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Installation, Operation and Maintenance Manual

IOMM AGR-1

Group:

Chiller

Part Number:

330145704

Effective:

August 2001

Supersedes:

IOMM AGR

Air-Cooled Reciprocating Chiller

AGR 070AS through 100AS
60 Hertz, English and Metric
Global Chiller Line

Содержание AGR 070AS

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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