
Std Lug Size
Disconnect Switch
300 Std Eff
50
400V
8
760A
(2/PH) #2 - 500 kcmil
400A
(2/PH) 3/0 - 500 kcmil
600A
(2/PH) 3/0 - 500 kcmil
300 High Eff
50
400V
8
760A
(2/PH) #2 - 500 kcmil
400A
(2/PH) 3/0 - 500 kcmil
600A
(2/PH) 3/0 - 500 kcmil
320 High Eff
50
400V
10
760A
(2/PH) #2 - 500 kcmil
600A
(2/PH) 3/0 - 500 kcmil
600A
(2/PH) 3/0 - 500 kcmil
350 High Eff
50
400V
10
760A
(2/PH) #2 - 500 kcmil
600A
(2/PH) 3/0 - 500 kcmil
600A
(2/PH) 3/0 - 500 kcmil
Note:
28
400A and larger circuit breakers are 100% rated; 250A and smaller are 80% rated.
IM 1002
Electrical Data
Table 20: Single Point Electrical Data
Pathfinder
HZ Voltage
Chiller Model
# of
Fans
Compressor
Fan
Single Point Electrical Data
Rated Load Amps Motors
Comp #1 Comp #2 FLA MCA Rec Fuse Size Max Fuse Size # of Leads Wire Size
# of Hubs Hub Size
280 Std Eff 50
400V
16
264
296
4.0
698
800
800
6
500 MCM
2
3
300 Std Eff 50
400V
16
296
296
4.0
730
1000
1000
6
500 MCM
2
3
300 High Eff 50
400V
16
286
286
4.0
708
800
800
6
500 MCM
2
3
320 High Eff 50
400V
20
286
316
4.0
761
1000
1000
12
250 MCM
2
3
350 High Eff 50
400V
20
316
316
4.0
791
1000
1000
12
250 MCM
2
3
Table 21: Single Point Terminal Amp Data
Pathfinder
HZ Voltage # of Fans
Chiller Model
Power Block
Disconnect Switch
High Short Circuit Current Rating
ircuit Breaker
Size
Std Lug Size
Size
Std Lug Size
Size
Std Lug Size
280 Std Eff 50
400V
16
760A
(2/PH) #2 - 500 kcmil
800A
(4/PH) 250 - 500 kcmil
1200A
(4/PH) 250 mcm - 500 kcmil
300 Std Eff 50
400V
16
760A
(2/PH) #2 - 500 kcmil
800A
(4/PH) 250 - 500 kcmil
1200A
(4/PH) 250 mcm - 500 kcmil
300 High Eff 50
400V
16
760A
(2/PH) #2 - 500 kcmil
800A
(4/PH) 250 - 500 kcmil
1200A
(4/PH) 250 mcm - 500 kcmil
320 High Eff 50
400V
20
1400A
(4/PH) 1/0 - 750 mcm
800A
(4/PH) 250 - 500 kcmil
1200A
(4/PH) 250 mcm - 500 kcmil
350 High Eff 50
400V
20
1400A
(4/PH) 1/0 - 750 mcm
1200A
(4/PH) 250 - 500 kcmil
1200A
(4/PH) 250 mcm - 500 kcmil
Note:
400A and larger circuit breakers are 100% rated; 250A and smaller are 80% rated.
IM 1002
29
30
!
!
!
!
!
"#
$
"#
$
"#
$
"#
$
"#
$
"#
$
#
#
0
#
0
#
%
0
#
#
0
0
#
-(
0
#
'
#
(
#
-
#
'
#
0
#
#
#
%
#
#
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(
#
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* - # #,#
* -- # #,(
) * + # #',#(
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-)/
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&
#
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Wiring Diagram
Wiring Diagram
Figure 23: Field Wiring Diagram
IM 1002
IM 1002
#$
""
!
Wiring Diagram
Figure 24: Field Wiring Diagram (continued)
31
Wiring Diagram
32
IM 1002
Troubleshooting Chart
Troubleshooting Chart
Table 22: Troubleshooting Chart
PROBLEM
POSSIBLE CAUSES
1.
2.
3.
Main power switch open.
Unit system switch open.
Circuit switch in pumpdown position.
POSSIBLE CORRECTIVE STEPS
1.
2.
3.
Close switch.
Check unit status on MicroTech III display. Close switch.
Check circuit status on MicroTech III display. Close switch. Check
pump operation for flow.
4.
5.
6.
Compressor will
not run.
Compressor Noisy
or Vibrating
Compressor
Overload Tripped
or Circuit Breaker
Trip or Fuses
Blown
Compressor Will
Not Load or
Unload
7.
Chilled water flow switch not closed.
Circuit breakers open.
Fuse blown or circuit breakers tripped.
4.
5.
6.
7.
Defective compressor contactor or contactor coil.
10.
11.
12.
No cooling required.
13.
Cycle timer active
1.
2.
Compressor Internal problem.
System shut down by protection devices.
Motor electrical trouble.
Loose wiring.
Close circuit breakers.
Check electrical circuits and motor windings for shorts or grounds.
Investigate for possible overloading. Check for loose or corroded
connections. Reset breakers or replace fuses after fault is
corrected.
Compressor overload tripped.
8.
9.
Check unit status on MicroTech display. Check Chilled water pump.
Overloads are manual reset. Reset overload at button on overload.
Clear alarm on Microtech III display.
8.
9.
Check wiring. Repair or replace contactor.
Determine type and cause of shutdown and correct problem before
attempting to restart.
10.
11.
12.
Check control settings. Wait until unit calls for cooling.
See 6,7,8 above.
Check circuits for voltage at required points. Tighten all power wiring
terminals.
Oil injection not adequate.
13.
1.
2.
3.
1.
2.
3.
4.
5.
1.
2.
Liquid slugging
Check pressure drop across oil filter and oil separator sight glasses
3.
Check suction and discharge superheat
1.
Check timer operation
Contact McQuayService.
Check that oil sight glass has oil visible during steady operation
Check supply voltage for excessive voltage drop.
Unloader mechanism defective.
1.
2.
3.
4.
5.
1.
2.
Noncondensables in the system.
1.
Remove noncondensables from the condenser coil after shutdown
Low voltage during high load condition.
Loose power wiring.
Power line fault causing unbalanced voltage.
Defective or grounded wiring in the motor.
High discharge pressure.
Defective capacity control solenoids.
Check and tighten all connections.
Check supply voltage.
Check motor and replace if defective.
See corrective steps for high discharge pressure.
Check solenoids for proper operation. See capacity control section.
Contact McQuayService .
per EPA regulations.
2.
3.
Fans not running.
Fan control out of adjustment.
2.
3.
4.
System overcharged with refrigerant.
4.
Check discharge superheat and condenser subcooling. Remove the
excess charge.
5.
6.
7.
1.
2.
Dirty condenser coil.
5.
6.
7.
1.
2.
Clean the condenser coil.
Low Discharge
Pressure
3.
4.
5.
Low suction pressure.
IM 1002
Check that fan setup in the controller matches unit fan number.
Check Microtech III condenser pressure sensor for proper operation.
High Discharge
Pressure
Check fan fuses and electrical circuits.
Air recirculation from fan outlet into unit coils.
Air restriction into unit.
Wind effect or a low ambient temperature.
Condenser fan control not correct.
Remove the cause of recirculation.
Remove obstructions near unit.
Protect unit against excessive wind into vertical coils.
Check that fan setup in the Microtech III controller matches unit fan
number. Check VFD fan on units with VFD option.
Compressor operating unloaded.
Compressor problem, not pumping properly
3.
4.
5.
See corrective steps for low suction pressure.
See corrective steps for failure to load.
Repair or replace compressor
33
Troubleshooting Chart
Table 22: Troubleshooting Chart
1.
Inadequate refrigerant charge quantity.
2.
3.
Clogged liquid line filter-drier.
4.
5.
6.
7.
8.
1.
2.
3.
1.
2.
3.
Insufficient water flow to evaporator.
1.
Check liquid line sight glass. Check unit for leaks. Repair and
recharge to clear sight glass at full load, all fans on, 75F min OAT..
Low Suction
Pressure
Low Oil Level Trip
High Suction
Pressure
2.
3.
Check pressure drop across the filter-drier. Replace filter-driers.
Check expansion valve superheat and valve opening position.
Replace valve only if certain valve is not working.
Water temperature leaving evaporator is too low.
Evaporator tubes fouled.
Suction valve (partially) closed.
Glycol in chilled water system
Insufficient oil.
Low discharge pressure.
Low discharge superheat
Excessive load - high water temperature.
Compressor unloaders not loading compressor.
Superheat is too low.
4.
5.
6.
7.
8.
1.
2.
3.
1.
2.
3.
Check water pressure drop across the evaporator and adjust gpm.
Adjust water temperature to higher value.
Inspect by removing water piping. Clean chemically.
Open valve.
Check glycol concentration
Check oil line and separator sight glasses.
Faulty EXV.
Check and correct cause of low DSH
Reduce load or add additional equipment.
See corrective steps below for failure of compressor to load.
Check superheat on Microtech III display. Check suction line sensor
installation and sensor.
4.
5.
34
Expansion valve malfunctioning.
System overcharged
Compressor bypassing gas
4.
5.
Check charge, an overcharge raises suction pressure
Check evaporator, suction and discharge pressures
IM 1002
McQuay Training and Development
Now that you have made an investment in modern, efficient McQuay equipment, its care should be a high priority.
For training information on all McQuay HVAC products, please visit us at www.mcquay.com and click on training,
or call 540-248-9646 and ask for the Training Department.
Warranty
All McQuay equipment is sold pursuant to its standard terms and conditions of sale, including Limited Product
Warranty. Consult your local McQuay Representative for warranty details. To find your local McQuay
Representative, go to www.mcquay.com.
This document contains the most current product information as of this printing. For the most up-to-date product
information, please go to www.mcquay.com.
© 2009 McQuay International • www.mcquay.com • 800-432-1342
06/09
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