Installation manual

303 C - 99/04 A
Date: April 1999 Supersedes: None

AG HA 030.2110.2 Air cooled water chillers Serial number:

Index
Chapter 1 - Introduction
1.1.0. 1.2.0. 2.1.0. 2.2.0. 2.2.1. 2.2.2. 2.2.3. 2.2.4. 2.2.5. 2.2.6. 2.3.0. 2.3.1. 2.3.2. 2.3.2.1. 2.3.2.2. 2.4.0. 2.4.1. 2.4.1.1. 2.4.1.2. 2.4.2. Purpose of the manual Responsabilities declined General description Characteristics Technical characteristics Electrical characteristics Water flow limits Water temperature limits Pressure limits Drawings and wiring diagrams Safety measures General cautions Cautions and specific warnings Lifting Access to the unit Installation Warnings Transport Inspection Handling

Chapter 2 - Manual content

2.4.3. 2.4.3.1. 2.4.4. 2.4.4.1. 2.4.4.2 2.4.4.3. 2.4.5. 2.4.6. 2.4.6.1. 2.5.0. 2.5.1. 2.5.2. 2.5.3. 2.5.3.1. 2.5.3.2. 2.5.3.3. 2.5.4. 2.5.5. 2.5.5.1 2.6.0. 2.7.0.

Location Clearance requirements Water piping General Chilled water piping Condenser water piping Testing Electrical field wiring Field wiring Start up and shut down Control centre layout Pre start-up Start-up Warning Sequence of start-up Warning Emergency stop Temporary shut down Warning System maintenance Problems: causes and possible steps

Chapter 1 - Introduction
1.1.0. Purpose of the manual
This manual allows both the installer and the operator to perform correctly all the operations referring to the installation and maintenance of the chiller without provoking any damages to the unit or the qualified personnel. Therefore the manual is of great help for the qualified personnel that have to arrange the equipment for providing the correct installation in accordance with local codes and regulations.

Chapter 2 - Manual content

2.1.0. General description
McQuay AG HA air cooled water chillers are manufactured in order to produce chilled water. Each unit is factory assembled and wired: then it is vacuued, charged with R22, R407C or R134a refrigerant and tested. The refrigerant circuit consists of a air condenser, scroll compressors for units from 030.2 to 045.2 and semihermetic compressors from 050.2 to 110.2 C, including a subcooler, and a shell and tube evaporator. The standard components of the liquid line are: stop valve, discharge valve, dehydrator filters, solenoid valve, sight glass moisture indicator, thermostatic expansion valve. Morever the following components are included: compressor crankcase heater, pump-down system, microprocessor with key pad display to control and set up all unit running conditions. The electrical panel is equipped with all the safety systems that ensure reliable automatic workings. The motors of the compressors are equipped with fuses on three phases and are started by threepole contactors.

1.2.0. Resposibilities declined

McQuay Italia declines all present and future resposibilities referring to injuries to people and damage to things and unit, coming from negligence of the operators, from the unrespected installation/maintenance data carried in this manual, the non-persuance of the current regulations referred to the safety of both the equipment and the qualified personnel in charge for the installation and maintenance.

303 C - 99/04 A - pag. 2

2.2.0. Characteristics
2.2.1. Technical characteristics
"AGZ HA ST, CN" unit size
Cooling capacity (HCFC 22) (1) kW Power input (HCFC 22) (1) kW Cooling capacity (HFC 407C) (1) kW Power input (HFC 407C) (1) kW Cooling capacity (HFC 134a) (1) kW Power input (HFC 134a) (1) kW Compressor type/No. of compressor No. of circuit No. of reduction steps Standard Condenser fans No. of fans/Fan motor kW Total air flow m3/s Evaporator No. of evaporator Max operating pressure bar Water volume l Condenser coil No. of coil Weight Operating weight kg Shipping weight kg

030.2
97,0 30,0 94,0 30,0 66,0 18,5 scroll/4 2 4 2/2,1 12,6 1 16 40 2 1520 1480

035.2
101,8 40,8 98,7 40,8 69,2 25,1 scroll/4 2 4 2/2,1 12,6 1 16 40 2 1520 1480

040.2
115,8 45,8 112,4 45,8 78,8 28,2 scroll/4 2 4 2/2,1 12,2 1 16 40 2 1520 1480

045.2
128,1 50,8 124,3 50,8 87,1 31,2 scroll/4 2 4 2/2,1 12,2 1 16 40 2 1520 1480

"AGR HA ST, CN" unit size

Cooling capacity (HCFC 22) (1) kW Power input (HCFC 22) (1) kW Cooling capacity (HFC 407C) (1) kW Power input (HFC 407C) (1) kW Cooling capacity (HFC 134a) (1) kW Power input (HFC 134a) (1) kW Compressor type/No. of compressor No. of circuit No. of reduction steps Standard Condenser fans No. of fans/Fan motor kW Total air flow m3/s Evaporator No. of evaporator Max operating pressure bar Water volume l Condenser coil No. of coil Weight Operating weight kg Shipping weight kg

050.2
172,7 60,2 167,5 60,2 117,4 37,0 recip/2 2 4 4/2,1 25,2 1 16 60 4 2310 2245

055.2
185,7 66,3 180,1 66,3 126,3 40,8 recip/2 2 4 4/2,1 25,2 1 16 60 4 2310 2245

060.2
198,7 72,4 192,7 72,4 135,1 44,5 recip/2 2 4 4/2,1 25,2 1 16 60 4 2310 2245

065.2
229,2 80,6 222,3 80,6 156,0 49,6 recip/2 2 4 4/2,1 25,2 1 16 100 4 2310 2245

070.2
260,1 88,8 252,3 88,8 177,0 54,6 recip/2 2 4 4/2,1 25,2 1 16 100 4 2310 2245

075.2
270,3 89,8 262,2 89,8 183,8 55,2 recip/2 2 4 4/2,1 25,2 1 16 90 4 2310 2245

Note: (1)

Nominal cooling capacity are based on: 12/7 C entering/leaving evaporator water temperature; 46C ambient temperature.

303 C - 99/04 A - pag. 3

"AGR HA ST, CN" unit size

Cooling capacity (HCFC 22) (1) kW Power input (HCFC 22) (1) kW Cooling capacity (HFC 407C) (1) kW Power input (HFC 407C) (1) kW Cooling capacity (HFC 134a) (1) kW Power input (HFC 134a) (1) kW Compressor type/No. of compressor No. of circuit No. of reduction steps Standard Condenser fans No. of fans/Fan motor kW Total air flow m3/s Evaporator No. of evaporator Max operating pressure bar Water volume l Condenser coil No. of coil Weight Operating weight kg Shipping weight kg Note: (1)

080.2
278,0 96,3 269,7 96,3 189,0 59,2 recip/2 2 4 6/2,1 37,75 1 16 90 4 3110 3025

085.2
295,7 103,8 286,8 103,8 201,1 63,8 recip/2 2 4 6/2,1 37,75 1 10,5 90 4 3110 3025

090.2
307,5 104,8 298,3 104,8 209,1 64,5 recip/2 2 4 6/2,1 37,75 1 10,5 90 4 3110 3025

095.2
326,1 112,0 316,3 112,0 221,7 68,9 recip/2 2 4 6/2,1 37,75 1 10,5 90 4 3500 3415

100.2
336,3 117,4 326,2 117,4 228,7 72,2 recip/2 2 4 6/2,1 37,2 1 10,5 90 4 3500 3415

110.2
346,4 122,8 336,0 122,8 235,6 75,5 recip/2 2 4 6/2,1 36,7 1 10,5 90 4 3500 3415

Nominal cooling capacity are based on: 12/7 C entering/leaving evaporator water temperature; 46C ambient temperature.

2.2.2. Electrical data

"AGZ HA ST, CN" (HCFC 22, HFC 407C)
Standard voltage Max absorbed current compressor (FLA) (2) Max inrush current bigger compressor AL Max inrush current bigger compressor PW Total fans absorbed current Max unit absorbed current Max unit inrush current AL Max unit inrush current PW A A A A A A A

030.2
53,0 116,0 NA 7,6 60,6 165,3 NA

035.2

040.2

045.2
90,0 159,0 NA 7,6 97,6 227,0 NA

400 V - 3f - 50 Hz (1) 72,0 81,0 128,0 159,0 NA NA 7,6 7,6 79,6 88,6 186,8 222,0 NA NA

"AGR HA ST, CN" (HCFC 22, HFC 407C)

Standard voltage Max absorbed current compressor (FLA) (2) Max inrush current bigger compressor AL Max inrush current bigger compressor PW Total fans absorbed current Max unit absorbed current Max unit inrush current AL Max unit inrush current PW A A A A A A A

050.2
106,5 NA 202,0 15,2 121,7 NA 282,0

055.2
117,3 NA 247,0 15,2 132,5 NA 332,0

060.2

065.2

070.2
157,0 NA 286,0 15,2 172,2 NA 391,0

075.2
158,8 NA 286,0 15,2 173,0 NA 392,0

400 V - 3f - 50 Hz (1) 128,0 142,5 NA NA 247,0 286,0 15,2 15,2 143,2 157,7 NA NA 337,6 384,0

"AGR HA ST, CN" (HCFC 22, HFC 407C)

Standard voltage Max absorbed current compressor (FLA) (2) Max inrush current bigger compressor AL Max inrush current bigger compressor PW Total fans absorbed current Max unit absorbed current Max unit inrush current AL Max unit inrush current PW Notes: (1) Allowed voltage tollerance 10%. (2) Absorbed current max. condition. A A A A A A A

080.2
170,2 NA 347,0 22,8 193,0 NA 462,5

085.2
183,5 NA 347,0 22,8 206,3 NA 470,0

090.2

095.2

100.2
207,7 NA 537,0 22,8 230,5 NA 671,0

110.2
217,2 NA 537,0 22,8 240,0 NA 676,0

400 V - 3f - 50 Hz (1) 185,4 198,0 NA NA 347,0 345,0 22,8 22,8 208,2 220,8 NA NA 470,5 474,5

303 C - 99/04 - pag. 4

"AGZ HA ST, CN" (HFC 134a)

Standard voltage Max absorbed current compressor (FLA) (2) Max inrush current bigger compressor AL Max inrush current bigger compressor PW Total fans absorbed current Max unit absorbed current Max unit inrush current AL Max unit inrush current PW A A A A A A A

030.2
32,7 116,0 NA 7,6 40,3 155,0 NA

035.2

040.2

045.2
55,3 159,0 NA 7,6 62,9 209,5 NA

400 V - 3f - 50 Hz (1) 44,3 49,9 128,0 159,0 NA NA 7,6 7,6 51,9 57,5 173,0 206,7 NA NA

"AGR HA ST, CN" (HFC 134a)

Standard voltage Max absorbed current compressor (FLA) (2) Max inrush current bigger compressor AL Max inrush current bigger compressor PW Total fans absorbed current Max unit absorbed current Max unit inrush current AL Max unit inrush current PW A A A A A A A

050.2
65,5 NA 114,0 15,2 80,7 NA 173,4

055.2
72,2 NA 155,0 15,2 87,4 NA 217,7

060.2

065.2

070.2
96,6 NA 247,0 15,2 111,8 NA 322,0

075.2
97,6 NA 247,0 15,2 112,8 NA 322,5

400 V - 3f - 50 Hz (1) 78,7 87,6 NA NA 155,0 247,0 15,2 15,2 93,9 102,8 NA NA 221,0 317,5

"AGR HA ST, CN" (HFC 134a)

Standard voltage Max absorbed current compressor (FLA) (2) Max inrush current bigger compressor AL Max inrush current bigger compressor PW Total fans absorbed current Max unit absorbed current Max unit inrush current AL Max unit inrush current PW Notes: (1) Allowed voltage tollerance 10%. (2) Absorbed current max. condition. A A A A A A A

080.2
104,6 NA 315,0 22,8 127,4 NA 398,0

085.2
112,8 NA 315,0 22,8 135,6 NA 402,0

090.2

095.2

100.2
127,6 NA 345,0 22,8 150,4 NA 439,2

110.2
133,5 NA 345,0 22,8 156,3 NA 442,2

400 V - 3f - 50 Hz (1) 114,0 121,7 NA NA 315,0 345,0 22,8 22,8 136,8 144,5 NA NA 402,5 436,3

2.2.3. Water flow limits

See Product Manual 303 B

2.2.4. Water temperature limits

EVAPORATOR
Min. outlet wtr temp. - C Standard unit Unit with glycole and low temperature kit Unit with water inlet max. temperature thermostat Unit off 5 -8 Max. inlet wtr temp. - C 19 19 32 40

2.2.5. Pressure limits

EVAPORATOR
Max operat. press. bar Refrigerant side: ISPESL TV Service des Mines S.A. Water side: ISPESL TV Service des Mines S.A. 10,5 10,5 10,5 10,5 14,0 14,0 14,0 14,0 16,5 16,5 13,0 16,5 21,5 21,5 26,0 21,5 30,0 30,0 37,6 39,0 Pressure test bar

CONDENSER COIL
Max operat. press. bar Pressure test bar

303 C - 99/04 A - pag. 5

2.2.6. Drawings and wiring diagrams

The overall dimensional drawings and electrical drawings are here attached and their reference numbers are those listed on the cover of this manual.

WARNING !
Avoid unrelated bodies into the water piping during the connection of the unit to the water system

2.3.0. Safety measures

2.3.1. General precautions
The unit must be placed internally arranged for the clamping to heart of the chiller and if necessary must be equipped with anti vibrations shock absorbers. "Warning and Danger" notices are supplied on the following parts: electrical panel, compressors, safety valves, expansion valves, compressors liquid line shutoff valves.

WARNING !
Forsee a mechanical filter for the piping connected to the entry of the exchangers of the unit

DANGER !
Disconnect all power to the unit while servicing condenser fan motors. Failure to do so may cause bodly injury or death

2.3.2. Cautions and specific warnings

DANGER !
Sharp edges and coil surface are a potential injury hazard. Avoid contact with them

2.4.0. Installation
Before any operation please check the instruction for use.

2.4.1. Warning
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. The installation of the unit in places that could be considered dangerous for all the maintenance operations must be avoided.

DANGER !
The unit must be lifted only by using the proper tools able to support the weight of the unit locking it through the lifting holes

2.4.1.1. Transport
In order to avoid problems it's necessary to be sure of the stability of the unit during transportation. This is why the unit is supplied with a transversal wooden beam placed at the base that have to be removed only when the unit has arrived at final destination. In case the unit has to be moved again, it's necessary to adapt a similar solution.

DANGER !
No admittance to unauthorized or unqualified personnel.

DANGER !
No operation on electrical components is allowed without having switched off electricity supply.

2.4.1.2. Inspection
All units are factory assembled and equipped. Before shipment, units are charged with the necessary quantity of refrigerant and oil and tested at working conditions requested by the client. When the equipment is received, all items should be carefully checked against the bill of lading to insure a complete shipment. All units should be carefully inspected for damage upon arrival. All shipping damage should be reported to carrier and a claim form should be filled.

DANGER !
No operation is allowed without using insulated platforms No water or moisture is should be present.

DANGER !
All the operations to refrigerant circuit and vessels, and all pressurised parts are to be performed by qualified personnel only

2.4.2. Handling
If the unit must be hoisted, it is necessary to lift the unit by attaching cables or chains at the lifting holes in the evaporator tube sheets. Spreader bars must be used to protect the
Size the cables and spreader bars in conjunction with lifting weight.

DANGER !
The substitution or addition of oil in the compressors must be performed by qualified personnel only

Use spreader bar to avoid damage to the unit

DANGER !
Convey the discharge of the safety valves outside the room

WARNING !
Before switching off the power supply performe the stop procedure reported on paragraph 2.5.5.
Use only these rigging holes

fig.1

303 C - 99/04 A - pag. 6

2.4.3.0. Location
A reasonably level and sufficiently strong floor is required in order to bear the weight of the chiller. If necessary, additional structural members should be provided to transfer the weight of the unit to the nearest beams. Rubber-in-shear isolator (see enclosure drawings) can be furnished and field placed under each corner of the package. Set the unit in place and level with a spirit level. Vibration eliminators in all water piping connected to the chiller are recommended to avoid straining the piping and transmitting vibrations and noise.

Check the proper installation of the unit respecting the regulations referred to safety. Check the proper lead of the piping considering the water inlet/outlet of the evaporator, on the condensers

2.4.6 Electrical Field wiring (see wiring diagram enclosure) 2.4.6.1 Field wiring
The unit's electrical panel has a terminal block board to lead a 3-pole cable with ground of adequate gross section for the motor rating, to the main cutout switches. If the main cutout switch is installed the line must be connected to its terminal block board. To provide power to the main cutout, if there is no transformer, it's necessary to provide monophase power

2.4.3.1. Clearance requirements

Each side of the unit must be accessible after installation for periodic service work. Clearance should be provided for cleaning evaporator tubes or for removing compressors. Minimum recommanded clearance requirements (see enclosure drawings).

WARNING !
Inside the electrical panel there is a yellow/green terminal block to lead the unit to the ground. Perform the connection in accordance with the local regulations. to terminal block 1 a 2.

2.4.4.0. Water piping 2.4.4.1 General

1 - Select piping according to local codes of praticies and security norms. 2 - Shut off valves should be provided at the unit so that normal servicing can be accomplished without draining the system. 3 - It's recommended that temperature and pressure indicators be installed at the inlet and outlet of the heat exchangers to and in the normal checking and servicing the unit. 4 - It's recommended the installation of a wire mesh strainer at the pump suction to protect the pump and the and the exchangers from foreign matter. 5 - Before insulating the piping and filling the system, a preliminary leak check should be made. 6 - Vibration eliminators are recommended in all lines connected to the unit. 7 - Automatic flow control devices, although not furnished with the chiller as they are plant components, must be installed. 8 - Drawings enclosure shows pipe connection sizes.

WARNING !
The power tension must fluctuate more than 10%. The balance between the phases must not be greater than 3%. Condenser and evaporator flow switches must be connected to the following terminals: Evaporator flow switch: terminal 5 and 6. Power inlet must be effected on the upper side of the electrical panel through a plate with references for the cables.

2.5.0. Start up and shut down

2.5.1. Control centre layout (see wiring diagram enclosure) 2.5.2. Pre start-up
1 - With main disconnect switch Q10 open, check all the electric connection in control panel and starter to be sure they are fight and provide good electrical contact. Althoughs connections are thightned at the factory, they many have last enough in shipment to cause a malfunction. 2 - Verify that the switches Q10, are to the OFF position. 3 - Check and inspect all water piping. Make sure flow direction is correct and piping is made to correct connection on evaporator and condenser. 4 - Check for inlet/outlet piping proper connections as indicated on the exchangers. 5 - Open all water flow valves to the condenser and evaporator. 6 - Start pumps (evaporator) and flush the piping to be sure the system is clear. 7 - Check all pipings for leaks. Vent the air from the evaporator and condenser water circuit. The cooler circuit should contain clean, non corrosive water. 8 - Is water regulating valves are provided, connect their capillary to the manual valves provided on the condensers and open the manual valves.

2.4.4.2. Chilled water piping (Evaporator)

The water flow entering the evaporator on the connection close the electrical panel and leaving on opposite connection. Design the piping so that it has a minimum number of elevation changes. Include manual or automatic vent valves at the high points of the chilled water piping, so that air can be sented from the water circuit. System pressure can be maintened by using an expantion tank or a combination pressure relief and reducing valve. (see par. 2.2.5). All chilled water piping should be insulated to prevent condensation on the lines. If insulation is not of the self contained vapor barrier type, it should be covered with a vapor seal. Piping should not be insulated until completly leak tested.

2.4.5 Testing

303 C - 99/04 A - pag.

9 - Check pressure drop across evaporator and condenser, and see that water flow is correct for the design flow rates and date. 10 - Only for AG 050.2110.2. Check compressor oil level. Prior to start-up the oil level should cover at least one - third of the sightglass. 11 - check the actual line voltage to the unit to make sure it is the same as called for on the compressor nameplate within 10% and that the phase voltage unbalance doesn't ex ceed 3%. 12 - Verify that adeguate power supply and capacity is available to handle load. 13 - Make sure all wiring and fuses are of the proper size. Also make sure all interlock wiring is completed per McQuay diagrams. 14 - Make sure all auxiliary load and control equipment is operative and that an adeguate cooling load is available for initial start-up.

the first menu. 10 - Switch the Q1 and Q2 switches on ON. 11 - Start the system by pushing the system switch Q0 to the ON position on local or remote control (position I or II). 12 - After running the unit for a short time, check the level in each compressor crankcase, and check for flashing in the refrigerant sightglass.

2.5.3.4 Microprocessor information

For further informations about all the function and set point available on the microprocessor controller see the operating manual.

2.5.4.0 Emergency stop

A red switch Q11 is provided on control box, to allow the unit emergency stop in case of false alarm, the unit be restarted following this procedure: 1 - Move switch Q10 to the OFF position. 2 - Reset emergency stop switch Q11. 3 - Repeat start-up procedure from beginning.

2.5.3.0. Start-up 2.5.3.1. Warning

Initial start-up to be performed only by McQuay autorized Service organization. This is a must to obtain full warranty benefits.

WARNING !
By this operation compressors heaters de-energized. It is important to complete compressors pump-down cycle prior to close the chiller water flow to avoid freezing.

WARNING !
Start-up must be performed by specialized personnel.

2.5.5.0. Temporary shut-down

Move switchs Q1 and Q2 to the OFF position. After pump down, turn OFF the chilled water pump.

2.5.3.2. Start-up sequences 2.5.3.3.

1 - Open the compressors suction (if available) and discharge shut-off valves (until backseated) always replace seal caps. 2 - Open the manual liquid line shut-off valve. 3 - Check to see that the unit circuit breakers are is the OFF position. 4 - Check to see that the switch Q0 is in the OFF position. 5 - Check to see that the switches Q1 and Q2 are in OFF position. 6 - Put the main switch in ON position 7 - Put the switch Q12 to ON position in order to power the crankcase electric motors. 8 - Verify crankcase heaters have operated for at least 8 hours prior to start-up. Crankcase should be warm. 9 - Verify the chilled water temperature set point on the microprocessor controller by the following procedure: press the push button "SET" on the key pad. Select on the display the "chilled water" function by using the UP/DOWN cursor. Push the "ENTER" button, check if the set point of the leaving water temperature is OK. If you need to adjust the value use the "UP/DOWN" cursor to increase/decrease the value. Push "ENTER" button and "MENU" button to return

2.5.5.1. 2.6.0. Maintenance

for maintenance please refer only to the McQuay authorized Service organization.

2.7.0. Trouble shooting: causes and corrective steps

In case the chiller should not work, verify the following: 1 if the power is on 2 if the water flow is on 3 if the cooling capacity is on Refer to the authorized personnel is none of the above mentioned points are the cause of the troubleshooting.

McQuay Italia S.p.A. - S.S. Nettunense, km 12+300 - 00040 Cecchina (Roma) Italia - Tel. (06) 93 7311- Fax (06) 93 74 014 303 C - 99/04 A - pag. 8