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IOMM AGR-1

AGR 070A through 100A

Notes

Summary of Contents for AGR 070AS

Page 1: ...on 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...

Page 2: ...escription 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...

Page 3: ...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 cen...

Page 4: ...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...

Page 5: ...ol 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 considerati...

Page 6: ...he 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 per...

Page 7: ...posite End Right Size lb kg lb kg lb kg lb kg 070 1071 486 1193 541 952 432 1060 481 075 1491 676 1633 741 1137 516 1245 565 080 1542 699 1745 792 1151 522 1302 591 085 1561 708 1822 826 1171 531 1367...

Page 8: ...ating 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 contr...

Page 9: ...ndicator 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 ins...

Page 10: ...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 correct...

Page 11: ...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 9...

Page 12: ...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...

Page 13: ...00 83 100 85 100 88 100 CONDENSERS HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING Coil Face Area sq ft 58 58 87 87 87 87 87 87 Coil Face Area m2 5 4 5 4 8 1 8 1 8 1 8 1 8 1 8 1 Finned Heig...

Page 14: ...88 100 0 25 50 63 75 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 Finne...

Page 15: ...minations 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 provide...

Page 16: ...6 3 0 2 2 00 500 230 373 3 500 1 3 00 500 380 240 3 250 1 2 50 300 460 187 3 3 0 1 2 00 250 080AS 080AM 575 151 3 2 0 1 1 50 200 208 411 6 4 0 2 2 00 500 230 408 6 4 0 2 2 00 500 380 256 3 300 1 2 50...

Page 17: ...103 4 1 6 20 0 365 740 N A N A 460 63 82 3 6 6 13 8 315 510 195 330 080AS 080AM 575 48 68 3 0 6 11 0 245 405 152 262 208 162 162 7 8 6 30 5 N A N A 654 654 230 162 162 7 2 6 27 6 N A N A 654 654 380 1...

Page 18: ...350 MCM 460 335 4 400 MCM 250 4 350 MCM 080AS 080AM 575 335 4 400 MCM 250 4 350 MCM 208 840 2 qty 1 0 600 MCM 600 2 qty 250 500 MCM 230 840 2 qty 1 0 600 MCM 600 2 qty 250 500 MCM 380 335 4 400 MCM 4...

Page 19: ...A 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 a...

Page 20: ...20 AGR 070A through 100A IOMM AGR 1 Figure 9 Typical Field Wiring with Global UNT Controller...

Page 21: ...IOMM AGR 1 AGR 070A through 100A 21 Figure 10 Typical Field Wiring Diagram with MicroTech Controller...

Page 22: ...22 AGR 070A through 100A IOMM AGR 1 Figure 11 Standard Single Point Connection with FanTrol...

Page 23: ...IOMM AGR 1 AGR 070A through 100A 23 Figure 12 Standard Single Point Connection with Optional SpeedTrol...

Page 24: ...24 AGR 070A through 100A IOMM AGR 1 Figure 13 Unit Control Schematic 2 compressor UNT...

Page 25: ...IOMM AGR 1 AGR 070A through 100A 25 Figure 14 Staging Schematic 2 compressor 4 stage UNT...

Page 26: ...26 AGR 070A through 100A IOMM AGR 1 Figure 15 Staging Schematic 2 compressor 6 stage UNT...

Page 27: ...IOMM AGR 1 AGR 070A through 100A 27 Figure 16 MicroTech Controller Schematic...

Page 28: ...28 AGR 070A through 100A IOMM AGR 1 Figure 17 Unit Control Schematic MicroTech...

Page 29: ...IOMM AGR 1 AGR 070A through 100A 29 Figure 18 Staging Schematic 4 stage MicroTech...

Page 30: ...30 AGR 070A through 100A IOMM AGR 1 Figure 19 Staging Schematic 6 stage MicroTech...

Page 31: ...IOMM AGR 1 AGR 070A through 100A 31 Figure 20 Unit Control Schematic 2 compressor MicroTech...

Page 32: ...32 AGR 070A through 100A IOMM AGR 1 Figure 21 UNT Instrument Layout See legend on page 34...

Page 33: ...IOMM AGR 1 AGR 070A through 100A 33 Figure 22 MicroTech Instrument Layout See legend on page 34...

Page 34: ...34 AGR 070A through 100A IOMM AGR 1 Figure 23 AGR Power Side Component Layout See legend on page 34 Figure 24 Component Layout Legend...

Page 35: ...IOMM AGR 1 AGR 070A through 100A 35 Figure 25 MicroTech Sensor Layout...

Page 36: ...80 88 2054 4 94 00 2387 6 X 6 50 165 1 31 50 800 1 2 5 63mm DIAMETER LIFTING HOLES 4 2 PER SIDE AS SHOWN UNIT ISOLATOR MOUNTING HOLE LOCATIONS 4 2 PER SIDE AS SHOWN 2 00 50 8 2 00 50 8 Y TYPICAL SPAC...

Page 37: ...2 COIL HEADERS AT THIS END OF UNIT NOTE 1 ALL DIMENSIONS IN INCUES mm 2 ALL UNITS HAVE 2 INDEPENDENT REFRIGERANT CIRCUITS C D EVAPORATOR 2 REFRIGERANT CIRCUITS OUTLET AGR Unit Dimensions Center of Gr...

Page 38: ...t 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...

Page 39: ...evel 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 Emerge...

Page 40: ...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 c...

Page 41: ...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...

Page 42: ...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...

Page 43: ...ation 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 a...

Page 44: ...es 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 RS...

Page 45: ...e 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 set...

Page 46: ...d Outputs Relay Output Number Output Description 1 Circuit 1 Liquid Line Solenoid Valve 2 Circuit 2 Liquid Line Solenoid Valve 3 Compressor 1 Unloader 1 4 Compressor 2 Unloader 1 5 Compressor 1 Unload...

Page 47: ...r 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 A...

Page 48: ...en 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...

Page 49: ...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 conti...

Page 50: ...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 compr...

Page 51: ...inate 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 p...

Page 52: ...ure OA Lockout Cir 2Lead On Pmp Stp 1 0 Lvg Water Temp Evap Pres 1 Evap Pres 2 OA AI3 Input LvgWtr RBnd SP Contrl Band SP Actual Lvg SP Unoccpd Lvg SP OA Lockout SP Lvg Low Lim SP SoftSta Capcty Cir 1...

Page 53: ...splays Symbols Keys Buttons DISPLAYS SYMBOLS KEYS BUTTONS DESCRIPTION Display Button 1 2 3 Select the value you want to monitor or adjust Enter Key Use to commit your changes Adjustments are not proce...

Page 54: ...y Figure 33 Connecting ZT to a Global UNT Controller Using 6 to 8 Pin Cable Connect ZT here BINARY IN ANALOG INPUT S B INAR Y OU T P U T S OF F 1 2 3 4 5 6 7 8 AS UNT 330 1 BINARY IN ANALOG INPUT S 1...

Page 55: ...SP 0 F 0 to 15 F Unoccpd Lvg SP 70 F 40 to 90 F OA Lockout SP 10 F 20 to 65 F Lvg Low Lim SP 20 F 20 to 40 F SoftSta Capcty 50 0 to 100 SoftStart Time 2 min 0 to 20 minutes Zone Terminal Glossary Lvg...

Page 56: ...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...

Page 57: ...Check UNT controller Replace if defective 3 Replace compressor 4 Check reasons for high condenser pressure Low Suction Pressure 1 Low refrigerant charge 2 Defective expansion valve 3 Dirty filter drie...

Page 58: ...ction 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 inclu...

Page 59: ...ettings 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...

Page 60: ...mp 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...

Page 61: ...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...

Page 62: ...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 trig...

Page 63: ...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 rem...

Page 64: ...re 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 troublesho...

Page 65: ...city 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 s...

Page 66: ...larm 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...

Page 67: ...everse 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 Eva...

Page 68: ...ndition 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 co...

Page 69: ...isconnect 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 pum...

Page 70: ...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 S...

Page 71: ...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 t...

Page 72: ...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...

Page 73: ...o 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...

Page 74: ...ring 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 Mo...

Page 75: ...in 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 stagin...

Page 76: ...r 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...

Page 77: ...Ready PumpingDown OpenSolenoid Capacity Starting LowAmbStart 1 Table 25 MENU 4 Water Temp s Screen Display Lvg Evap xxx x F C Short F C 1 Open F C Ent Evap xxx x F C Short F C 2 Open F C D T Evap Sho...

Page 78: ...Screen Display Satur Evap xxx F C 1 N A F C SuctLine xxx x F C Open F C 2 Short Super Ht xxx x F C 3 N A F C Satur Cond xxx F C 4 N A F C Liquid Ln xxx x F C 5 N A F C SubCoolg xxx x F C 6 N A F C Co...

Page 79: ...None 8 ResetSig xx xma Not Changeable 9 MaxChWRst xx x F C 10 0 5 5 0 0 45 0 0 0 25 0 10 ReturnSpt xx x F C 54 0 12 3 15 0 80 0 9 4 26 7 the minus sign is not displayed with three digit numbers Table...

Page 80: ...100 483 690 3 MinLift100 xxx 140 966 100 140 690 966 4 DeadBandMult x x 1 0 8 1 3 5 StageUpErr xxx 400 2760 300 990 2070 6830 6 StageDnErr xxx 100 690 50 400 340 2760 Table 40 MENU 17 Head Pres Spt V...

Page 81: ...1 14 7 Dur 0 Day s 0 0 31 15 8 Date N A 0 N A 0 Jan Dec 1 31 16 8 Dur 0 Day s 0 0 31 17 9 Date N A 0 N A 0 Jan Dec 1 31 18 9 Dur 0 Day s 0 0 31 19 10 Date N A 0 N A 0 Jan Dec 1 31 20 10 Dur 0 Day s 0...

Page 82: ...8 MENU 24 1 Curr Alarm Screen Display 1 Current Alarm 2 0 00 0 00 00 3 Evap x x psi kPa 4 Cond x x psi kPa 5 SuctLine xxx x F C 6 LiquidLn xxx x F C 7 Evap Lvg xxx x F C 8 OAT xx xx F C 9 Capacity xxx...

Page 83: ...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...

Page 84: ...ber Status LED Indication Amber LED State Indication Off Normal operation On 1 2 second Off 1 2 second Alarm condition Keypad LCD Display Connection The MCB receives input commands and operating param...

Page 85: ...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 sta...

Page 86: ...e 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 1 Verify that circuit breaker CB1 is clo...

Page 87: ...ssively 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...

Page 88: ...or Garbled If the MCB appears to be functioning properly and the display is completely blank or garbled perform the following procedure 1 Try cycling power to the controller by opening and then closin...

Page 89: ...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 c...

Page 90: ...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 rel...

Page 91: ...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 w...

Page 92: ...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...

Page 93: ...ce 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 suppl...

Page 94: ...or damaged components X Inspect thermal insulation for integrity X Clean and paint as required X Electrical Check terminals for tightness tighten as necessary X Clean control panel interior X Visually...

Page 95: ...ture 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...

Page 96: ...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 sl...

Page 97: ...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 approxim...

Page 98: ...essors running in reverse 4 Check for proper phasing 1 Lack of refrigerant 1 Check for leaks Repair and add charge Check liquid sightglass 2 Clogged liquid line filter drier 2 Check pressure drop acro...

Page 99: ...IOMM AGR 1 AGR 070A through 100A 99 Notes...

Page 100: ...Post Office Box 2510 Staunton Virginia 24402 USA 800 432 1342 www mcquay com...

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