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McQuay TGZ 040, Operation And Maintenance Manual, Page: 1 / 84

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 Operation and Maintenance Manual 

OMM TGZ-1

 

 

Group: Chiller 

 

Part Number: 331975601 

 

Effective: February 2011 

 

Supercedes: June 2009 

 

 

 

TGZ Scroll Compressor Templifiers

 

TGZ 040A to TGZ 190A, Packaged Water Heater 

600 to 3100 MBH 

R134a  

Software: WGZDU0102E 

 

 

 

 

Corrections 
2/22/11  Changed/added setpoints pgs 62, 63,+ 

Summary of Contents for TGZ 040

Page 1: ...Chiller Part Number 331975601 Effective February 2011 Supercedes June 2009 TGZ Scroll Compressor Templifiers TGZ 040A to TGZ 190A Packaged Water Heater 600 to 3100 MBH R134a Software WGZDU0102E Corre...

Page 2: ...tional Controls 74 Part Winding Start 74 Phase Voltage Monitor Optional 74 Hot Gas Bypass Optional 74 System Maintenance 76 General 76 Electrical Terminals 77 Operating Limits 77 Compressor Oil 77 Oil...

Page 3: ...al information not included in this manual such as unit dimensions and weights physical data and performance data can be found in Catalog Templifier 1 Nomenclature T G Z 100 A Water Pressure Drop The...

Page 4: ...89 6 8 11 9 20 3 315 17 9 19 9 53 6 110A AC350 182DQ 113 2 2 7 1 6 4 218 7 5 13 8 22 4 363 19 8 22 9 59 1 120A AC350 182DQ 128 2 7 8 1 8 2 246 9 5 15 5 28 4 410 25 1 25 9 74 9 150A EV34191111 9 147 2...

Page 5: ...23 1 93 1 45 5 77 47 7 5 3 0 22 4 63 13 1 4 0 39 1 TGZ050 C1010 62 32 2 44 2 02 7 29 64 9 1 4 0 27 2 86 16 0 5 4 47 7 TGZ060 C1010 76 38 3 40 2 40 10 16 77 13 0 4 9 38 9 103 22 6 6 5 67 5 TGZ080 C1410...

Page 6: ...8 13 0 17 3 330 14 2 20 8 42 3 TGZ100 C1410 128 150 2 5 9 5 7 3 240 6 0 15 1 17 9 384 14 7 24 2 43 8 TGZ110 C1610 164 173 2 0 10 9 6 0 276 4 9 17 4 14 6 442 12 0 27 9 35 8 TGZ120 C1610 164 195 2 5 12...

Page 7: ...9 599 460 35 3 35 3 45 5 45 5 31 2 31 2 40 0 40 0 250 250 310 310 110 575 60 28 2 28 2 36 5 36 5 25 2 25 2 32 0 32 0 198 198 239 239 208 93 6 93 6 93 6 93 6 88 8 88 8 88 8 88 8 599 599 599 599 230 93...

Page 8: ...1 0 460 79 79 70 70 3 4 4 3 4 4 100 575 60 64 64 57 57 3 6 6 3 6 6 208 165 211 156 200 3 2 0 4 0 3 2 0 3 0 230 165 211 140 180 3 2 0 4 0 3 1 0 3 0 460 79 102 70 90 3 4 2 3 4 3 110 575 60 64 82 57 72 3...

Page 9: ...00 575 60 120 107 3 1 3 2 208 357 338 6 2 3 0 6 2 2 0 230 357 305 6 2 3 0 3 350 460 173 152 3 2 0 3 2 0 110 575 60 139 122 3 1 0 3 1 208 398 377 6 2 3 0 6 2 3 0 230 398 340 6 2 3 0 6 2 2 0 460 193 170...

Page 10: ...25 90 90 80 80 080 575 60 125 110 70 70 60 60 208 350 350 225 225 200 200 230 350 300 225 225 200 200 460 175 150 110 110 100 100 100 575 60 125 125 90 90 80 80 208 450 400 225 300 200 250 230 450 350...

Page 11: ...500 kcmil 600 2 3 0 500 kcmil 460 175 14 2 0 250 6 350 kcmil 250 6 350 kcmil 100 575 60 175 14 2 0 250 6 350 kcmil 200 6 350 kcmil 208 380 4 500 kcmil 400 2 3 0 500 kcmil 600 2 3 0 500 kcmil 230 380 4...

Page 12: ...3 0 500 kcmil 460 335 6 400 kcmil 250 6 350 kcmil 250 6 350 kcmil 100 575 60 335 6 400 kcmil 250 6 350 kcmil 250 6 350 kcmil 208 760 2 2 500 kcmil 400 2 3 0 500 kcmil 600 2 3 0 500 kcmil 230 760 2 2...

Page 13: ...0 250 6 350 kcmil 250 6 350 kcmil 230 175 14 2 0 175 14 2 0 250 6 350 kcmil 250 6 350 kcmil 460 175 14 2 0 175 14 2 0 100 10 1 0 100 10 1 0 100 575 175 14 2 0 175 14 2 0 100 10 1 0 100 10 1 0 208 380...

Page 14: ...350 kcmil 250 6 350 kcmil 230 175 14 2 0 175 14 2 0 250 6 350 kcmil 250 6 350 kcmil 460 175 14 2 0 175 14 2 0 100 10 1 0 100 10 1 0 100 575 175 14 2 0 175 14 2 0 100 10 1 0 100 10 1 0 208 380 4 500 kc...

Page 15: ...tionally a field installed control power source can be wired to the unit Wiring and conduit selections must comply with the National Electrical Code and or local requirements An open fuse indicates a...

Page 16: ...ALARM BELL OPTION 10 15 CONTROLLER TB2 ICE MODE SWITCH BY OTHERS 51 52 42 60 40 53 43 55 49 50 ALARM BELL RELAY ALARM BELL OPTION BELL 1 2 COM NO AUTO TIME CLOCK OFF ON MANUAL AUTO OFF ON MANUAL REMO...

Page 17: ...former Control Transformer Fuses Primary Control Transformer Fuse Secondary Optional Disconnect Switch Microtech II Controller 2 Circuit Mechanical Hi Pressure Switch Relays 4 Compressor Contactors Gr...

Page 18: ...ailable to handle load 10 Make sure all wiring and fuses are of the proper size Also make sure all interlock wiring is completed per McQuay diagrams 11 Verify that all mechanical and electrical inspec...

Page 19: ...t leave the vessels or piping open to the atmosphere over the shutdown period Start up after Extended Shutdown 1 Inspect all equipment to see that it is in satisfactory operating condition 2 Backseat...

Page 20: ...her way the Start Delta Temperature set point is the number of degrees below the Active Heat Leaving Water Temperature set point minus the Control Band that determines when the first compressor starts...

Page 21: ...rature falls below 141 5 F all running compressors will remain on No compressor staging occurs within the Control Band The next on compressor will start when the condenser leaving water temperature dr...

Page 22: ...al Pumpdown When the Pumpdown Switch is in the pumpdown position all compressors except 1 and 2 will shut off Then the Liquid Line and Hot Gas Bypass Valves will close The operating compressor will pu...

Page 23: ...nostic checks monitoring all system temperatures pressures and protection devices and will automatically shutdown a compressor a refrigerant circuit or the entire unit should a fault occur The cause o...

Page 24: ...data screens as indicated by the arrows default mode 2 Select a specific data screen in a hierarchical fashion using dynamic labels on the right side of the display this mode is entered by pressing t...

Page 25: ...igerant Pressure 2 C2 0 1 to 0 9 VDC 3 6 to 410 psi 7 Reset of Leaving Water Temperature UT 4 20 mA Current 0 10 to 80 F 8 Condenser Leaving Water Temperature UT NTC Thermister 10k 25 C 58 to 212 F 9...

Page 26: ...trical Circuit 2 Table 12 Digital Outputs The following parameters are digital outputs from this controller C1 Refrigerant Circuit 1 C2 Refrigerant Circuit 2 UT Unit n Refrigerant Dependent Descriptio...

Page 27: ...parameters are remembered during power off are factory set to the Default value and can be adjusted to any value in the Range column The PW password column indicates the password level that must be ac...

Page 28: ...r of Compressors 4 4 6 M Clear Cycle Tmr Off On Off M Stage Up Delay 240 seconds 120 to 480 seconds M Stage Down Delay 30 20 to 60 sec M Start Start 15 min 10 to 60 min M Stop Start 5 min 3 to 20 min...

Page 29: ...F M Maximum Start Position 100 0 to 100 M Maximum Position 90 F 0 to 100 F M Error Gain 25 10 to 99 M Slope Gain 25 10 to 99 M Set at McQuay factory Table 16 Automatic Adjusted Limits The following a...

Page 30: ...ise that require some action from the chiller or that should be logged for future reference Conditions that cause a shutdown and require manual reset is known as a stop alarm Other conditions can trig...

Page 31: ...trigger it can auto reset the first two times each day with the third occurrence being manual reset For the auto reset occurrences the alarm will reset automatically when the condenser pump state is...

Page 32: ...ge Cir N Trigger PVM input is low and Phase Voltage set point enable Action Taken Rapid stop circuit Reset Auto reset when PVM input is high Ground Fault Protection Alarm description as shown on scree...

Page 33: ...Trigger Sensor shorted or open Action Taken Normal stop all circuits Reset This alarm can be cleared manually via the keypad if the sensor is back in range Evaporator Water Freeze Protect Alarm descr...

Page 34: ...in the Alarm Log Low Evaporator Pressure Hold Event description as shown on screen Evap Press Low HoldN Trigger This event is triggered if all of the following are true circuit state Run circuit is n...

Page 35: ...ff or since midnight See table below CONDENSER CONFIGURATION COMPRESSORS R134a STEP INCREASE 4 30 psi 10 psi Water Cooled 6 20 psi 10 psi Failed Pumpdown Event description as shown on screen Pumpdown...

Page 36: ...pon the InterStage Dn set point time interval Reset N A EXB Comm Failure on CP1 TGZ unit only Event description as shown on screen No EXB comm CP1 Trigger CP1 does not have communication with either E...

Page 37: ...Cool LWT 39 0 F Stage Up temperature is calculated as Stage Up temperature Cool LWT Control Band Cool LWT 39 0 F In all other Unit modes the compressor staging temperatures are calculated as shown be...

Page 38: ...ng For use in some control functions the negative slope is converted to a positive value by multiplying by 1 Evaporator Saturated Temperature Evaporator saturated temperature is calculated from the ci...

Page 39: ...e value is ignored Unit Off Input Control Source Set Point Remote Input Key pad Entry BAS Request Unit Enable OFF X x x x OFF x SWITCHES OFF x x OFF ON SWITCHES ON x x ON ON KEYPAD x OFF x OFF ON KEYP...

Page 40: ...ble if the circuit switch is in the on position and no circuit alarms are active Timers that delay startup or staging of a circuit do not render it unavailable Power Up Start Delay After powering up t...

Page 41: ...No Unit Alarm AND IF Unit Mode Cir 1 Available OR Cir 2 Available T2 Auto to Pumpdown Keypad Enable Off OR BAS Enable Off OR Remote Switch Off OR T3 Pumpdown to Off Unit Alarm OR Unit Switch Off OR No...

Page 42: ...he pump designated as primary will start first If the evaporator state is start for a time greater than the recirculate timeout set point and there is no flow then the primary pump will shut off and t...

Page 43: ...ed If a third loss of flow is indicated in a twenty four hour time frame the unit will shut down on an Evaporator Water Flow Loss alarm and it will be locked out until this alarm is manually cleared T...

Page 44: ...ondenser Water Flow Loss The Condenser Water Flow Loss logic allows the Unit to shutdown compressors on a loss of flow up to two times every twenty four hours before locking the unit out on a Condense...

Page 45: ...bove conditions are met for the next stage plus the following condition VFD Speed is the Stage Up set point only if Valve VFD Control set point VFD Stage OR Valve SP VFD Stage Down staging occurs when...

Page 46: ...d the Valve Control Range Max set point A valve increment shall be computed once every 5 seconds according to the following equation Increment Error Error Gain set point Slope Slope Gain set point Whe...

Page 47: ...acity limit AND Stage up timer expired THEN Stage Up Now True If Unit mode Heat AND no compressors are running AND LWT error Start delta 0 5 Control Band AND Motor Protect Timer expired AND Stage up t...

Page 48: ...The following conditions shall override the automatic capacity control when the chiller is in cool mode only These overrides keep a circuit from entering a condition in which it is not designed to ru...

Page 49: ...ial Offset Step Increase Condenser Configuration No of Compressors R134a Step Increase 4 30 psi 10 psi Water Cooled 6 20 psi 10 psi 4 N A 15 psi Air Cooled 6 N A 15 psi Example of Operation Assume a p...

Page 50: ...only enabled if the unit control source is set to network The maximum unit capacity stage is based on the network limit value received from the BAS and is determined as shown in the following graph In...

Page 51: ...arises that requires a circuit to shut down but it is not an emergency situation then the circuit will do a pump down A normal circuit shutdown will be initiated when any of the following occur Unit S...

Page 52: ...on the number of compressors running and number of compressors on unit Compressors Running Number of Compressors Valve Position 1 2 3 EXV Min 8 8 4 EXV Max 60 100 EXV Min 8 8 8 6 EXV Max 35 45 65 Manu...

Page 53: ...e four ARROW keys The other way is to use shortcuts to work through the matrix hierarchy From any menu screen pressing the MENU key will take you to the top level of the hierarchy The display will sho...

Page 54: ...display this mode is entered by pressing the ENTER key Most menus containing setpoint values have several different setpoints shown on one menu When in a setpoint menu the ENTER key is used to procee...

Page 55: ...EW FAN TOWER 1 VIEW EVENT LOG 1 VIEW UNIT STATUS 5 VIEW UNIT TEMP 2 VIEW COMP 1 STATUS 3 VIEW CIRC 2 STATUS 3 VIEW EVAP 2 VIEW EVAP 2 VIEW FAN TOWER n VIEW EVENT LOG n Right side of matrix continued f...

Page 56: ...it Status VIEW UNIT STATUS 1 Auto Cooling Stage 0 Evap Pump RUN Unit states can be OFF COOL GYLCOL or ALARM as determined from the Unit Mode setpoint the Unit Enable and the presence of an alarm Circu...

Page 57: ...78 000000000000000000 This menu gives the status of digital inputs D I 1 ON 0 OFF Numbers are 1 through 18 See Table 11 on page 25 for number reference VIEW UNIT STATUS 6 Analog Output volts x 100 1 0...

Page 58: ...Only in Heat Mode VIEW UNIT TEMP 5 VIEW UNIT TEMP 5 Cond LWT XX X F Cond LWT XX X F Evap EWT XX X F Evap EWT XX X F View Circuit VIEW CIRCUIT 1 1 OFF VIEW CIRCUIT 1 2 Comp 1 OFF Hours XXXXX Starts XX...

Page 59: ...ss XXX X psi Cond Press XXX X psi VIEW REFRG Cir 1 2 Sat Evap XXX X F Sat Cond XXX X F i VIEW REFRG Cir 1 3 SuctionTemp XXX X F Surperheat XXX X F EvapApproach XX X F TGZ Only R134a VIEW REFRG Cir 1 4...

Page 60: ...with EEV only VIEW REFRG Cir 2 5 EXV Ctrl XXX EXV Pos XXX X SH Target XX X F TGZ Units Only R134a VIEW REFRG Cir 2 6 EXV Ctrl Range XX X XX X View Tower VIEW TOWER 1 Stages ON 1 of 2 EntCondTemp XXX F...

Page 61: ...r type alarm will light a red light in back of the LEFT ARROW KEY The light will go out when the fault is cleared To clear the fault scroll down to the last screen and press ENTER If other faults have...

Page 62: ...erature glycol applications It allows a lower LWT setpoint to be used ICE w GLYCOL used with ice storage systems is not an option with TGZ Templifiers Unit Mode settings can be COOL COOLw Glycol or IC...

Page 63: ...ce settings available mid 2003 SET UNIT SPs 11 Evap Press Sensor Cir 1 Cir 2 Offset 00 0 00 0 psi The pressure offsets on menus 8 and 9 and the temperature offsets on menus 10 11 and 12 correct the co...

Page 64: ...ing can be changed The operator password is 0100 The manager level is 2001 This screen can be accessed either through the SET OTHER menu or by simply pressing the ENTER key while on one of the SET scr...

Page 65: ...have thermal expansion valves TGZ 150 190 have electronic valves Expansion Valve Type Electronic SET COMP SPs 6 Cir 1 EXV EXV Control Auto Manual EXV Pos XXX X Expansion Valve Type Electronic SET COM...

Page 66: ...StartTMR XXsec GroundFault and PhaseVoltage entries are Y Yes or N No depending on whether the options are on the unit CondFreeze is an alarm that reduces the chance of freezing the water in the conde...

Page 67: ...stage up timer completes The ECWT is Stage 1 ON setpoint Bypass valve position is the Stage Up setpoint only if Valve VFD Control setpoint Valve Stage Additional stages can turn on up to the number s...

Page 68: ...staging down the fan motors SET TOWER SPs 4 Valve VFD Control ValveSP VFDStage Valve Type NC to Twr Valve VFD Control settings are None Valve Setpoint Valve Stage VFD Stage or ValveSP VFDStage Default...

Page 69: ...e Type Valve Type settings are NC normally closed to tower or NO normally open These settings establish the operation of a tower bypass valve must be a 3 way valve Initial Valve Position When the cond...

Page 70: ...ntrol Loop Error Gain XX Slope Gain XX Defaults are 25 for both error and slope TEST The test screens are only available when the unit is in TEST mode Using these screens any digital output can be con...

Page 71: ...alarm occurs the alarm type limit value if any date and time are stored in the active alarm buffer corresponding to that alarm viewed on the Alarm Active screens and also in the alarm history buffer...

Page 72: ...sible Available Parameters Types A Analog I Integer D Digital I O I Input only O Output only I O Input Output Type Index I O Description LONWORKS BACnet Modbus A 1 I O Network Cool LWT set point x x x...

Page 73: ...Flag x x x I 28 O Unit model type refrigerant x x x I 29 O Unit language x x x I 30 O Unit software version x x x I 32 I Compressor select x x x I 35 I O Clock year x x I 36 I O Clock month x x I 37 I...

Page 74: ...ave been provided to prevent nuisance tripping due to rapid power fluctuations When three phase power has been applied the output relay should close and the run light should come on If the output rela...

Page 75: ...adjustment screw clockwise To lower the setting turn the screw counterclockwise Do not force the adjustment beyond the range it is designed for as this will damage the adjustment assembly The regulat...

Page 76: ...at the center of the oil sightglass Low oil level can cause inadequate lubrication and oil must be added use oils referred to in Compressor Oil Level section below A pressure tap has been provided on...

Page 77: ...pon initial start up and for sometime thereafter Oil Type Compressor oil must be Copeland brand Ultra 22 CC Copeland brand Ultra 32 CC Copeland brand Ultra 32 3MAF Mobil EAL Artic 22 CC Uniqema RL32 3...

Page 78: ...at the system is short of refrigerant charge Refrigerant gas flashing in the sight glass could also indicate an excessive pressure drop in the line possibly due to a clogged filter drier or a restrict...

Page 79: ...l switch S1 to the off position Remove the jumper Front seat the suction line King valve s Remove and replace the filter drier s Evacuate the lines through the liquid line manual shutoff valve s to re...

Page 80: ...re of the hot water Check operation of the supplementary heater 2 Clean 3 Purge the noncondensables 4 Remove excess refrigerant 5 Open valve 6 Check condenser rating tables against the operation Low D...

Page 81: ...Low voltage during high load conditions 2 Defective or grounded wiring in motor or power circuits 3 Loose power wiring 4 High condensing temperature 5 Power line fault causing unbalanced voltage 6 Hig...

Page 82: ...82 TGZ 040A through TGZ 190A OMM TGZ 1...

Page 83: ......

Page 84: ...product information please go to www mcquay com Warranty and Terms of Sale All McQuay equipment is sold pursuant to McQuay s Standard Terms and Conditions of Sale and Limited Product Warranty Consult...

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