Om 129

Operation and Maintenance Manual OM 129
Group: Chiller
Part Number: 594898Y
Effective: January 1997
Supersedes: None
PFS 150B through 315B

Water-Cooled Water Chillers
Operation and Maintenance Manual
50 and 60 Hertz
Refrigerant R-22 and Refrigerant R-410A
© 1997 McQuay International

Table of Contents
Unit Layout and Principles of Operation ...................................................................3
Control Center..........................................................................................................................................3
Sequence of Operation.............................................................................................................................3
Start-up and Shutdown .................................................................................................5
Pre Start-up...............................................................................................................................................5
Start-up .....................................................................................................................................................5
Temporary Shutdown ...............................................................................................................................6
Start-up After Temporary Shutdown .......................................................................................................6
Extended Shutdown..................................................................................................................................6
Start-up After Extended Shutdown..........................................................................................................6
System Maintenance......................................................................................................7
General......................................................................................................................................................7
Lubrication System...................................................................................................................................7
Compressor Maintenance.........................................................................................................................8
Electrical Terminals .................................................................................................................................8
Refrigerant Sightglass ..............................................................................................................................8
Lead-Lag ...................................................................................................................................................8
Crankcase Heaters ....................................................................................................................................8
Service..............................................................................................................................9
Compressor Solenoids .............................................................................................................................9
Filter-Dryers ...........................................................................................................................................10
Pump-down ............................................................................................................................................10
Liquid Injection Line Solenoid Valves..................................................................................................11
Electronic Expansion Valve...................................................................................................................11
Electronic Expansion Valve Operation .................................................................................................11
Evaporator ..............................................................................................................................................12
Condenser ...............................................................................................................................................12
Refrigerant Charging..............................................................................................................................12
Liquid Presence Sensor..........................................................................................................................13
High Condenser Pressure Control.........................................................................................................13
Mechanical High Pressure Safety Control ............................................................................................13
Compressor Motor Protection...............................................................................................................13
Phase/Voltage Monitor...........................................................................................................................13
Controls, Settings, and Functions..............................................................................14
200 Series MicroTech Control Panel....................................................................................................14
Control Panel Layout.............................................................................................................................16
Component Description.........................................................................................................................16
Keypad / Display Operation...................................................................................................................20
Menu Structure.......................................................................................................................................24
MicroTech Menus........................................................................................................25
Troubleshooting Chart ................................................................................................44
Maintenance Schedules...............................................................................................46
2 PFS 150B - 315B OM 129

Unit Layout and Principles of Operation
Control Center
All electrical controls are enclosed in a control center with keylocked, hinged access doors. The
control center is composed of two separate compartments, MicroTech Controller and shelf mounted
starter.
The MicroTech control panel contains a model 280 microprocessor based controller which provides
all monitoring and control functions required for the safe, efficient operation of the chiller. The
operator can monitor all operating conditions by using the panel’s built in 4-line by 40-character
keypad / display or by using an IBM compatible computer running McQuay Monitor software. In
addition to providing all normal operating controls, the MicroTech controller monitors all safety
devices on the unit and will take corrective action if the chiller is operating outside of it’s normal
design conditions. If a fault condition develops, the controller will shut the system down and activate
an alarm output. Important operating conditions at the time an alarm condition occurs are retained in
the controller’s memory to aid in troubleshooting and fault analysis.
The system is protected by a simple password scheme which only allows access by authorized
personnel. A valid password must be entered into the panel keypad by the operator before any setpoints
may be altered.
Sequence of Operation
The following sequence of operation is typical for McQuay models PFSXXXB screw water chillers.
The sequence may vary depending on the software revision or various options that may be installed on
the chiller.
Off conditions
With power supplied to the unit, 115 VAC power is applied through the circuit breaker (CB) to the
primary of the 24V control circuit transformer and Output Board Relays. The compressor heater
(HTR) is energized through the normally closed contacts on the starter.
Note: Before start-up, the compressor heater must be on for at least 12 hours to ensure
there is not any liquid refrigerant in the compressors.
The 115V / 24V transformer provides power to the MicroTech controller, two 24V center tapped
transformers and related components. With 24V power applied, the controller will check the position
of the front panel system switch. If the switch is in the “Stop” position the chiller will remain off and
the display will indicate the operating mode to be OFF: System Sw. If the system switch is in the
“Auto” position the controller will then check the remote start/stop switch. If the remote start stop
input is open, the chiller will be OFF: RemoteSw. The chiller may also be commanded off via
communications from a separate communicating panel such as the Chiller System Controller Panel or
an Open Protocol interface. The display will show OFF: RemoteComm if this operating mode is in
effect. If an alarm condition exists which prevents normal operation, the chiller will be turned off and
the display will indicate OFF: Alarm. If the control mode on the keypad is set to “Manual Unit Off,”
the chiller will be turned off and the unit status will display OFF: Manual Mode. If none of the above
stop conditions are true, the controller will examine the internal time schedule to determine whether
the chiller should be permitted to start. The operating mode will be OFF: TimeClock if the time
schedule indicates time remaining in an “off” time period.
OM 129 PFS 150B - 315B 3

Ice Mode Operation
For operations requiring ice mode feature, logic in MicroTech must be programmed to adjust the
operating parameters for the specific application . Refer to the Controls, Settings, and Functions
section of this manual for additional information.
Alarm
The alarm light on the MicroTech control panel will be illuminated when any alarm condition exists.
Unless the alarm condition affects both compressors, the remaining compressor will operate as
required. Refer to the Controls, Settings, and Functions section of this manual for additional
information.
Start-up
If none of the above “off” conditions are true, the MicroTech controller will initiate a start sequence
and energize the chilled water pump output relay. If flow is not proven within 15 seconds, the alarm
output will be turned on and the keypad display will be No Evap Flow. When evaporator flow is
confirmed, the controller will sample the chilled water temperature and compare it against the Leaving
Chilled Water Setpoint and the Start-up Delta Temperature, pre-programmed into the controller’s
memory. If the leaving chilled water temperature is above the Leaving Chilled Water Setpoint plus the
adjustable Start-up Delta Temperature, the controller will start the condenser pump. The same time
and alarm conditions exist for the condenser flow. The compressor with the lowest number of starts
will be the lead compressor. The controller will open the electronic expansion valves to a
predetermined value. This value is dependent upon the starting parameters. The controller will start
the lead compressor and energize the compressor suction injection and motor cooling solenoid valves.
Liquid injection is activated through the auxiliary starter contacts. The lead compressor will increase
capacity by staging up according to the chilled water leaving evaporator setpoint. The lead compressor
will stage to 100% capacity before the lag compressor can be started. If additional cooling capacity is
required, the controller will energize the lag compressor and stage it up according to setpoint. The
compressors capacity control solenoids will automatically be controlled as required to meet the
cooling needs of the system.
The electronic expansion valves are operated by the MicroTech controller to maintain desired
refrigerant control to the evaporator at all conditions.
Condenser control
The condenser pump will be started in conjunction with the above logic to provide condenser water
flow. The MicroTech controller has the capabilities to control up to two cooling tower fans. The
minimum entering condenser water temperature for full load air conditioning duty shall be 65°F with
nominal cooling tower water flow of 3 GPM. When condenser water temperatures are lower and or
chiller load is less than 100%, the condenser water flow or entering condenser water temperature must
be controlled to maintain satifactory operating refrigerant pressures. The MicroTech controller can
control condenser water entering temperature by a condenser water bypass valve based upon entering
condenser water temperature. It can also control condenser water flow by a flow control valve based
upon condenser pressure. When using a flow control valve, a minimum water flow through the
condenser must be maintained. This minimum water flow is based upon system conditions and can
vary with each installation.
Shutdown
As the system chilled water requirements diminish, the compressors will be unloaded. As the system
load continues to drop, thecompressor with the most run hours will be stopped. A continuing load
reduction will start the hot gas option or the chiller can shut down on the shut down delta set point.
The hot gas control will allow the unit to maintain minimum operating parameters if proper condenser
control is available. This type of control is standard and selectable from the keypad. If hot gas control
4 PFS 150B - 315B OM 129

is not selected, the unit will shut down on the shut down delta setpoint. This feature can be used to
minimize chiller run time under light load conditions.
The condenser water pump will be stopped upon chiller shutdown and the chilled water pump output
relay will remain energized until the time schedule’s “on” time expires, the remote stop switch is
opened, the system switch is moved to the stop position, or a separate communications panel such as
the Chiller System Controller or an Open Protocol interface disables the chiller.
Start-up and Shutdown
CAUTION
To ensure correct compressor rotation, field power supply leads must be properly phased
before start-up. A phase monitor protects the compressors after proper phasing has been
confirmed.
Pre Start-up
1. With all electric disconnects open, check all screw or lug type electrical connections to be sure
they are tight.
2. Check voltage of the unit power supply and verify voltage is within 10% of nameplate rating.
Voltage unbalance between phases must be within 3% of nameplate rating.
3. Make certain all auxiliary control equipment is operative and an adequate cooling load is available
for startup.
4. Check all compressor valve connections for tightness to avoid refrigerant loss at start-up. Open
the compressor suction and discharge shutoff valves. Open the liquid line shutoff valves until
backseated. Always replace valve seal caps.
5. Turn compressor circuit breakers to “off” position until ready to start unit. Place main power and
control disconnect switches in “on” position. This will energize compressor heaters. Wait at least
12 hours before starting unit.
6. Vent air from the evaporator and condenser system piping. Open all water flow valves and start
chilled water and condenser water pumps. Check all piping for leaks. Flush the evaporator and
condenser water system piping to obtain clean, noncorrosive water in the chiller water circuits.
Note: Evaporator and condenser water should be chemically treated.
Start-up
1. Ensure compressor suction and discharge shutoff valves are fully open. Always replace valve seal
caps.
2. Ensure manual liquid line shutoff valves at the outlet of the condenser and liquid line drier are
open.
3. Start the auxiliary equipment for the installation by turning on the time clock, and/or remote
on/off switch.
4. Under menu 11 of the keypad place the unit into the automatic cool mode. Place the front panel
switch into the auto position. Make the remote start / stop input.
5. Superheat is factory adjusted to maintain between 1° and 10°F (1° and 7°C).
OM 129 PFS 150B - 315B 5

Temporary Shutdown
CAUTION
To prevent evaporator freeze-up, continue chilled water flow to the unit for 5 minutes after
the compressors have stopped.
If all power is turned off to the unit the compressor heaters will become inoperable. Once power is
resumed to the unit it is important that the compressor heaters are energized a minimum of 12 hours.
Failure to do so could damage the compressors due to excessive accumulation of liquid in the
compressor.
CAUTION
The unit must not be cycled off by using the evaporator pump or the disconnect switch. A
start / stop input is required.
Start-up After Temporary Shutdown

1. Ensure compressor heaters have been energized for at least 12 hours
2. Start the chilled water pump.
3. Place unit control switch in “auto” position.
4. Observe unit operation until the system has stabilized.
5. Record unit operating conditions.
Extended Shutdown
1. Place control panel switches in "stop" position.
2. After compressors have shut down and electronic expansion valves have closed, turn off chilled
water pump.
3. Turn off all power to the unit and to the chilled water and condenser water pumps.
4. Tag all opened disconnect switches to warn against accidental startup before completing
compressor checks.
5. If the unit is shut down during winter and glycol is not used in the system, drain all water from
unit evaporator, condenser and all water piping . Do not leave the vessels or piping open to the
atmosphere over the shutdown period.
Start-up After Extended Shutdown

1. Inspect all equipment to ensure a satisfactory operating condition.
2. Clean cooling tower. Remove all debris that has collected near the tower.
3. Place compressor suction and discharge valves in the fully open position. Always replace valve
seal caps.
4. Open manual liquid line shutoff valves.
5. Make certain circuit breakers are in the "off" position.
6. Make certain control panel rocker switches are in "stop" position.
7. Place main power and control circuit disconnects in ”on” position.
8. Allow the crankcase heaters to operate for a least 12 hours.
6 PFS 150B - 315B OM 129

9. Start chilled water and condenser water pumps and vent air from the water piping as well as the
evaporator and condenser water sides. Start auxiliary equipment by making the remote start / stop
input.
10. Check resets of all safety controls.
11. Place unit circuit breakers in “on" position.
12. Place control panel switch in "auto" position.
13. After running the unit for a short time, verify there is no flashing in the refrigerant sightglass.
System Maintenance
General
Check the liquid line sightglasses and take condensing and suction pressure readings. Using the
MicroTech keypad, ensure the unit has normal superheat and subcooling readings.
Lubrication System
No maintenance is required on the flooded chiller lubrication system. Oil is carried by the refrigerant
through the system. A small portion of the discharge gas is diverted to a passage in the bottom
discharge end of the compressor. This gas contains oil and the combination is forced through an oil
filter in the jet pump assembly and then through the jet pump nozzle. The flow through the jet pump
nozzle induces flow of trapped oil from the bottom side of the evaporator vessel. The oil then passes
through a second oil filter in the jet pump assembly and is mixed in the jet stream that passes out of the
jet pump assembly and is delivered to the fitting on the underside of the compressor discharge housing.
The oil is then heated inside the discharge housing and is forced by pressure difference to the cavity in
top of the compressor below the oil sight glass. At this location, the oil flows by gravity through four
individual orifices to each bearing in the compressor. Check for oil in the compressor by viewing the
oil sight glass. If a spray or droplets can be seen through the sightglass, then there is adequate
lubrication.
Figure 1, Jet pump assembly
Connection
Number 3 Connection
Number 1
Connection
Number 2
Table 1, Jet Pump assembly connections

Connection
Number Connects To:
1 Discharge area outlet at the base of compressor
2 The lower side of evaporator
3 The under side of discharge housing
OM 129 PFS 150B - 315B 7

Compressor Maintenance
The semi-hermetic compressor does not require an oil separator, oil heaters or pumps, so yearly
maintenance is not normally required. However, vibration is an excellent check for proper mechanical
operation. Excessive compressor vibration indicates maintenance may be required and contributes to a
decrease in unit performance and efficiency. Using a vibration analyzer, check compressor at or shortly
after start-up and again on an annual basis. When performing the test the maintain the load as closely
as possible to the load of the original test.
The compressor is checked at the factory for minimum vibration of 0.14”/second (3.56mm/
second) at 3500 rpm (2917 rpm).
The compressor is supplied with a lifetime oil filter. If a visual inspection shows possible
restriction, then replace filter.
Electrical Terminals
WARNING
Electric shock hazard. Turn off all power before continuing with following service.
Re-tightened all electrical power teminals for compressors every six months (normal heating and
cooling of the wire may loosen connection).
Refrigerant Sightglass
Observe the refrigerant sightglasses weekly. A clear glass of liquid indicates that there is adequate
refrigerant charge in the system. Bubbling refrigerant in the sightglass, during stable run conditions,
indicates the system may be short of refrigerant charge. Refrigerant gas flashing in the sightglass
indicates an excessive pressure drop in the liquid line, possibly due to a clogged filter-drier or a
restriction in the liquid line. If subcooling is low add charge to clear the sightglass. If subcooling is
normal 10° to 15°F (6° to 13°C), at full load, and flashing is visible in the sightglass check pressure
drop across the filter drier.
An element inside the sightglass indicates the moisture condition corresponding to a given element
color. If the sightglass does not indicate a dry condition after about 12 hours of operation, pump down
the unit and change filter-dryers.
Lead-Lag
McQuay PFS water-cooled chillers alternate the sequence in which the compressors start to balance
the number of starts and run hours. Lead-lag of the compressors is accomplished automatically by the
MicroTech controller.
When in the auto mode the compressor with the fewest number of starts will be started first. If
both compressors are operating and a stage down to one compressor is required, the compressor with
the most operating hours will cycle off first. The operator may override the MicroTech controller, and
manually select the lead compressor as #1 or #2.
8 PFS 150B - 315B OM 129

Crankcase Heaters
The compressors are equipped with crankcase heaters. Crankcase heaters keep the temperature in the
crankcase high enough to prevent refrigerant from migrating to the crankcase and condensing in the oil
during the off-cycle.
Turn on power to the heaters for at least 12 hours before the compressors are started. The
crankcase temperature should be at least 80°F (26.7°C) before the system is started minimizing
lubrication problems of liquid slugging .
Service
Disconnect all power before doing any service inside the unit.
CAUTION
Service on this equipment is to be performed by qualified refrigeration personnel familiar
with equipment operation, maintenance, correct servicing procedures, and the safety
hazard inherent to this work. Causes for repeated tripping of safety controls must be
investigated and corrected.
Note: Anyone servicing this equipment must comply with EPA requirements concerning
refrigerant reclamation and venting.
Compressor Solenoids
There are three solenoids to control compressor capacity. The solenoids are controlled by MicroTech
outputs (see unit wiring diagrams). The solenoids are energized at various compressor load conditions
as indicated in Table 1.
Table 1, Solenoid status

Compressor Unloading Solenoid Staus
Percent Compressor Top Bottom Front Bottom Rear
Loading Solenoid Solenoid Solenoid
100 Energized Off Energized
75 Energized Energized Off
50 Off Off Energized
25 Off Energized Off
Location of the solenoids is as follows:

• The top solenoid is on top of the compressor near the discharge end.
• The bottom solenoids are on the lower side of the compressor on the opposite end from the
terminal box. The bottom front solenoid is the one closest to the discharge end of the compressor.
The bottom rear solenoid is the one closest to the motor end of the compressor.
If the compressor is not loading properly check the solenoids to see if they are energized. A complete
check will include a check of the MicroTech output, the wiring to the solenoid and the solenoid coil
itself.
OM 129 PFS 150B - 315B 9

Filter-Dryers
Change the filter-dryer every scheduled service maintenance of the unit, or when any one of the
following conditions occur:
• Excessive pressure drop is read across the filter-dryer (The maximum recommended pressure
drop across the filter-dryer is shown in Table 2.
Table 2, Filter-drier pressure drop

Maximum recommended pressure drop
Percent Circuit Loading PSIG (kPa)
100 10 (69)
75 8 (55.2)
50 5 (34.5)
25 4 (27.6)
• When bubbles occur in the sightglass with normal subcooling

• A partially clogged filter causes a trip on the no liquid run sensor
• Moisture indicating liquid line sightglass indicates excess moisture
Pump-down
Note: Pump-down the unit before changing filter-drier cores, replacing solenoid valves
(except solenoid valve coils), or to change expansion valve.
Unit condensers are sized to hold the entire refrigerant charge.

1. Stop the unit by opening the remote start / stop input.
2. Close all liquid line shutoff valves at the condenser liquid line outlets.
3. When the compressor shuts off, close the discharge line ball valve in each compressor circuit.
4. Connect a refrigerant transfer pump between the service valve on the evaporator and the service
valve on the top of condenser. Pump all remaining refrigerant out of evaporator, compressors,
and liquid line.
5. Complete pump-down according to EPA refrigerant guidelines before opening the circuit.
6. Servicing of the components may now continue.
WARNING
The discharge housing of the component contains internal discharge side check valves. If
these valves are tight seating, then this housing will contain high pressure refrigerant
captured between these check valves and the discharge line shutoff valve. The
MicroTech's high pressure transducer should reflect this pressure. Be careful when
servicing the discharge housing.
10 PFS 150B - 315B OM 129

Liquid Injection Line Solenoid Valves
The solenoid valves that shut off refrigerant flow in the event of a power failure, do not normally
require any maintenance. They may, however, require replacement of the solenoid coil or of the entire
valve assembly.
The solenoid coil can be checked to see that the stem is magnetized when energized by touching a
screwdriver to the top of the stem. If there is no magnetization either the coil is bad or there is no
power to the coil. The solenoid coil may be removed from the valve body without opening the
refrigerant piping. For personal safety shutoff and lockout the unit power.
Remove coil from valve body by simply removing a nut or snap-ring located at the top of the coil. The
coil can then be slipped off its mounting stud for replacement. Be sure to replace the coil on its
mounting stud before re-applying power.
Liquid injection is required during compressor operation to seal and cool the screw. A liquid injection
sensor is installed on the compressor to assure that liquid injection occurs whenever the compressor is
running. A failure of the liquid injection solenoid valve to open will cause the compressor to shut
down due to lack of liquid injection. The liquid injection solenoid valve only closes when the
compressor stops.
Electronic Expansion Valve

The expansion valve is responsible for allowing the proper amount of refrigerant to enter the
evaporator to match the cooling load. It does this by maintaining a constant superheat. (Superheat is
the difference between refrigerant temperature of the vapor as it leaves the evaporator and the
saturation temperature corresponding to the evaporator pressure.).
All PFS chillers are factory set for the proper superheat. The superheat is controlled by the MicroTech
controller and is not adjustable
The expansion valve, like the solenoid valve, should not normally require maintenance, but if it
requires replacement, the unit must be pumped down by following the steps involved when changing a
filter-drier.
If the problem can be traced to the electric motor only, it can be unscrewed from the valve body
without removing the valve but only after pumping the unit down.
Electronic Expansion Valve Operation

There are three colored indicator LEDs (green, red, yellow) located in the control panel on the
electronic expansion valve (EXV) board. When the control panel is first powered the microprocessor
will automatically step the valve to the fully closed (shut) position and the indicator lights on the EXV
will blink in sequence. The valve can also be heard closing as it goes through the steps. The valve will
take approximately 14 seconds to go from a full open position to a full closed position.
The position of the valve can be viewed at any time by is using the MicroTech keypad through menu 3
(circuit pressures). There are a total of 760 steps between closed and full open.
A feature of the electronic expansion valve is a maximum operating pressure setting (MOP). This
setting limits the load on the compressor during start-up periods where high return evaporator water
temperatures may be present. The valve will limit the maximum suction pressure at start-up to
approximately 85 psig (586 kPa). The valve will close to a point necessary to maintain the 85 psig
(586 kPa). During this time the superheat will rise above 12°F (6.7°C) and not drop below 12°F
(6.7°C) until the suction pressure drops below 85 psig (586 kPa). The valve will maintain evaporator
pressure close to 85 psig (586 kPa) until the evaporator water temperature decreases to approximately
55°-60°F (12.8°-15.6°C).
OM 129 PFS 150B - 315B 11

The valve opens to a predetermined position before the compressor starts. At the end of the cooling
cycle and after the compressor stops the valve closes. The valve closes at the rate of approximately 55
steps per second, or from full open to full closed in approximately 14 seconds.
Evaporator
The evaporator is of the flooded, shell-and-tube type with water flowing through the tubes and
refrigerant flowing through the shell over the tubes. Normally no service work is required on the
evaporator. When a tube must be replaced, the old tube can be removed and replaced. Follow the
requirements set forth by the EPA for the pumpdown and recovery of refrigerant.
Condenser
The condenser is of the shell-and-tube type with water flowing through the tubes and refrigerant in the
shell. External finned condenser tubes are rolled into steel tube sheets. Integral subcoolers are
incorporated on all units. All condensers are equipped with 450 psig (3104 kPa) relief valves. Either
end on the condenser can be easily removed in the field.
Refrigerant Charging
PFS water-cooled screw chillers are shipped factory charged with a full operating charge of refrigerant
but there may be times that a unit must be recharged at the jobsite. Follow these recommendations
when field charging.
PFS water-cooled screw chillers are more sensitive to undercharging than to overcharging.
Therefore, it is preferable to be slightly overcharged rather than undercharged on a circuit. The
optimum charge is the charge that allows the unit to run with a solid stream of liquid in the liquid line
at all operating conditions. When the liquid line temperature does not drop with the addition of 5-10
lb. (2.3-4.5 kg) of charge then the subcooler is nearly full and proper charge has been reached. If the
liquid line temperature does not drop and the discharge pressure goes up 3-5 psig (21-35 kPa) as 5-10
lb. (2.3-4.5 kg) of refrigerant is added the correct maximum charge has been reached.
Unit charging can be done at any steady load condition. Unit must be allowed to run 5 minutes or
longer.
Note: As the unit changes load the subcooling will vary but should recover within several
minutes and should never show below 6°F (3.4°C) subcooling at any steady state run
condition. Subcooling will vary somewhat with evaporator leaving water temperature and
suction superheat. As the evaporator superheat goes lower the subcooling will drop slightly.
Excessive refrigerant losses can also leak oil from the system. When adding charge, if there is
visible evidence of a significant oil leakage, and an additional oil charge equivalent to 0.04 pints x the
lb. (189 mL x the kg) of refrigerant charge required. (Example: for every 10 lb. (4.5 kg) of refrigerant
charge add .4 pints (189 mL) of oil.)
Using a hand oil pump, charge oil into the evaporator inlet.
A refrigerant leak in the unit could be very small and have little effect on system operation or
could be severe enough to cause the unit to shut down on a safety trip.
1. If the unit is slightly undercharged the unit will show bubbles in the sightglass. Recharge the unit
2. If the unit is moderately undercharged the unit will most likely trip on freeze protection. Recharge
the unit.
3. If the unit is severely undercharged the unit will trip off due to lack of liquid injection. In this case
either remove the remaining charge using a proper reclamation system and recharge the unit with
the amount of refrigerant stamped on unit nameplate, --OR-- add refrigerant through the suction
valve back seat port on the compressor. Feed liquid into the suction valve when the compressor is
running. If the unit is severely undercharged the unit may nuisance trip during this charging
12 PFS 150B - 315B OM 129

procedure. If this happens close off the refrigerant from the tank and restart the unit. Once the unit
has enough charge so that it does not trip out continue with the charging procedure below.
Procedure to charge a moderately undercharged PFS unit:
Note: Refrigerant can be satisfactorily added at less than full load conditions. Condensing
temperature should be reasonably high and characteristic of normal cooling tower type
operation. Saturated suction temperatures should also be at a value not higher than the
design leaving chilled water temperature.
1. Connect a refrigerant drum to the service valve on evaporator -- OR -- to the backseat port on the
suction service valve on compressor.
2. Open refrigerant drum adding a "weighed-in" amount -- OR -- charge refrigerant during operation
of the compressor(s) until liquid line and liquid injection line sightglasses are clear.
Liquid Presence Sensor

Each compressor is equipped with a liquid sensor to assure that liquid flows to the compressor for
cooling and sealing during operation. The sensor will shutdown the compressor in the event no liquid
is sensed. At start-up the liquid sensor checks for excessive liquid in the compressor and will delay
start until the compressor heater transfers the liquid out of the compressor and into the condenser. A
liquid trip by the sensor will produce an alarm message on the MicroTech display.
High Condenser Pressure Control

MicroTech is also supplied with high pressure transducers on each compressor. Although the main
purpose of the high pressure transducer is to maintain proper head pressure control, another purpose is
to convey a signal to the MicroTech control to stop the compressor in the event of an excessive rise in
discharge pressure. If the high condenser pressure control trips, the MicroTech must be manually reset.
Mechanical High Pressure Safety Control

The high pressure safety control is a single pole pressure activated switch that opens on pressure rise.
When the switch opens, the control relay circuit is de-energized stopping the compressors.
The control is mounted on the compressor ahead of the discharge shut off valve.
Compressor Motor Protection

The compressors are supplied with two types of motor protection.
Repeat overload trips under normal operation may indicate wiring or compressor motor problems. The
overloads are manual reset and must be reset at the overload as well as through MicroTech.
Also, the compressors have a solid-state Guardistor™ circuit which provides motor over temperature
protection. The Guardistor™ circuit has automatic reset but must also be reset through MicroTech.
OM 129 PFS 150B - 315B 13

Phase/Voltage Monitor
The phase/voltage monitor is a device which provides protection against three-phase electrical motor
loss due to power failure conditions, phase loss, and phase reversal. Whenever any of these conditions
occur, a contact opens which then de-energizes the starter.
When proper power is restored, contacts close and MicroTech enables compressors for operation.
When three-phase power has been applied, the output relay should close and the “run light” should
come on. If the output relay does not close, perform the following tests.
1. Check the voltages between L1 - L2, L1 - L3 and L2 - L3. These voltages should be approximately
equal and within +6% of the rated three-phase line-to-line voltage.
2. If these voltages are extremely low or widely unbalanced check the power system to determine the
cause of the problem.
3. If the voltages are good, using a phase tester, verify that phases are in A, B and C sequence for L1,
L2 and L3. Correct rotation is required for compressor operation. If phases are out of sequence,
turn off the power and interchange any two of the supply power leads at the disconnect.
4. Turn on the power. The output relay should now close after the appropriate delay.
Controls, Settings, and Functions
200 Series MicroTech Control Panel

General Description
The MicroTech control panel contains a model 280 microprocessor based controller which provides
all monitoring and control functions required for the safe, efficient operation of the chiller. The
operator can monitor all operating conditions by using the panel’s built in 4-line by 40-character
keypad / display or by using an IBM compatible computer running McQuay Monitor software. In
addition to providing all normal operating controls, the MicroTech controller monitors all safety
devices on the unit and will take corrective action if the chiller is operating outside of it’s normal
design conditions. If a fault condition develops, the controller will shut the system down and activate
an alarm output. Important operating conditions at the time an alarm condition occurs are retained in
the controller’s memory to aid in troubleshooting and fault analysis.
The system is protected by a password scheme which only allows access by authorized personnel. A
password must be entered into the panel keypad by the operator before any setpoints may be altered.
14 PFS 150B - 315B OM 129

Features of the Control Panel
• Control of leaving chilled water within an adjustable control band.
• Readout of all temperature and pressure readings:
§ entering and leaving chilled water temperature
§ enter and leaving condenser water temperature
§ saturated evaporator refrigerant temperature and pressure
§ saturated condenser temperature and pressure
§ outside air temperature (Optional)
§ suction line, liquid line and discharge line temperatures
§ calculated superheat for discharge and suction lines
§ optional evaporator and condenser heat recovery temperature
• Automatic control of evaporator and condenser pumps.
• Control of up to 2 stages of cooling tower fans
• Control of modulating cooling tower bypass valve.
• Control of modulating condenser water flow valve.
• Panel mounted 12 key keypad plus 6 Quick Access function keys. Operator can log chiller
operating conditions from a single keypad/display instead of reading gauges, thermometers, pots,
etc. The display is a backlit, 4 line by 40 character LCD type for easy viewing in all lighting
conditions.
• Two levels of security protection against unauthorized changing of setpoints and other control
parameters.
• Complete fault diagnostics to inform operators of fault conditions in plain language. All faults
are time and date stamped so there is no guessing of when the fault condition occurred. In
addition, the operating conditions that existed just prior to shutdown can be recalled to aid in
isolating the cause of the problem.
• Eight previous faults and related operating conditions are available from the display.
• Soft Loading feature reduces electrical consumption and peak demand charges during loop
pulldown.
• Hot gas low load control
• Adjustable load pull-down rate reduces undershoot during loop pulldown.
• Easy integration into building automation systems via separate 4-20mAdc signals for chilled
water reset and demand limiting.
• Internal time-clock for on/off scheduling. The time clock accommodates a 7 day schedule plus
holiday, 1 start and stop per day, and 14 holidays with programmable duration.
• Communications capabilities for remote monitoring, changing of setpoints, trend logging, remote
reset, alarm and event detection, via IBM-PC running McQuay MicroTech (tm) software.
• Manual control mode allows the service technician to command the unit to different operating
states. Useful for system checkout.
• BAS communication capability via McQuay’s Open Protocol strategy to over 10 major BAS
manufacturers.
• Service Test mode for troubleshooting controller hardware.
• Display available in either U.S.Customary or S.I. units.
• Keypad programmable alarm contacts for normally open or normally closed.
• Pressure transducers for direct reading of system pressures.
• Pre-emptive control of low evaporator pressure conditions to take corrective action prior to a
fault trip.
OM 129 PFS 150B - 315B 15

• Pre-emptive control of high discharge temperature.
Control Panel Layout

Figure 2, Major Component Locations
HP
Relay
1 - 3 AOX Boards
Guardistor Optional
Board
Modem
Optional
Model 280 ADI

Controller Board
MCB1
Output Wire Channel
Board
Terminal Board
Wire Channel
T3
T2 Signal
Convertor
Board
Optional Wire Channel
CB
Component Description
Microprocessor Control Board (MCB1)
The Model 280 Microprocessor Control Board contains the electronic hardware and software required
to monitor and control the unit. It receives input from the ADI Board and sends commands to the
Output Board to maintain the unit's optimum
operating mode for the current conditions. Status
lights are mounted on the control board to indicate
the operating condition of the microprocessor.
16 PFS 150B - 315B OM 129

Status LEDs
There are three status LEDs located on the model 280
controller which will indicate the microprocessor’s operating RUNNING green
CPU
condition. When power is first applied to the control panel, STATUS
RESET red
the red reset LED will illuminate for approximately 3
seconds. During this time, the microprocessor is checking the ACTIVE amber OUTPUT 0
control software and performing internal hardware tests.

When these tests are complete the reset LED will turn off
and the green running LED will illuminate indicating the controller’s circuitry and software are
operating correctly. The amber output 0 active LED is associated with the external alarm output. This
LED may or may not be illuminated at this time based on the setpoints under menu 23. If the reset
LED stays on or the running LED fails to illuminate, disconnect the controller power by opening
circuit breaker CB-1 and re-check the field wiring. Observe the controller’s LEDs while re-connecting
power by closing CB-1. If the green running LED still does not turn on, a hardware failure exists or
the control software is corrupted. Downloading new control software or replacing the 280 controller
should correct the problem.
With the controller powered up and the green running LED illuminated, the backlite panel on the
display module will be illuminated and the unit status menu will be visible. If the display text looks
faded or appears as “blocks” the contrast control needs to be adjusted. Watch the display and adjusting
the contrast control with a small flat-blade screwdriver until the best setting is determined.
Figure 3, Contrast adjustment
KDI BOARD
(back side)
Contrast
Adjustment
Power Ribbon
Wiring Cable
The MicroTech controller contains factory installed default setpoints which will be appropriate for
most common installations. Step through all of the unit’s setpoints by using the keypad / display and
adjust them as required to meet the specific job requirements. Any faults appearing on the display
should be cleared at this time by pressing the clear key.
Digital Output Board

The Output Board contains up to 24 solid state relays which are used to control the compressor,
cooling tower fans, solenoid valves and alarm annunciation. It receives control signals from the
Microprocessor Control Board through a 50 conductor ribbon cable.
Figure 4, Digital output board
OM 129 PFS 150B - 315B 17

Analog / Digital Input Board (ADI)
The ADI Board provides low voltage power for the temperature and pressure sensors. It also provides
optical isolation between the Microprocessor Control Board and all 24V switch inputs. LED's are
furnished on the board to give a visual indication of the status of all digital inputs. All analog and
digital signals from sensors, transducers and switches are received by the ADI Board and then sent to
the Microprocessor Control Board for interpretation.
Figure 5, ADI board
Analog Output Board (AOX)

The AOX board converts control instructions from the Microprocessor Control Board’s expansion bus
into an analog control signal suitable for driving a cooling tower bypass valve. Each AOX board is
factory set via jumper to provide an output signal range of 0 - 10 VDC. An additional output on the
AOX board provides an analog signal that is proportional to compressor motor current.
Figure 6, AOX board
18 PFS 150B - 315B OM 129

Signal Converter Board
The AC current signal generated by the starter is converted by the signal converter board into a 0-5
VDC signal that is directly proportional the chillers amp draw. The amp draw signal is sent to the ADI
board for conditioning and then to the M280 controller.
Figure 7, Signal converter board
TB1 TB2
Guardistor Board
The Guardistor board monitors the motor winding temperature via the embedded Guardistor sensors.
If the motor temperature rises to an unsafe level, the board will signal the M280 controller and the
chiller will be shut down.
Figure 8, Guardistor board
OM 129 PFS 150B - 315B 19

Power Transformers
Transformers T2,T3 and T4 provide operating power to the MicroTech controller and it’s associated
components. T2 is a conventional ferrite core transformer that converts 120VAC from the control
transformer into 24VAC. T3 and T4 are high efficiency toroidal design that converts 24VAC from T2
into a center-tapped 18VAC.
Keypad / Display
The Keypad/Display is the primary operator interface to the unit. All operating conditions, system
alarms and setpoints can be monitored from this display and all adjustable setpoints can be modified
from this keyboard if the operator has entered a valid operator password.
Figure 9, Keyboard / Display
Alarm
3.Refrig Temps/Press 12:55 Mar-01-95
Saturated Evap= 50.7°F / 46.2psi
Load
Saturated Cond= 90.8°F / 105.9psi
Suct Line= 53.1°F Liq Line=81.7°F
Unload
CATEGORY MENU - ITEM ACTION
Prev.
Stop Auto Status Alarm Item
+ Help
Incr. Clear
Prev. Next
Menu Menu
O Decr. Enter
Control Switch
Next - =
Item
Water Refrig.
Motor Oil Alarm
QUICK ACCESS Set-
points
Data
Reports
Temps
Temp's
Press's
History
Figure 10, Example of a typical MicroTech display screen indicating Item lines and fields
Screen Previous screen indicator
Menu line 3.Refrig Temps/Press 12:55 Mar-01-95

0
Item line 1
Saturated Evap=50.7 F/46.2psi
Item line 2
Saturated Cond=90.80F/105.9psi
Item line 3
Suct Line= 53.10F Liq Line= 87.10F
Field One Field Two Next screen indicator
Keypad / Display Operation

General Description
The MicroTech keypad consists of eighteen pressure sensitive membrane switches used to step
through, access, and manipulate the information in the MicroTech controller. The selected information
is presented on a four line by forty character backlit LCD display.
20 PFS 150B - 315B OM 129

The information stored in the MicroTech controller can be accessed through the keypad by following
the tree-like structure of menus and menu items. The keypad keys are divided into four groups with
four or more keys in each to facilitate navigation through the available menus and items.
See Figure 9
Figure 11, Category group

The keys in this
group provide quick
STATUS ALARM
access to strategic
menus throughout the
menu tree-structure.
This reduces the
need to step through CONTROL SWITCH
all the menus, one by
one, in order to reach
the desired
information. Status Key
Menus and menu items in this category provide information on the MicroTech operating conditions
and the chiller operating conditions. The entries under each menu item in this category provide
information only and are not changeable through the MicroTech keypad.
Pressing the "STATUS" key at any time shifts the display to Menu #1 (Unit Status) which is the first
menu of the STATUS category.
Control Key
Menus and menu items in this category provide for the adjustment of all the unit control parameters.
These include capacity control, pump control and cooling tower control parameters as well as time
schedules and alarm limits. The entries under these menu items are changeable through the MicroTech
keypad.
Pressing the "CONTROL" key at any time shifts the display to Menu #7 (Control Mode) which is the
first menu of the CONTROL category.
Alarm Key
Menus and menu items in this category provide information regarding current and previous fault
conditions along with the operating temperatures and pressures at the time the fault occurred.
Pressing the "ALARM" key at any time shifts the display to Menu #19 (Current Alarm) which is the
first menu of the ALARM category.
Switch Key
Pressing the "SWITCH" key at any time toggles the display between the current menu (status/control)
item and the related menu (control/status) item somewhere else in the tree- structure. This allows
checking actual conditions against setpoints. Pressing the “SWITCH” key the second time takes the
operator back to the original menu item. For example, if this key is pressed while the current menu
item is menu item 2B (Leaving Evaporator =), the display shifts to menu item 8B (Local Evaporator
Setpoint =). This provides for easy review of actual versus setpoint values.
OM 129 PFS 150B - 315B 21

Figure 12, Menu - Item Group
The keys in this
group are used to
scroll through the Prev.
various menus and Item
items presented on
Prev. Next
the controller’s
Menu Menu
display. A menu
contains a specific
Next
group of items.
Item
Previous Menu
Pressing "PREV." shifts the display to the previous menu.
Note: When Menu #1 is currently in the display (the first menu in the menu tree-structure),
pressing "PREV." causes an "beginning of menus" message to appear in the display.
Next Menu
Pressing "NEXT" shifts the display to the next menu.
Note: When Menu #37 is currently in the display (the last menu in the menu tree-structure),
pressing "NEXT" causes an "end of menus" message to appear in the display.
Previous Item
Pressing "PREV." shifts the display to the previous group of items within a menu.
Note: When the first item in a menu is currently in the display, pressing "PREV." causes an
"beginning of items" message to appear in the display.
Next Item
Pressing "NEXT" shifts the display to the next group of items in a menu.
Note: When the last item in a menu is currently in the display, pressing "NEXT" causes and
"end of items" message to appear in the display
Figure 13, Action Group

The keys in this
group are for making + Help
changes to unit Incr. Clear
control parameters or
for clearing fault
conditions. Decr. Enter
- =
Note: Before a change to a parameter can be made or before a fault can be cleared, the
display prompts the user with an "Enter Password" message. At this point, the password
must be entered before the user can continue with the action.
22 PFS 150B - 315B OM 129

Increment (+)
When changing the value of a menu item entry, pressing "INCR. +" shifts the selected menu item to the
next higher value or next available selection.
Decrement (-)
When changing the value of a menu item entry, pressing "DECR.-" shifts the selected menu item to the
next lower value or previous available selection.
Enter (=)
Once a change has been made to a desired value, pressing "ENTER =" locks in the new value.
Help / Clear
Pressing "ALARMS" followed by "CLEAR" clears the current fault. Also, when a change is made to a
menu item, pressing "CLEAR" returns the display to the original value as long as "ENTER" has not yet
been pressed.
Note: The cause of a fault should always be determined and corrected before clearing the
fault through the keypad.
Keypad Password
When changing any menu item entry (+ or - key), the user is prompted to enter a valid password. The
change will not be allowed until the correct password is entered. The password for centrifugal units is
always four successive presses of the “Enter” key.
Once this has been done, the user can make changes to menu item entries. After entering the correct
password, the controller will allow a 5 minute time period during which the operator may make any
necessary setpoint adjustments. Any keypad activity will reset the timer for the full 5 minutes so the
password only needs to be entered once per session. After 5 minutes of inactivity, the password access
time will expire providing protection against unauthorized users.
Figure 14, Quick Access Group

The Quick Access
keys provide a fast Water Refrig.
Motor Oil Alarm
Set- Reports Temp's
shortcut directly into Data Temps History
points Press's
the most frequently
used MicroTech
menus. For example,
pressing the Water Display Format
Setpoints key moves
The information stored in the MicroTech controller tree structure can be viewed directly on the control
you directly to menu
#12 without having to panel’s 4 line by 40 character display. The currently selected MENU is shown on the top line along
step through with the current date and time. Up to six menu items may be shown on the lower three lines of the
intermediate menus display. Alarm menus may have an additional field on line 1.
via the Previous and
Next keys. Either U.S.Customary or S.I. engineering units may be displayed by installing the appropriate
controller software.
OM 129 PFS 150B - 315B 23

U.S.Customary Units:
Temperature = ºF (Fahrenheit)
Pressure = Psi (Pound per sq. inch)
Psig
Psid
S.I. Units:
Temperature = ºC (Centigrade)
Pressure = kPa (Kilo Pascals)
kPag
kPda
Menu Structure
Displaying Setpoints
To view setpoints or operating conditions press the ‘Prev Menu’ or ‘Next Menu’ key until menu of
interest appears. (Remember pressing a key in the Category group goes to the first menu of that group)
To view additional setpoints or conditions under the menu selected press the ‘Prev Item’ or ‘Next
Item’ key.
Changing Setpoints
Setpoints / values that can be modified are under the control and alarm categories. Once the menu is
selected, the setpoint / value can be changed by pressing the ‘+ incr.’ or ‘- decr.’ key. The display
screen will change and in place of the date and time the term “Enter Password:” will be displayed. The
operator must enter the appropriate password by pressing the correct four keys in sequence. The
display will indicate “Password Verified:” or “Invalid Password:” in place of the time and date. When
the correct password is entered, the term”<Change Values Mode>“ is displayed in place of the time and
date. The first value on the display that can be changed will flash on and off. Pressing the ‘Next/Prev
Menu’ or ‘Next/Prev Item’ keys will select the next setpoint / value on the screen that can be changed.
Pressing the ‘+ incr.’ or ‘- decr.’ key will change the numeric value or select the next option. When the
correct value or option is flashing, press the ‘enter =‘ key to store it into memory. The flashing will
stop and the time and date is returned to the display screen. Follow this sequence to change additional
setpoints / values. (The term “Enter Password” will not be displayed unless there has not been any
keypad activity for five minutes.)
Display Screen
The display screen is divided into lines and fields. The top line will indicate the menu number and a
menu description on the left side, and the time and date on the right side. The time and date will be
replaced with directions when modifying setpoints and values.
The first line normally will have two fields except when viewing alarms then there is a third field. Line
2 and line 3 have two fields. Different menus will have varying amounts of information and not all the
fields will be used.
When selecting new menus using the 'next menu' and 'prev menu' keys, the display is considered screen
one. If additional screens are available, there will be a arrow pointing down in the last block in the
right hand screen corner. To obtain additional information available under a specific menu, press the
'next item' and 'prev item' keys. This will toggle between the available screens displaying the various
setpoints and values. Most menus will have only one screen; however, Menu 10 (Auto Logging) has
24 screens. The range of information that can be displayed in a field is extensive and the next section
will show all possible field names, setpoints and values.
24 PFS 150B - 315B OM 129

MicroTech Menus
Table 3, Menu 1 Unit Status

Item Extended
Screen Line Display Field Range Name
1 1 Running: Spt 44.0 oF 1 All Systems Off Chiller Operating Mode
Off: Alarm
Off: Ambient Lockout
Off: Front Panel Sw
Off: Remote Switch
Off: Remote Comm
Off: Time Schedule
Off: Manual
Start Requested
Startup Unloadiang
Evap Pump Off
Evap Pump on-Waiting
For Load
Cond Pump Off
Cond Pump On
MCR Started
MCR Off: Rapid Shtdn
MCR Off: Routn Shtdn
Evap Pump Off
Evap Pump on-Recirc
Evap Pump on-cycle
Timer
Evap Pump on-Waiting
Flow
Evap Pump on-Waiting for
Flood
Evap Pump on-Recirc
Cond Pump on-Waiting for
Flow
MCROn PrePurge
MCROn Open Solenoid
ShutdnPumpdown
CondPmpOff Shutdn
EvapPmpOff Shutdn
Running OK:
Motor Amps=xx%RLA 2 0-100% Motor Current Draw
2 Ent Evap=xx.xoF 1 Entering Evap Water Temp
Ent Cond=xx.xoF 2 Entering Cond Water Temp
3 Lvg Evap=xx.xoF 1 Leaving Evap Water TEmp
Lvg Cond=xx.xoF 2 Leaving Cond Water Temp
OM 129 PFS 150B - 315B 25

Table 4, Menu 2 Water Temps/Flow
Item Extended
1 1 Ent Evap=xx.xoF 1 Entering Evap Water Temp
Ent Cond=xx.xoF 2 Entering Cond Water Temp
2 Lvg Evap=xx.xoF 1 Leaving Evap Water Temp
Lvg Cond=xx.xoF 2 Leaving Cond Water Temp
o
3 Delta T=xx.x F 1 Evap Water Delta Temp
Delta T=xx.xoF 2 Cond Water Delta Temp
2 1 Evap Flow=xxxxgpm 1 Averaged Evap Water Flow
2 Cond Flow=xxxxgpm 1 Averaged Cond Water Flow
Table 5, Menu 3 Refrig Temps/Press

Item Extended
1 1 Saturated Evap=xx.xoF/xx.xpsi 1 Saturated Refg Evap Temp/Press
2 Saturated Cond=xx.xoF/xx.xpsi 1 Saturated Refg Cond Temp/Press
o
3 Suct Line=xx.x F 1 Suction Line Refg Temp
Liquid Line=xx.xoF 2 Liquid Line Refg Temp
2 1 Suct Suprht=xx.xoF 1 Suction Superheat
SubCool=xx.xoF 2 Liquid SubCooling
2 Discharge=xx.xoF 1 Discharge Temp
EXV Position=xxx 2 Electronic Expansion Valve Position
o
3 Dsch Suprht=xx.x F 1 Discharge Superheat
EXV Vlv Spt=xxxoF 2 EXV Vale Setpoint
3 1 Cond Apprch=xx.xoF 1 Condenser Approach Temp
2 Evap Apprch=xx.xoF 1 Evaporator Approach Temp
3 Lift Press=xx.xpsi 1 System Lift Pressure
o
4 1 Saturated Cond=xx.x F/xx.xpsi 1 Saturated Refg Cond Temp/Press
2 Liquid Line=xx.xoF/xx.xpsi 1 Liquid Line Refg Temp/Press
3 Filter DPress= x.xoF/x.xpsi 1 Pressure Drop Across Filter/Drier
Table 6, Menu 4 Motor Amps

Item Extended
1 1 %Rated Ld Amps=xx.x% 1 Percent Rated Load Amps
2 Motor Amps=xxxx 1 Actual Motor Amps
3 Limit=xxx 1 Effective Amp Limiting
Table 7, Menu 5 Oil Temps/Press

Item Extended
1 Oil temperatures and pressures Menu information is not available for
are not monitored on this type of this unit type
chiller.
26 PFS 150B - 315B OM 129

Table 8, Menu 6 Pump Status
Item Extended
1 1 Evap 1 Pumps Off Evaporator Pump Status
Pmp #1 Start
Pmp #2 Start
Pump #1 On
Pump #2 On
Pumps Fail
Cond 2 Pumps Off Condenser Pump Status
Pmp #1 Start
Pmp #2 Start
Pump #1 On
Pump #2 On
Pumps Fail
2 Evap Lead= 1 Pmp #1 Currently Selected Lead Pump
Pmp #2
Cond Lead= 2 Pmp #1 Currently Selected Lead Pump
Pmp #2
Table 9, Menu 7 Tower Status

Item Extended
1 1 Cooling Tower Stage=x 1 1-4 Current Cooling Tower Stage
2 Entering Condenser Water Entering Condenser Water Temp
Temp=xx.xoF
3 Coolg Tower Bypass Valve 0-100% Cooling Tower Bypass Valve Position
Pos=xxx%
2 1 Outdoor Air=xx.xoF 1 Outdoor Air Temp
Table 10, Menu 8 Operating Hours

Item Extended
1 1 Compr Hours=xxxxx 1 Compressor Operating Hours
Starts=xxxx 2 Compressor Starts
2 Last Start=xx:xx mm/dd/yy 1 Time of Last Chiller Start
2 Date of Last Chiller Start
3 Last Stop=xx:xx mm/dd/yy 1 Time of Last Chiller stop
2 Date of Last Chiller Stop
2 1 Evap Pmp #1=xxxx 1 Evap Pump #1 Run Hours
Cond Pmp #1=xxxx 2 Condenser Pump #1 Run Hours
2 Evap Pmp #2=xxxx 1 Evaporator Pump #2 Run Hours
Cond Pmp #2=xxxx 2 Condenser pump #2 Run Hours
OM 129 PFS 150B - 315B 27

Table 11, Menu 9 Network Status
Item Extended
1 1 Master Command= 1 Stop Active Master Command
Auto
Recr
Run
Lead Unit= 2 Master Control Panel Definition
Slave
2 Slave Command= 1 Stop Active Slave Command
Auto
Recr
Run
Status= 2 Lead&Lag Off Lead/Lag System Status
Lead On
Lag On
Lead&Lag On
3 Comm Status= 1 No Comm Status of Communication Link
Comm Ok
Table 12, Menu 10 Auto Logging

Item Extended
1 1 Wk Ending 1 Date of Current Log
2 Peak=xxx% 1 Recorded Peak %RLA
Evap=xx.xxpsi 2 Recorded Evaporator Pressure
3 mm-dd xx:xx 1 Date and Time of Log Entry
Cond=xxx.xpsi 2 Recorded Condenser Pressure
2 1 Ent Evap=xx.xoF 1 Recorded Ent Evap Water Temp
Ent Cond=xx.xoF 2 Recorded Ent Cond Water Temp
2 Lvg Evap=xx.xoF 1 Recorded Lvg Evap Water Temp
Lvg Cond=xx.xoF 2 Recorded Lvg Cond Water Temp
3 Evap Aprch=xx.xoF 1 Recorded Evap Approach
o
Cond Apprch=xx.x F 2 Recorded Cond Approach
3 1 Discharge=xx.xoF 1 Recorded Discharge Temp
SubCool=xx.xoF 2 Recorded Subcooling
2 Dsch Suprht=xx.xoF 1 Recorded Discharge Superheat
Suct Suprht=xx.xoF 2 Recorded Suction Superheat
o
4 1 Sump Temp=xx.x F 1 Recorded Oil Sump Temp
2 Evap Flow=xx.xgpm 1 Recorded Evap Water Flow
3 Cond Flow=xxxxpgm 1 Recorded Cond Water Flow
5 1 Wk Ending 1 Date of Previous Log
2 Peak=xxx% 1 Recorded Peak % RLA
Evap=xx.xpsi 2 Recorded Evap Press
Cond=xxx.xpsi 2 Recorded Cond Press
Table continued on next page
28 PFS 150B - 315B OM 129

Table 12, Menu 10 Auto Logging (continued)
Item Extended
o
2 Lvg Evap=xx.x F 1 Recorded Lvg Evap Water Temp
Cond Apprch=xx.xoF 2 Recorded Cond Approach
Subcool=xx.xoF 2 Recorded Subcooling
o
Suct Suprht=xx.x F 2 Recorded Suction Superheat
8 1 Sump Temp=xx.xoF 1 Recorded Oil Sump Temp
2 Evap Flow=xxxxgpm 1 Recorded Evap Water Flow
3 Cond Flow=xxxxgpm 1 Recorded Cond Water Flow
o
Ent Cond=xx.x F 2 Recorded Ent Cond Water Temp
o
2 Dsch Suprht=xx.x F 1 Recorded Discharge Superheat
2 Feed Temp=xx.xoF 1 Recorded Oil Feed Temp
Evap Flow=xx.xgpm 2 Recorded Evap Water Flow
3 Feed Press=xx.xpsi 1 Recorded Oil Feed Pressure
Cond Flow=xxxxpgm 2 Recorded Cond Water Flow
OM 129 PFS 150B - 315B 29

Item Extended
o
2 Lvg Evap=xx.x F 1 Recorded Lvg Evap Water Temp
o
Suct Suprht=xx.x F 2 Recorded Suction Superheat
Evap Flow=xxxxgpm 2 Recorded Evap Water Flow
Cond Flow=xxxxgpm 2 Recorded Cond Water Flow
o
18 1 Ent Evap=xx.x F 1 Recorded Ent Evap Water Temp
o
19 1 Discharge=xx.x F 1 Recorded Discharge Temp
Evap Flow=xx.xgpm 2 Recorded Evap Water Flow
Cond Flow=xxxxpgm 2 Recorded Cond Water Flow
30 PFS 150B - 315B OM 129

Item Extended
o
22 1 Ent Evap=xx.x F 1 Recorded Ent Evap Water Temp
o
23 1 Discharge=xx.x F 1 Recorded Discharge Temp
o
2 Feed Temp=xx.x F 1 Recorded Oil Feed Temp
Evap Flow=xxxxgpm 2 Recorded Evap Water Flow
Cond Flow=xxxxgpm 2 Recorded Cond Water Flow
Table 13, Menu 11 Control Mode

Item Extended
1 1 Mode= 1 Man Cmpr Load Selected Unit Operation
Service Testing
Manual Enable
Auto:Network
Auto:Local
Manual Off
2 Man Cmpr Load=xx% 1 0-100% Manual Compressor Load Setpoint
Table 14, Menu 12 Lvg Evap Spts

Item Extended
Screen Line Diaplay Field Range Name
1 1 Spt Source=Local 1 Local Lvg Evap Setpoint Source
Network
Active Spt=xx.xoF 2 Current Active Setpoint
2 Local Spt=44.0oF 1 40-80 User Adjustable Chw Setpoint
Startup DT=3.0oF 2 1-10 Startup Delta Temp
o
3 Network Spt=xx.x F 1 Chw Setpoint Supplied by Network
Shutdn DT=3.0oF 2 1-3 Shutdown Delta Temp
2 1 Control Band=0.4oF 1 0.4 - 2.0oF Control Band Leaving Evap Setpoint
Reset Signal=xx.xmA 2 0-20mA External Reset Signal Amplitude
2 Chw Reset=No Reset 1 No Reset Chw Reset Method
Return
4-20mA
OAT
Ice
Max Lvg Spt=54.0oF 2 10-80 Upper Chw Setpoint Limit
3 Return Spt=54.0oF 1 20-80 Setpoint for Return Water Reset
o
No Reset At 70 F 2 10-90 Lower OAT Reset Limit
3 1 Max Reset At 50oF 1 10-90 Upper OAT Reset Limit
2 Pulldn Rate=0.5/m 2 0.1-5.0 Maximum Chw Pulldown Rate
OM 129 PFS 150B - 315B 31

Table 15, Menu 13 Motor Amp Setpoints
Item Extended
1 1 Amp Reset= No Reset 1 No Reset Current Limit Method
Demd Lim
Network Spt=xx% 2 Network Amp Limit Value
2 Active Spt=100% 1 Active Amp Limit Setpoint
Min Amp Spt=30% 2 0-100% Minimum Amp Limit Value
3 Reset Signal=0.0mA 1 0-20mA Magnitude of External Signal
Max Amp Spt=100% 2 0-100% Maximum Amp Limit Value
Table 16, Menu 14 Set Time Date

Item Extended
1 1 hh:mm:ss 1 00:00:00-23:59:59 Current Hour, Min, Sec
day 2 Sun - Sat Current Day
mm-dd-yy 3 Jan - Dec, 1-31,00-99 Current Date
Table 17, Menu 15 Schedule

Item Extended
1 1 Override=0.00Hr 1 00.00-63.75 Manual Schedule Override
Network Sched=N/A 2 1-32 Network Time Schedule
2 Sun 00:00-23:59 1 00:00-23:59 Sunday Run Schedule
Tue 00:00-23:59 2 00:00-23:59 Tuesday Run Schedule
3 Mon 00:00-23:59 1 00:00-23:59 Monday Run Schedule
Wed 00:00-23:59 2 00:00-23:59 Wednesday Run Schedule
2 1 Thu 00:00-23:59 1 00:00-23:59 Thursday Run Schedule
Sat 00:00-23:59 2 00:00-23:59 Saturday Run Schedule
2 Fri 00:00-23:59 1 00:00-23:59 Friday Run Schedule
Hol 00:00-23:59 2 00:00-23:59 Holiday Run Schedule
3 One Event N/A-00 00:00-00:00 1 Jan-Dec Time Schedule Override
2 00-31
3 00:00-23:59
32 PFS 150B - 315B OM 129

Table 18, Menu 16 Holiday Date
Item Extended
1 1 #1=N/A-00 00 Day(s) 1 Jan-Dec Holiday Month
2 00-31 Holiday Date
3 00-31 Duration Days
#4=N/A-00 00 Day(s) 1 Jan-Dec Holiday Month
2 #2=N/A-00 00 Day(s) 1 Jan-Dec Holiday Month
OM 129 PFS 150B - 315B 33

Table 19, Menu 17 Timers
Item Extended
1 1 Start-Start=40Min 1 15-60 Min Start to Start Delay Timer
Suct Inj Delay=6Sec 2 5-30Sec Suction Injection Time Delay
2 Evap Recirc=30Sec 1 15Sec-5 Min Chilled Water Recirculation Timer
Interstage Tmr=60Sec 2 50 - 90 Sec Compressor Interstage Timer
3 Stop-Start=3Min 1 3-20 Min Stop to Start Delay Timer
Table 20, Menu 18 Pump Setpoints

Item Extended
1 1 Evap=Pmp 1 Only 1 Pmp 1 Only Evap Pump Selection Mode
Pmp 2 Only
Auto Lead
#1 Primary
#2 Primary
2 Cond=Pmp 1 Only 1 Pmp 1 Only Cond Pump Selection Mode
Pmp 2 Only
Auto Lead
#1 Primary
#2 Primary
Table 21, Menu 19 Cooling Tower

Item Extended
1 1 Tower Control=Yes 1 Yes-No Tower Control
Tower Stages=2 2 1-4 Total Cooling Tower Stages
2 StageUp Time=2Min 1 1-60 Min Stage Up Delay
StageDn Time=5Min 2 1-60 Min Stage Down Delay
3 Stage Differential=3.0 oF 1 1-10oF Staging Differential
2 1 Stage #1 On=70.0oF 1 40-120oF Stage #1 Setpoint
Stage #4 On=85.0oF 2 40-120oF Stage #4 Setpoint
2 Stage #2 On=75.0oF 1 40-120oF Stage #2 Setpoint
o o
3 Stage #3 On=80.0 F 1 40-120 F Stage #3 Setpoint
34 PFS 150B - 315B OM 129

Table 22, Menu 20 Cooling Tower Valve
Item Extended
1 1 Valve Control=None 1 None CoolingTower Bypass Control Type
Valve Setpoint
Stage Setpoint
2 Valve Spt=65.0 oF 1 40-99.5oF Bypass Valve Control Setpoint
o o
Valve Deadb=2.0 F 2 1.0-10.0 F Bypass Valve Control Dead Band
3 Min Position=20% 1 0-50% Used for Calculating Valve Position
Max Position=80% 2 50-100% Used for Calculating Valve Position
2 1 Valve Type=NC To Tower 1 NC to Tower Bypass Valve Default Position
NO to Tower
2 Mod Limit=7.5oF 1 4.0-25.0oF Bypass Valve Modulation Limit
Sample Time=15Sec 2 1Sec-15Min Entering Cond Temp Integration Time
3 Max Change=4% 1 1-20% Max Allowable Valve Position Change
PA Time=47.0Min 2 1.0 60.0 Min Project Ahead Calculation Window
3 1 Min Start Pos=0% 1 0-100% Min Valve Position at Startup
Max Start Position=100% 2 0-100% Max Valve Position at Startup
2 Min Pos At=60oF 1 0-99.5oF OAT for Minimum Position
o
Max Pos At=90 F 2 0-99.5oF OAT for Maximum Position
Table 23, Menu 21 Oil Setpoints

Item Extended
1 Menu information is not available Menu information is not available for
for this unit type. this unit type.
Table 24, Menu 22 Alarm Setpoints

Item Extended
1 1 High Condenser Press-Shutdown.. 256psi 1 240-480psi
2 High Condenser Press-Unload.... 240psi 1 240-480psi
3 High Condenser Press Hold...... 226psi 1 240-480psi
2 1 High Discharge Temp-Shutdown... 130.0o F 1 20-90o F
2 Low Evaporator Press-Unload.... 57.0psi 1 10.0-45.0psi
3 Low Evaporator Press-Shutdown.. 54.0psi 1 10.0-45.0psi
3 1 Motor Current Threshold.. 10% 1 1-20%
2 Evap Water Freeze................ 34.0o F 1 -9 - 45o F
o
3 Cond Water Freeze................ 34.0 F 1 -9 - 45o F
OM 129 PFS 150B - 315B 35

Table 25, Menu 23 Lead Lag Setup
Item Extended
1 1 Slave Address=01.00 1 00-09 Slave Unit Network Address
Lag-Standby=No 2 No-Yes Lag Unit Standby Operation
2 LL Mode=Auto 1 Auto Lead Lag Control Mode
Slave Lead
Master Lead
Delay Timer Up =5 Min 2 1 - 5 Minutes Delay Starting of Lag Compressor
3 LL SwOver= 00:00 1 00:00 Lead Lag Switch over Time
Delay Timer Dn =5 Min 2 1 - 5 Minutes Delay Stopping of Lag Compressor
Table 26, Menu 24 Service

Item Extended
1 1 Manual Load=Off 1 Off-On Enable Manual Loading
Setpoint=40% RLA 2 0-100% Manual Load Setpoint
2 Manual EXV=Off 1 Off-On Enable Manual Expansion Valve
EXV Steps=0 2 -100 - 100 Manual Expansion Valve Position
3 Timers=Normal 1 Normal Setup Timers for Service
Fast
Hot Gas Bypass=2.0oF 2 0.0 - 2.0 Hot Gas Bypass Enable Delta Temp
2 1 Manual Pumpdown=No 1 No-Yes Enable Manual Pumpdown
Evap Offset=0.0psi 2 -9.9 - 15.0psi Evap Press Transducer Calibration
2 PumpDn EvapT=10psi 1 0-100oF Evap Temp Pumpdown Setpoint
Cond Offset=0.0psi 2 -9.9 - 15.0psi Cond Press Transducer Calibration
3 PmpDn SuperHt=40oF 1 0-100oF Pmp Dn Protection
Ligl Offset=0.0psi 2 Liquid line Transducer Calibration
3 1 CmprFlood Dly=20min 1 1-20Min Compressor Flood Delay
00:00 - Sat 23:59 2
2 Auto-Log Window:Sun 1 1 - 10 Minutes Auto Log Start Day
36 PFS 150B - 315B OM 129

Table 27, Menu 25 Service Testing
Item Extended
1 1 Output #0=Off 1 Off-On Manual Output Control
EXV Position=0 2 0-999 Manual Expansion Valve Control
2 Output #1=Off 1 Off-On Manual Output Control
Output #5=Off 2 Off-On Manual Output Control
5 1 DI #0-7=00000000 1 Digital Input Status (0-7)
2 DI #8-15=00000000 1 Digital Input Status (8-15)
6 1 AI #13=xx.xoF 1 Analog Signal at Input 13 (Reference)
AI #19=0.00Vdc 2 Analog Signal at Input 19 (Reference)
2 AI #14=xx.xoF 1 Analog Signal at Input 14 (Reference)
o
AI #21=xx.x F 2 Analog Signal at Input 21 (Reference)
3 AI #15=xx.xoF 1 Analog Signal at Input 15 (Reference)
AI #22=xx.xoF 2 Analog Signal at Input 22 (Reference)
OM 129 PFS 150B - 315B 37

Table 28, Menu 26 Unit Setup
Item Extended
1 1 Config=L2-TTY-Slave 1 L1-TTY-Mastr Unit Controoler Configuration
L1-TTY-TTY
L2-Mastr-Slv
L2-TTY-Slave
L3-TTY-Slave
IDENT=PES2E-02-K 2 Software Version
2 Port A Baud =9600 1 1200 Port A Comm Rate
2400
9600
Chiller Only 2 Only Chiller Control Options
/Templifier
3 Unit Type=PES075 1 PES075 Chiller Model Number
PES095
PES105
PFS150
PFS170
PFS180
PFS200
PFS215
Low Temperature=No 2 No-Yes Ice Operation
2 1 Master/Slave=Slave 1 Master Network Configeration
Slave
Evap Gpm Sensor=No 2 No-Yes Evaporator Flow Transmitter
2 OaT Sensor=None 1 None Location of OAT
Local
Remote
Evap Full Gpm=6500 2 0-65535 Maximum Flow Rate
3 Ambient Lockout=No 1 No-Yes Lockout on OAT
Cond Gpm Sensor=No 2 No-Yes Condenser Flow Transmitter
3 1 Cond Full Gpm=6500 1 0-65535 Maximum Flow Rate
Full Load Amp=300 2 Chiller RLAOil Cooler Control Method
2 Refrig Leak Sen=No 1 No-Yes Refrigerant Leak Sensor Signal
Alarm-Normal=Open 2 Open Alarm Reporting
Close
Slow
Fast
3 Ht Recovery Sen=No 1 No-Yes Heat Recovery Temp Sensor
Comm Loss=Slow 2 Open Alarm Reporting
Close
Slow
Fast
38 PFS 150B - 315B OM 129

Table 28 Menu 26 Unit Setup (continued)
Item Extended
4 1 Warnings=Slow 1 Open Alarm Reporting
Close
Slow
Fast
CSC= No 2 CSC Panel Present
2 Problems = Fast 1 Open Alarm Reporting
Close
Slow
Fast
3 Faults=Close 1 Open Alarm Reporting
Close
Slow
Fast
Table 29, Menu 27 Current Alarm

Item Extended
1 1 No Active Alarms 1 Alarm Status Table Current Alarm
At 0:00 2 00:23:59 Time of Alarm
On N/A-00 3 Jan-Dec /01-31 Date of Alarm
2 Unit Status 1 Alarm Status Table Unit Operating Mode at Alarm
Ent Evap=xxx.x o F 2 Ent Evap Chw Temp at Alarm
3 Motor Current=xxx% 1 0-100% Percent RLA at Alarm
Lvg Evap=xxx.x o F 2 Lvg Evap Chw Temp at Alarm
2 1 Ent Cond=xxx.x o F 1 Ent Cond Water Temp at Alarm
Cond=xxx.xpsi 2 Cond Refrigerant Press at Alarm
2 Lvg Cond=xxx.x o F 1 Lvg Cond Water Temp at Alarm
Evap Aprch=512.0 o F 2 Evap Approach at Alarm
3 Evap=xx.xpsi 1 Evap Refrigerant Press at Alarm
Cond Aprch=xxx.xo F 2 Cond Approach at Alarm
3 1 Discharge=xxx.x o F 1 Discharge Temp at Alarm
Subcool=xxx.x o F 2 Subcooling at Alarm
2 Dsch Suprht=512.0 o F 1 Discharge Superheat at Alarm
EXV Position= 0 2 EXV Position at Alarm
3 Suct Suprht=512.0 o F 1 Suction Superheat at Alarm
4 1 Evap Flow= 0gpm 1 Evap Flow at Alarm
2 Cond Flow=0gpm 1 Condenser Water Flow at Alarm
3 Suct Suprht 00o F 1 Suction Superheat at Alarm
OM 129 PFS 150B - 315B 39

Table 30, Menu 28 Alarm Buffer #1
Item Extended
o
Ent Evap=xxx.x F 2 Ent Evap Chw Temp at Alarm
2 1 Ent Cond=xxx.xºF 1 Ent Cond Water Temp at Alarm
2 Lvg Cond=xxx.xo F 1 Lvg Cond Water Temp at Alarm
Evap Aprch=xxx.x o F 2 Evap Approach at Alarm
Cond Aprch=xx.xoF 2 Cond Approach at Alarm
2 Dsch Suprht=xxx.x o F 1 Discharge Superheat at Alarm
EXV Position=xxx 2 EXV Position
o
3 Suct Suprht= xxx.x F 1 Suction Superheat at Alarm
4 1 Evap Flow=xxxxgpm 1 Evaporator Water Flow at Alarm
2 Cond Flow=xxxxgpm 1 Condenser Water Flow at Alarm
3 Suct Suprht xxºF 1 Condenser Water Flow at Alarm

Item Extended
o
Subcool=xxx.x F 2 Subcooling at Alarm
EXV Positon=xxx 2 EXV Position
3 Suct Suprhtxxx.x o F 1 Suction Superheat at Alarm
4 1 Feed Press=xx.xpsi 1 Oil Feed Pressure at Alarm
2 Evap Flow=xxxxgpm 1 Evaporator Water Flow at Alarm
40 PFS 150B - 315B OM 129

Item Extended
o
EXV Position=xxxx 2 EXV Position
o
3 Suct Suprhtxxx.x F 1 Suction Superheat at Alarm

Item Extended
o
OM 129 PFS 150B - 315B 41

Item Extended
o
o

Item Extended
o
42 PFS 150B - 315B OM 129

Item Extended
o
o

Item Extended
o
OM 129 PFS 150B - 315B 43

Table 38, Menu 36 Message Board
Item Extended
1 1 No Message A Message Can Be Posted Via a
Connected Computer
Troubleshooting Chart
PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS
Compressor will not nun 1. Main power switch open 1. Close switch
2. Evaporator flow switch not closed. 2. Check unit status on MicroTech display Close
switch.
3. Circuit t breakers open 3. Close circuit breakers
4. Fuse b own or circuit breakers tripped 4. Check electrical circuits and motor windings for
shorts or grounds. Investigate for possible
overloading. Check for loose or corroded
connections Reset breakers or replace fuses after
fault s corrected.
5. Unit phase voltage monitor not satisfied 5. Check unit power wiring to unit for correct phasing.
Check voltage
6. Compressor overload tripped 6. Overloads are manual reset. Reset overload at

button on overload. Clear alarm on MicroTech.
7. Defective compressor contactor or contactor coil 7. Check wiring Repair or replace contactor
8. System shut down by safety devices 8. Determine type and cause of shutdown and correct
problem before attempting to restart.
9. No cooling required 9. Check control settings. Wait until unit calls for
cooling
10.Motor electrical trouble 10.See 6 7 8 above.
11.Loose wiring 11.Check circuits for voltage at required points.

Tighten all power wiring terminals
Compressor Noisy or 1. Compressor internal problem'. 1. Contact McQuayService.

Vibrating
2. Liquid injection not adequate. 2. Check to assure Iiquid line sightplass is fulI during
steady operation
Compressor Overload Relay 1. Low voltage during high load condition. 1. Check supply voltage for excessive voltage drop
Tnpped or Circuit Breaker Trip
or Fuses Blown
2. Loose power wiring. 2. Check and tighten all connections.
3. Power line fault causing an unbalanced voltage 3. Check supply voltage
4. Defective or grounded wiring in the motor. 4. Check motor and replace if defective.
5. High discharge pressure 5. See Corrective Steps for high discharge pressure
Compressor Will Not Load or 1. Defective capacity control solenoids 1. Check solenoids for proper operas on
Unload
2. Unloader mechanism defective. 2. Replace.
Troubleshooting chart continued on next page
44 PFS 150B - 315B OM 129

PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS
Compressor Liquid Injection 1. Liquid injection solenoid did not open at start 1. Check and replace Iiquid injection solenoid
Protection Trip
2. Inadequate liquid to liquid injection at start due to a 2. Check liquid inject on line sightglass. If flashing
clogged filter-drier or low charge check filter-drier and unit charge
3. Inadequate liquid to liquid injection during run 3. Check liquid injection line sightglass If flashing
check filter-drier and unit charge Discharge
pressure too low
High Discharge Pressure 1. Discharge shutoff valve partially closed 1. Open shutoff valve.
2. Noncondensables in the system 2. Purge the noncondensables from the condenser

coil after shutdown
3. Condenser water insufficient or temperature too 3. Read temperature control or water regulating valve
high Investigate ways to increase water supply
4. Fouled condenser tubes (water cooled condenser. 4. Clean. Dirty tube and fin surface (cooling tower)
5. System overcharged with refrigerant 5. Check for excessive subcooling above 30°F (-1 °C).
Remove excess charge.
6. Cooling tower is undersized. 6. Check cooling tower rating tables against the
operation
7. High ambient conditions. 7. Check cooling tower rating tables against the
operation
8. Air restrict on at cooling tower. 8. Remove obstructions near unit
Low Discharge Pressure 9. Cooling tower too large. 9. Check cooling tower rating tables against the
operas r n
10.Faulty cooling tower temperature regulation 10.Check cooling tower control operation
11.Suction shutoff valve partially closed. 11.Open valve.
12.insufficient refrigerant in system. 12.Check for leaks. Repair and add charge.
13.Low suction pressure. 13.See corrective Steps for low suction pressure.
14.Low ambient condition. 14.Check cooling tower control operation
15.Compressor operating unloaded. 15.See corrective Steps for failure to load
Low Suction Pressure 1. Inadequate refrigerant charge quantity 1. Check liquid line sightglass Check unit for leaks.
2. Inadequate liquid to liquid injection at star 2. Repair and recharge to clear sightglass
3. Clogged liquid line filter drier 3. Check pressure drop across filter drier Replace
cores.
4. Expansion valve malfunctioning. 4. Check expansion valve superheat and valve opening
position Replace valve only if certain valve is not
working.
5. insufficient water flow to evaporator 5. Check water pressure drop across the evaporator
and adjust gpm
6. Water temperature leaving evaporator is too low. 6. Adjust water temperature to higher value.
7. Evaporator tubes fouled. 7. Inspect by removing water piping Clean chemically
8. Evaporator head ring gasket slippage 8. Low suction pressure and low superheat both
present may indicate an internal problem Consult
factory.
High Suction Pressure 1. Excessive load - high water temperature 1. Reduce load or add additional equipment.
2. Superheat is too low. 2. Check superheat on MicroTech display. Check

suction line sensor installation and sensor.
OM 129 PFS 150B - 315B 45

Maintenance Schedules
I. COMPRESSOR
A. Performance Evaluation (log condition and analysis)# O
B. Motor
• Megger windings X
• Ampere balance (within 10%) X
• Terminal check (tight connections, porcelain clean) X
• Motor cooling (check DC voltage across GDR coils)# X
C. Lubrication System
• Oil line temperatures (no abnormal temperature drop)# O
• Oil appearance (clear color, quantity, as viewed through O
sightglass)#
• Oil filter change X
D. Compressor capacity change #
• Compressor loads
• Lower leaving chilled water temp. control X
• Record motor amps X
• Compressor unloads
• Raise leaving chilled water temp. control X
• Record motor amps X
• Reset leaving chilled water control to design
• Observe water temp. And record amps X
E. Internal compressor check X
II. CONTROLS
A. Operating controls
• Check water temp. Setpoints against operating temps. X
• Check panel is clean and dry X
• Verify motor overload control setpoints X
• Verify wiring terminations are tight X
• Check contactor contacts (replace if required) X
• Check MicroTech service test X
B. Protective controls (test operation of)
• Alarm relay (if connected) X
• Pump interlocks X
• Guardistor relays X
• High pressure switches X
III. WATER-COOLED CONDENSER

A. Performance evaluation (include water press. drop)# O
B. Test water quality X
C. Clean condenser tubes X
D. Eddy current test --tube wall thickness X
E. Seasonal protection X
KEY:
O = performed by in-house personnel
X = performed by qualified HVAC service personnel
# = Test to be performed with compressor circuit in operation
46 PFS 150B - 315B OM 129

IV. EVAPORATOR
A. Performance evaluation (include water press. drop)# O
B. Test water quality X
C. Clean evaporator tubes X
D. Eddy current test --tube wall thickness X
E. Seasonal protection X
V. EXPANSION VALVES
A. Performance evaluation (observe superheat)# X
VI. COMPRESSOR - CHILLER UNIT

A. Performance evaluation O
B. Leak test:
• Compressor fittings and terminal X
• Pipe fittings X
• Oil pump line fittings X
• Vessel relief valves X
C. Check sightglasses and press. Drop across filter/drier X
D. General appearance:
• Paint O
• Insulation O
VII. STARTERS
A. Examine contactors (hardware and operation) X
B. Verify overload setting and trip X
C. Test electrical connections X
D. Pump down controls (verify operation) X
VIII. OPTIONAL CONTROLS

A. Hot gas bypass controls (verify operation) X
B. Liquid injection controls (verify operation) X
C. Pump down control (verify operation) X
KEY:
O = performed by in-house personnel
X = performed by qualified HVAC service personnel
# = Test to be performed with compressor circuit in operation
Note: Some motors use power factor correction capacitors and others use a surge capacitor. In all cases,
capacitors must be disconnected from the circuit to obtain a useful megohmmeter reading. Failure to disconnect
capacitors will result in low readings. Only qualified electrical technicians should perform service.
OM 129 PFS 150B - 315B 47

13600 Industrial Park Boulevard, P.O. Box 1551, Minneapolis, MN 55440 USA (612) 553-5330

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Operation and Maintenance Manual OM 129

PFS 150B through 315B

© 1997 McQuay International

2 PFS 150B - 315B OM 129

OM 129 PFS 150B - 315B 3

4 PFS 150B - 315B OM 129

Start-up and Shutdown

Note: Evaporator and condenser water should be chemically treated.

OM 129 PFS 150B - 315B 5

Start-up After Temporary Shutdown

Start-up After Extended Shutdown

6 PFS 150B - 315B OM 129

Figure 1, Jet pump assembly

Table 1, Jet Pump assembly connections

OM 129 PFS 150B - 315B 7

8 PFS 150B - 315B OM 129

Table 1, Solenoid status

Location of the solenoids is as follows:

OM 129 PFS 150B - 315B 9

Table 2, Filter-drier pressure drop

• When bubbles occur in the sightglass with normal subcooling

Unit condensers are sized to hold the entire refrigerant charge.

10 PFS 150B - 315B OM 129

Electronic Expansion Valve

Electronic Expansion Valve Operation

OM 129 PFS 150B - 315B 11

12 PFS 150B - 315B OM 129

Liquid Presence Sensor

High Condenser Pressure Control

Mechanical High Pressure Safety Control

Compressor Motor Protection

OM 129 PFS 150B - 315B 13

Controls, Settings, and Functions

200 Series MicroTech Control Panel

14 PFS 150B - 315B OM 129

OM 129 PFS 150B - 315B 15

Control Panel Layout

Model 280 ADI

16 PFS 150B - 315B OM 129

control software and performing internal hardware tests.

Figure 3, Contrast adjustment

Digital Output Board

Figure 4, Digital output board

OM 129 PFS 150B - 315B 17

Figure 5, ADI board

Analog Output Board (AOX)

Figure 6, AOX board

18 PFS 150B - 315B OM 129

Figure 7, Signal converter board

Figure 8, Guardistor board

OM 129 PFS 150B - 315B 19

Figure 9, Keyboard / Display

Menu line 3.Refrig Temps/Press 12:55 Mar-01-95

Keypad / Display Operation

20 PFS 150B - 315B OM 129

Figure 11, Category group

OM 129 PFS 150B - 315B 21

Figure 13, Action Group

22 PFS 150B - 315B OM 129