McQuay AGS 120CM/B Installation And Maintenance Manual Download Page 70

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IMM AGS-2

Component Location

Major Component Location

Figure 38, Unit Cutaway View

Control Panel

Power Panel

Two-circuit DX Evaporator

Filter-drier (2)

Electronic

Expansion

Valve (2)

Suction Connection for
Remote Evaporators (2)

Liquid Connection for Remote

Evaporators, Models AGS 120C – 175C

Chilled Water Inlet

Chilled Water Outlet

Summary of Contents for AGS 120CM/B

Page 1: ...nance Manual IMM AGS 2 Group Chiller Part Number 331373301 Date July 2008 Supersedes March 2008 Air Cooled Screw Compressor Chiller AGS 120CS H AGS 210CS H Packaged AGS 120CM B AHS 210CM B Remote Evap...

Page 2: ...tarters 63 Component Location 70 Major Component Location 70 Power Panel 72 Control Panel 73 System Maintenance 74 General 74 Compressor Maintenance 74 Lubrication 74 Electrical Terminals 75 Condenser...

Page 3: ...standard efficiency model numbers ending in 0 and high efficiency units ending in 5 The high efficiency units have certain larger components The units are optionally available with the evaporator ship...

Page 4: ...ot expose sparks arcing equipment open flame or other ignition source to the refrigerant Handling Avoid rough handling shock due to impact or dropping the unit Do not push or pull the unit Never allow...

Page 5: ...ter 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...

Page 6: ...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...

Page 7: ...on one side serve one compressor Every compressor always has its own independent refrigerant circuit The MicroTech II control is proactive in response to off design conditions In the case of single or...

Page 8: ...ning 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...

Page 9: ...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 Mounting units end to end will not necessitate adjust...

Page 10: ...ly on their inside circuits Their adjustment factors will be the same as Case 2 All inside units only chiller 2 in this case are influenced on both sides and must be adjusted by the factors shown belo...

Page 11: ...support This is usually satisfactory for concealment If the wall height is greater than the unit height see Case 5 Pit Installation The distance from the ends of the unit to the end walls must be suf...

Page 12: ...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 op...

Page 13: ...s All other coil types such as ElectroFin and Blackfin use the aluminum fin data Isolator bolting the unit base is an enclosed box design and may have six or ten mounting locations depending on the da...

Page 14: ...4091 145 3075 1395 1896 860 1916 869 1810 821 1517 688 10485 4756 9942 4510 160 2933 1330 1809 821 1802 817 1742 790 1561 708 10209 4631 9484 4302 165 3017 1369 2489 1129 2137 969 2038 924 1789 811 11...

Page 15: ...9571 4341 210 3196 1450 1590 721 2099 952 1764 800 923 419 9571 4341 9571 4341 Table 5 Lifting Mounting Weights Remote Evaporator Copper Fins AGS CM B Lifting Weights Mounting Weights L1 L2 L3 L4 MM1...

Page 16: ...CP2 31 CP2 31 CP2 31 CP2 31 CP2 31 CP2 31 190 GRAY GRAY GRAY GRAY GRAY GRAY CP2 31 CP2 31 CP2 31 CP2 31 CP2 31 CP2 31 195 GRAY GRAY GRAY GRAY GRAY GRAY CP2 31 CP2 31 CP2 31 CP2 31 CP2 31 CP2 31 210 G...

Page 17: ...04105 CP2 32 CP2 32 CP2 31 CP2 31 CP2 31 CP2 31 190 WHITE WHITE GRAY GRAY GRAY GRAY 330904105 CP2 32 CP2 32 CP2 32 CP2 32 CP2 31 CP2 31 195 WHITE WHITE WHITE WHITE GRAY GRAY 330904106 CP2 32 CP2 32 CP...

Page 18: ...hite 2600 1180 0 5 12 7 10 2 259 1 9 0 228 6 7 7 195 6 2 7 68 6 5 75 146 0 226103B 00 2 226120A 00 Table 11 Neoprene in Shear Isolators Dimensions In mm Type Max Load Each Lbs kg Defl In mm A B C D 1...

Page 19: ...ould 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 p...

Page 20: ...d unloading of compressors erratic refrigerant flow in the chiller improper motor cooling shortened equipment life and other undesirable consequences For normal comfort cooling applications where the...

Page 21: ...2 Draining the water from outdoor equipment and piping and blowing the chiller tubes dry from the chiller Do not energize the chiller heater when water is drained from the vessel CAUTION If fluid is...

Page 22: ...ast digit in the model number such as AGS 175C are designed for operation up to 125 degrees without unloading for leaving water temperatures between 40 and 45 degrees Fahrenheit Contact your sales rep...

Page 23: ...ow Lpm 2 8 4 1 6 1 7 3 11 4 27 7 53 4 81 8 90 8 NOTES 1 A segmented 3 inch paddle 1 2 and 3 inches is furnished mounted plus a 6 inch paddle loose 2 Flow rates for a 2 inch paddle trimmed to fit the p...

Page 24: ...tive 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...

Page 25: ...1 5 4 9 14 6 292 18 5 11 8 35 2 486 30 8 29 2 87 2 130 188 11 9 5 3 15 8 300 19 0 12 9 38 5 501 31 7 30 4 90 7 135 196 12 4 5 6 16 7 314 19 9 13 5 40 3 524 33 1 33 5 100 0 140 201 12 7 5 9 17 6 321 20...

Page 26: ...9 185 49 185 Max Water Pressure psi kPa 152 1048 152 1048 152 1048 Max Refrigerant Press psi kPa 352 2427 352 2427 352 2427 Table 17 Physical Data AGS 160C AGS 180C AGS MODEL NUMBER DATA 160C 170C 180...

Page 27: ...9 Physical Data AGS 125C AGS 145C AGS MODEL NUMBER 125C 135C 145C DATA Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2 BASIC DATA Unit Cap 44 F LWT 95 F Ambient Temperature kW tons 121 6 428 130 9 460 143 0 503 U...

Page 28: ...85 299 95 334 95 334 CONDENSERS HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER Pumpdown Capacity lbs kg 438 199 438 199 438 199 438 199 438 199 438 199 CONDENSER FANS DIRECT DRIVE PROPELLE...

Page 29: ...2 9 31 5 800 1 3307127 00 01 A B 18 4 467 4 C VICTAULIC CONNECTION 186 6 4739 6 D INLET OUTLET POWER ENTRY FIELD CONTROL CONNECTION 100 4 2550 2 88 5 2247 9 CONTROL PANEL POWER PANEL POWER PANEL Dimen...

Page 30: ...ECTION 224 8 5709 9 D INLET OUTLET POWER ENTRY FIELD CONTROL CONNECTION 100 4 2550 2 88 5 2248 9 POWER PANEL POWER PANEL CONTROL PANEL Dimensions In mm UNIT SIZE A B C D AGS125C 39 3 998 2 70 3 1785 6...

Page 31: ...5 800 1 3307127 00 03 A B 18 4 467 4 C VICTAULIC CONNECTION 263 0 6680 2 D INLET OUTLET POWER ENTRY FIELD CONTROL CONNECTION 100 4 2550 2 88 5 2247 9 POWER PANEL POWER PANEL Dimensions In mm UNIT SIZ...

Page 32: ...ower panel A separate disconnect is required if the McQuay optional factory mounted disconnect is not ordered Isolation circuit breakers for each circuit are included It can be desirable to have the u...

Page 33: ...0 298 350 MCM 350 400 575 227 4 0 AWG 250 300 208 660 2 400 MCM 800 800 230 593 2 350 MCM 700 800 140C 380 60 359 2 250 MCM 400 500 460 301 350 MCM 350 400 575 231 250 MCM 300 300 208 674 2 400 MCM 80...

Page 34: ...IELD FUSING POWER SUPPLY FIELD FUSING AGS UNIT SIZE VOLTS HZ MINIMUM CIRCUIT AMPS MCA FIELD WIRE REC FUSE SIZE MAX FUSE SIZE MINIMUM CIRCUIT AMPS MCA FIELD WIRE REC FUSE SIZE MAX FUSE SIZE 208 320 400...

Page 35: ...400 243 250 MCM 300 400 460 193 3 0 AWG 250 300 193 3 0 AWG 250 300 575 154 2 0 AWG 200 250 154 2 0 AWG 200 250 208 434 2 300 MCM 600 700 434 2 300 MCM 600 700 230 393 2 250 MCM 500 600 393 2 250 MCM...

Page 36: ...8 267 267 7 3 8 40 0 230 240 240 6 6 8 40 0 140 380 60 145 145 4 0 8 20 0 460 122 122 3 3 8 20 0 575 94 94 2 4 8 12 8 208 267 267 7 3 10 40 0 230 240 240 6 6 10 40 0 145 380 60 145 145 4 0 10 20 0 460...

Page 37: ...400 3 0 500 MCM 2 C 460 400 6 350 MCM 2 c 400 3 0 500 MCM 2 C 575 400 6 350 MCM 2 c 250 6 350 MCM 1 C 208 800 1 0 750 MCM 4 C 800 1 0 500 MCM 3 C 230 800 1 0 750 MCM 4 C 800 1 0 500 MCM 3 C 125 380 6...

Page 38: ...60 800 1 0 750 MCM 4 C 600 3 0 500 MCM 2 C 460 400 6 350 MCM 2 C 600 3 0 500 MCM 2 C 575 400 6 350 MCM 2 C 400 3 0 500 MCM 2 C 208 1000 1 0 750 MCM 4 C 1200 250 500 MCM 4 C 230 1000 1 0 750 MCM 4 C 1...

Page 39: ...6 350 MCM 2 C 460 400 400 6 350 MCM 2 C 6 350 MCM 2 C 575 400 400 6 350 MCM 2 C 6 350 MCM 2 C 208 400 400 6 350 MCM 2 C 6 350 MCM 2 C 230 400 400 6 350 MCM 2 C 6 350 MCM 2 C 145 380 60 400 400 6 350 M...

Page 40: ...NNECTOR WIRE RANGE PER PHASE COPPER WIRE ONLY AGS UNIT SIZE VOLTS HZ CKT 1 CKT 2 CKT 1 CKT 2 208 400 400 3 0 500 MCM 2 C 3 0 500 MCM 2 C 230 400 400 3 0 500 MCM 2 C 3 0 500 MCM 2 C 120 380 60 250 250...

Page 41: ...2 C 460 250 250 6 350 MCM 1 C 6 350 MCM 1 C 575 250 250 6 350 MCM 1 C 6 350 MCM 1 C 208 600 600 3 0 500 MCM 2 C 3 0 500 MCM 2 C 230 600 600 3 0 500 MCM 2 C 3 0 500 MCM 2 C 180 380 60 400 400 3 0 500 M...

Page 42: ...SED CONTROL CIRCUIT TRANSFORMER 120 VAC NOTE ALL FIELD WIRING TO BE INSTALLED AS NEC CLASS 1 WIRING SYSTEM WITH CONDUCTOR RATED 600 VOLTS TB1 115 VAC TB1 2 1 82 2 EVAP PUMP RELAY 1 BY OTHERS 120 VAC 1...

Page 43: ...6 ID7 ID8 IDC1 808 809 810 811 807 897 RS1 REMOTE SWITCH MS1 EVAP FLOW SWITCH CHWI MODE SWITCH D IG IT AL OU T P U TS CONTROLLER A GND B 813 C1 NO1 NO2 NO3 C1 C4 NO4 NO5 NO6 C4 WJ 802 C7 C7 NO8 C8 NC8...

Page 44: ...X 855 1 HEATER 2 HTR EVAP 852 822 829 823 824 FU10 1 2 FU11 1 2 SEE LINE 301 120V 120V LINE NO CONTACT LOCATION TERMINAL BLOCK AND LEAD NUMBERS 85 82 81 1 UNIT ALARM EVAPORATOR PUMP 1 EVAPORATOR PUMP...

Page 45: ...ETAIL 1 ID9 ID10 ID11 ID12 IDC9 J7 142 N A ON NON VFD UNITS 129 131 21 WHT DPS C 1 BLK DIFFERENTIAL PRESSURE SWITCH GRN PE MHPR 2 4 130 MECHANICAL HIGH PRESSURE FAULT 132 133 134 24 4 20MA 3 SLIDE LOA...

Page 46: ...1 2 GRN PE LOAD SOLENOID 1 GRN PE 2 50 UNLOAD SOLENOID SCHEM 330590401 REV 0D SV 50 PUMPDOWN DETAIL 1 EXV DRIVER ANALOG OUTPUT J4 Y3 126 TB1 40 139 PID GREEN WHITE RED BLACK 195 196 117 TO TB1 2 116 T...

Page 47: ...isconnect switch s or HACR breakers must be field supplied Note On single point power units a non fused disconnect switch in the cabinet is available as an option 10 All wiring must be done in accorda...

Page 48: ...aporator and field refrigerant piping is furnished by the contractor and must be added in the field The location and size of the refrigerant and water connections are shown on the dimension drawings b...

Page 49: ...the top or side of the pipe Connection is inch flare with a flare Schrader Kit Components The kit shipped with the unit has the following components for field installation Filter drier and cores Sigh...

Page 50: ...line Size Up to 50 Equiv Ft Up to 75 Equiv Ft Up to 100 Equiv Ft AGS Model Circuit Size PD Size PD Size PD 120 125 Both 3 1 8 1 09 3 1 8 1 64 3 1 8 2 19 1 3 1 8 1 09 3 1 8 1 64 3 1 8 2 19 130 135 2 3...

Page 51: ...ION 3 62 O D LIQUID CONNECTION 1 38 O D 2 POWER ENTRY FIELD CONTROL 2 CONNECTIONS 100 4 2550 2 88 5 2247 9 LIQUID CONNECTIONS NOTE COMPRESSORS HIDDEN Figure 28 Models AGS 125CM B 135CM B 145CM B 170CM...

Page 52: ...D 2 POWER ENTRY FIELD CONTROL 2 CONNECTIONS 100 4 2550 2 88 5 2247 9 LIQUID CONNECTION 1 38 O D Figure 30 AGS 180CM B AGS 190CM B with Remote Evaporator 0 875 KNOCK OUT QTY 4 TOTAL 330712801D020C AGS...

Page 53: ...10CM B with Remote Evaporator 0 875 KNOCK OUT QTY 4 TOTAL 330712801D030C AGS C 195 210 263 0 6680 2 LIQUID CONNECTIONS LIQUID CONNECTION 1 38 O D SUCTION CONNECTION 3 62 O D 2 POWER ENTRY FIELD CONTRO...

Page 54: ...0 76 2 3 0 76 2 MTG 11 9 302 3 04 125 IDS FLANGE QTY 2 HEATER LEADS 90 2 6 66 0 LIQUID INLET OUTLET SUCTION Figure 33 Evaporator for AGS 160C AGS 125C 135C DWG 330645900 EVAP AGS 125C 135C AGS 160C 68...

Page 55: ...3 04 125 IDS FLANGE QTY 2 HEATER LEADS 3 0 76 2 2 6 66 0 90 LIQUID INLET OUTLET SUCTION Figure 35 Evaporator for AGS 165C 195C AGS 170C 210C 330646100 EVAP AGS 165C 195C AGS 170C 210C 90 6 2301 2 20 0...

Page 56: ...2 00 69 25 212 80 74 80 224 80 140 36 00 136 60 12 00 57 30 174 60 61 36 186 60 145 36 00 168 85 12 00 69 25 212 80 74 80 224 80 160 36 00 136 60 12 00 57 30 174 60 61 36 186 60 165 36 00 189 00 12 00...

Page 57: ...9571 9571 210 3196 1451 1590 722 2071 940 1741 790 974 442 9571 9571 NOTE Refer to Figure 36 Table 32 Lifting and Mounting Weights Copper Fins Remote Evaporator Lifting Weights Mounting Weights L1 L2...

Page 58: ...EEN GREEN WHITE WHITE CP2 31 CP2 31 CP2 28 CP2 28 CP1 31 CP1 31 180 GRAY GRAY GREEN GREEN WHITE WHITE CP2 31 CP2 31 CP2 28 CP2 28 CP1 31 CP1 31 190 GRAY GRAY GREEN GREEN WHITE WHITE CP2 31 CP2 31 CP2...

Page 59: ...GRAY GRAY CP2 31 CP2 31 CP2 31 CP2 31 CP2 31 CP2 31 190 GRAY GRAY GRAY GRAY GRAY GRAY 330904123 CP2 32 CP2 32 CP2 31 CP2 31 CP2 31 CP2 31 195 WHITE WHITE GRAY GRAY GRAY GRAY CP2 32 CP2 32 CP2 31 CP2...

Page 60: ...ter Pressure psi kPa 152 1048 152 1048 152 1048 Max Refrigerant Press psi kPa 352 2427 352 2427 352 2427 NOTE Charge quantity does not include field piping Table 38 Physical Data AGS 160C AGS 180C Rem...

Page 61: ...40 Physical Data AGS 125C AGS 145C Remote Evaporator 125C 135C 145C DATA Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2 BASIC DATA Unit Operating Charge lbs kg 159 72 159 72 159 72 159 72 159 72 159 72 Cabinet...

Page 62: ...TEGRAL SUBCOOLER Pumpdown Capacity lbs kg 296 134 296 134 296 134 296 134 296 134 296 134 CONDENSER FANS DIRECT DRIVE PROPELLER TYPE No of Fans Fan Dia in mm 12 12 12 No of Motors hp kW 12 2 1 5 12 2...

Page 63: ...ed to the motor thus helping to protect the motor from overheating or drawing excessive current The starter will automatically stop the motor if the line to line current is not within acceptable range...

Page 64: ...hout proper security Three decimal places blink when remote display is active Fxx xx Fault Code Table 42 Fault Codes Number Description Controlled Stop Auto Reset 00 No Fault 01 UTS Time Limit Expired...

Page 65: ...oning This includes factory wired components Check all of the control wiring in the package for loose connections During the first month after the starter has been put in operation Re torque all power...

Page 66: ...d Wiring OK Swap Any 2 Power Leads Correct and Wait to Cool Replace Control Card Lower Motor Load Correct and Wait to Cool Correct Wiring Return To Service Replace Circuit Breaker Replace Fuses Correc...

Page 67: ...es No No No Yes Yes No No No No Motor Problem Repair or Replace Motor Contact Benshaw For Assistance Replace Control Card Check Jumpers Parameters and CTs Correct Wiring Replace Defective SCRs Does Pr...

Page 68: ...s load is too large for the motor size 11 Current Imbalance Fault If Fault Codes F23 or F24 are displayed on the control card LED display diagnose and correct the cause of the current imbalance parame...

Page 69: ...9 P14 Overcurrent Trip Level 140 Off 50 to 800 RLA P15 Overcurrent Trip Time 2 sec Off 1 90 sec P16 Rated RMS Voltage 460 100 110 120 200 208 220 230 24 0 350 380 400 415 440 460 480 500 525 575 600 6...

Page 70: ...38 Unit Cutaway View Control Panel Power Panel Two circuit DX Evaporator Filter drier 2 Electronic Expansion Valve 2 Suction Connection for Remote Evaporators 2 Liquid Connection for Remote Evaporator...

Page 71: ...RELIEF VALVE SCHRADER VALVE HEADER 330591001 PACKAGE The above diagram illustrates one of the two circuits of an AGS chiller The evaporator has two single pass circuits with water passing over baffle...

Page 72: ...ir 1 Circuit Breaker Single Point Power Only Primary Control Power Fuses Control Transformer Cir 2 Circuit Breaker Single Point Power Only Unit Circuit Breaker Optional Incoming Power Connection Cir 1...

Page 73: ...oller so that if one circuit controller is inoperative the other circuit controller will still be able to run its compressor and circuit components Figure 42 Control Panel Components T2 24V Unit Contr...

Page 74: ...alyzer at or shortly after start up and again on an annual basis The load should be maintained as closely as possible to the load of the original test and only one compressor should be running at a ti...

Page 75: ...s recovery of the noncondensables will be required strictly following Clean Air Act regulations governing refrigerant discharge to the atmosphere The service Schrader valves are located on both vertic...

Page 76: ...and visible leaks X Inspect thermal insulation for integrity X Clean and paint as required X Electrical Sequence test controls X Check contactors for pitting replace as required X Check terminals for...

Page 77: ...nherent in this work Causes for repeated tripping of equipment protection controls must be investigated and corrected 2 Anyone servicing this equipment must comply with EPA requirements regarding refr...

Page 78: ...two liquid line shutoff valves upstream of the filter drier on the circuit to be serviced plus the optional suction shutoff valve Manually open the EXV then remove the remaining refrigerant from the e...

Page 79: ...ust be recharged at the job site Follow these recommendations when field charging Refer to the unit operating charge found in the Physical Data Tables beginning on page 26 for packaged units and page...

Page 80: ...iquid line ahead of the EXV It is used to determine liquid pressure and subcooling and is used to control the EXV Outside air This sensor is located on the back of the control box It measures the outs...

Page 81: ...atically cycles the condenser fans in response to condenser pressure Each fan in a circuit is cycled independently for 4 5 or 6 steps per circuit depending on the unit size This maintains head pressur...

Page 82: ...or Card To provide motor temperature protection at about 220o F 104o C K2 Fault None Inherent in design Auto Power Panel Mechanical High High Pressure Switch For UL ETL etc safety code to prevent high...

Page 83: ...ice High Discharge Pressure 1 Noncondensables in the system 2 Fans not running 3 Fan control out of adjustment 4 System overcharged with refrigerant 5 Dirty condenser coil 6 Air recirculation from fan...

Page 84: ...ircuit status 1 Capacity Circuit status 2 Capacity 13 Water temperature Evaporator Entering Leaving Circuit 1 Circuit 2 14 No of fan states active 15 Evaporator pressure 16 Condenser pressure 17 EXV p...

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Page 88: ...800 432 1342 www mcquay comIMM AGS 2 07 08 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...

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