Goodman AGZ 035A Installation Manual

Installation, Operation and Maintenance Manual IOMM AGZ-1

Air-Cooled Scroll Compressor Chiller

AGZ 035A through 065A 60 Hertz, R-22 Global Chiller Line

Group: Chiller Part Number: 074641001 Effective: March 2000

Supersedes: IOMM AGZ

Table of Contents

Introduction.........................................3

General Description...........................................3

Inspection...........................................................3

Nomenclature......................................................3

Installation...........................................4

Handling..............................................................4

Location...............................................................5

Service Access...................................................5

Vibration Isolators..............................................7

Water Piping.......................................................8

Flow Switch.........................................................9

Water Connections..........................................10

Glycol Solutions...............................................10

Evaporator Flow and Pressure Drop.............11

Physical Data.....................................13

Electrical Data...................................15

Field Wiring.......................................................15

Dimensional Data..............................28

Startup...............................................29

Refrigerant Charging.......................................34

Thermostatic Expansion Valve.......................34

Crankcase Heaters ...........................................35

Water Cooler.....................................................35

Global UNT Controller Installation

and Operation....................................36

General Description.........................................36

Optional Sensors..............................................36

Controller Inputs /Outputs.............................38

Additional Global UNT Features...................42

Alarms................................................................44

Zone Terminal (Optional)................................45

Zone Terminal Glossary ..................................49

UNT Troubleshooting Chart..........................51

MicroTech Controller Installation and

Operation...........................................53

General Description.........................................53

Optional Sensor Packages..............................53

Installation........................................................53

Sequence of Operation....................................62

Start-Up and Shutdown ..................................64

Keypad / Display.............................................65

Menu Descriptions..........................................68

Trouble Analysis for the MicroTech.............79

Test Procedures................................................82

Pre Start-up.......................................................29

Start-Up .............................................................29

Shutdown..........................................................29

Water Piping Checkout...................................30

Refrigerant Piping Checkout..........................30

Electrical Check Out.........................................31

Operation...........................................32

Sequence of Operation....................................32

Hot Gas Bypass (Optional).............................33

Filter Driers........................................................34

System Adjustment..........................................34

Liquid Sightglass and Moisture Indicator...34

Our facility is ISO 9002 Certified

"McQuay" is a registered trademark of McQuay International

"Illustrations and data cover McQuay International products at the time of publication and we reserve the right

to make changes in design and construction at anytime without notice"



1997 McQuay International

Unit Maintenance..............................89

Preventative Maintenance Schedule ............90

Service...............................................91

Liquid Line Solenoid Valve.............................91

Evaporator.........................................................92

Refrigerant Charging.......................................92

AGZ Troubleshooting Chart..........................94

2 AGZ 035A through 065A IOMM AGZ-1

Introduction

Global

General Description

McQuay Air-Cooled Global water chillers are complete, self-contained automatic refrigerating units. Every unit is completely assembled, factory wired, charged, and tested. Each unit consists of twin AirCooled condensers with integral subcooler sections, two tandem scroll compressors, replaceable tube dual circuit shell-and-tube evaporator, and complete refrigerant piping. Liquid line components include manual liquid line shutoff valves, sight-glass/moisture indicators, solenoid valves, and double diaphragm hydraulic element thermal expansion valves. Other features include compressor crankcase heaters, an evaporator heater for chilled water freeze protection, limited pumpdown during “on” or “off” periods, compressor lead-lag switch to alternate the compressor starting sequence, and sequenced starting of compressors.

The electrical control center includes all safety and operating controls necessary for dependable automatic operation. Condenser fan motors are fused in all three phases and started by their own three-pole contactors. Compressors are not fused but may be protected by optional circuit breakers.

Inspection

Check all items carefully against the bill of lading. Inspect all units for damage upon arrival. Report shipping damage and file a claim with the carrier. Check the unit nameplate before unloading, making certain it agrees with the power supply available. McQuay is not responsible for physical damage after unit leaves the factory.

Note: Unit shipping and operating weights are available in the Physical Data tables beginning on page 13.

Nomenclature

A G Z - XXX A S

Application

Air-Cooled

Scroll Compressor

S= Standard Cooling

Design Vintage

Model Size 035 through 065

IOMM AGZ-1 AGZ 035A through 065A 3

Installation

Note: Installation is to be performed by qualified personnel who are familiar with local codes

and regulations.

WARNING

Sharp edges and coil surfaces are a potential hazard. Avoid contact with them.

Handling

Be careful to avoid rough handling of the unit. Do not push or pull the unit from anything other than the base. Block the pushing vehicle away from the unit to prevent damage to the sheet metal cabinet and end frame (see Figure 1).

To lift the unit, 2 1/2" (64mm) diameter lifting holes are provided in the base of the unit. Arrange spreader bars and cables to prevent damage to the condenser coils or cabinet (see Figure 2).

Figure 1, Suggested Pushing Arrangement

Blocking is required across full width

Figure 2, Suggested Lifting Arrangement

Number of fans may vary

Spreader Bars

recommended

(use caution)

4 AGZ 035A through 065A IOMM AGZ-1

from this diagram. The

lifting method will remain

the same

These rigging holes must be used.

Location

Unit Placement

AGZ units are for outdoor applications and can be mounted on a roof or ground level. Set units on a solid and level foundation. For roof mounted applications, install the unit on a steel channel or I-beam frame to support the unit above the roof. For ground level applications, install the unit on a substantial base that will not settle. A one piece concrete slab with footings extended below the frost line is recommended. Be sure the foundation is level (within 1/2” [13 mm] over its length and width). The foundation must support the operating weights listed in the Physical Data tables beginning on page 13.

On ground level applications protect fins against vandalism using the optional coil guards or by erecting a screen fence. The fence must allow free flow of air to the condenser coil for proper unit operation.

Clearances

The flow of air to and from the condenser coil must not be limited. Restricting air flow or allowing air recirculation will result in a decrease in unit performance and efficiency. There must be no obstruction above the unit that would deflect discharge air downward where it could be recirculated back to the inlet of the condenser coil. The condenser fans are propeller type and will not operate with ductwork on the fan outlet.

Install the unit with enough side clearance for air entrance to the coil and for servicing. Provide service access to the evaporator, compressors, electrical control panel and piping components as shown in Figure 3.

Do not allow debris to accumulate near the unit. Air movement may draw debris into the condenser coil causing air starvation. Give special consideration to low ambient operation where snow can accumulate. Keep condenser coils and fan discharge free of snow or other obstructions to permit adequate airflow.

Sound Isolation

The ultra-low sound level of the AGZ chiller is suitable for most applications. When additional sound reduction is necessary, locate the unit away from sound sensitive areas. Avoid locations beneath windows or between structures where normal operating sounds may be objectionable. Reduce structurally transmitted sound by isolating water lines, electrical conduit and the unit itself. Use wall sleeves and rubber isolated piping hangers to reduce transmission of water or pump noise into occupied spaces. Use flexible electrical conduit to isolate sound transmission through electrical conduit. Spring isolators are effective in reducing the low amplitude sound generated by scroll compressors and for unit isolation in sound sensitive areas.

Service Access

Each end of the unit must be accessible after installation for periodic service. Compressors, filterdriers, and manual liquid line shutoff valves are accessible. The high pressure control is located in the control panel when using the Global UNT controller, and on the compressor when using the MicroTech controller. Low pressure, and motor protector controls are on the compressor. Most other operational, safety and starting controls are located in the unit control box.

The condenser fan and motors can be removed from the top of the unit.

IOMM AGZ-1 AGZ 035A through 065A 5

Figure 3, Clearance Requirements

6 AGZ 035A through 065A IOMM AGZ-1

Vibration Isolators

Vibration isolators are recommended for all roof mounted installations or wherever vibration transmission is a consideration.

Table 1 and Table 2 list isolator point loads for all unit sizes. Figure 4 shows isolator locations. See Dimensional Data for detailed dimensions required to secure each isolator to the mounting surface.

The spring flex isolators are white type CP2-32, McQuay part number 047792932. A total of four per unit is required.

Figure 4, Isolator Locations Spring Iso lator Dimensions

Table 1 , Isolator Loads At Each Mounting Location With Aluminum Fins

Size

035AS 850 386 960 435 785 356 885 401 3480 1579 040AS 864 392 974 442 797 362 900 408 3535 1603 045AS 928 421 1048 475 858 389 966 438 3800 1724 050AS 940 426 1062 482 868 394 980 445 3850 1746 055AS 990 449 1118 507 915 415 1032 468 4055 1839 060AS 1006 456 1134 514 928 421 1047 475 4115 1867 065AS 1050 476 1184 537 970 440 1091 495 4295 1948

1 2 3 4 Total UnitUnit

lb Kg lb Kg lb Kg lb Kg lb Kg

Table 2, Isolator Loads At Each Mounting Location With Copper Fins

Size

035AS 960 435 1082 491 886 402 997 452 3925 1780 040AS 973 441 1096 497 899 408 1012 459 3980 1805 045AS 1038 471 1170 531 958 435 1079 489 4245 1926 050AS 1050 476 1184 537 970 440 1091 495 4295 1948 055AS 1154 523 1300 590 1066 484 1200 544 4720 2141 060AS 1166 529 1320 599 1078 489 1216 552 4780 2168 065AS 1252 568 1412 640 1156 524 1305 592 5125 2325

1 2 3 4 Total UnitUnit

lb Kg lb Kg lb Kg lb Kg lb Kg

IOMM AGZ-1 AGZ 035A through 065A 7

Water Piping

Local authorities can supply the installer with the proper building and safety codes required for safe and proper installation.

Install piping with minimum bends and changes in elevation to minimize pressure drop. Consider the following when installing water piping:

1. Vibration eliminators to reduce vibration and noise transmission to the building.

2. Shutoff valves to isolate the unit from the piping system during unit servicing.

3. Manual or automatic air vent valves at the high points of the system. Install drains at the lowest

points in the system.

4. A means of maintaining adequate system water pressure (expansion tank or regulating valve).

5. Temperature and pressure indicators located at the unit to aid in unit servicing.

6. A strainer or other means of removing foreign matter from the water before it enters the pump.

Place the strainer far enough upstream to prevent cavitation at the pump inlet (consult pump manufacturer for recommendations). The use of a strainer will prolong pump life and keep system performance up.

7. Place a strainer in the water line just before the inlet of the evaporator. This will help prevent

foreign material from entering and decreasing the performance of the evaporator.

CAUTION

If separate disconnect is used for the 115V supply to the evaporator heating cable, mark the disconnect clearly to ensure disconnect is not accidentally shut off during cold seasons.

8. The shell-and-tube evaporator has a thermostat and heating cable to prevent freeze-up down to 20°F (-29°C). It is suggested that the heating cable be wired to a separate 110V supply circuit. As shipped from the factory, the heating cable is wired to the control circuit. All water piping to the unit must also be protected to prevent freezing.

9. If the unit is used as a replacement chiller on a previously existing piping system, flush the system thoroughly before unit installation. Regular water analysis and chemical water treatment for the evaporator loop is recommended immediately at equipment start-up.

10. The total water volume in the system should be sufficient to prevent frequent “on-off” cycling. Turnover rate should not be less than 15 minutes for normal variable cooling loads. Turnover rate for process cooling or a constant load, should not be less than 6 minutes.

11. When glycol is added to the water system for freeze protection, the refrigerant suction pressure will be lower, cooling performance less, and water side pressure drop greater. If the percentage of glycol is high, or if propylene is used instead of ethylene glycol, the added pressure drop and loss of performance could be substantial. Reset the freezestat and low leaving water alarm temperatures. The freezestat is factory set as follows:

• UNT Control; Low Water Temp=38°F, Low Press=54psig

• MicroTech Control; Low Water Remp=36°F, Low Press=54psig

Reset the freezestat setting to approximately 4 to 5 degrees F (2.3 to 2.8 degrees C) below the leaving chilled water setpoint temperature. See the section titled “Glycol Solutions” for additional information concerning glycol.

12. Perform a preliminary leak check before insulating the piping and filling the system.

13. Piping insulation should include a vapor barrier to prevent condensation and possible damage to the building structure.

8 AGZ 035A through 065A IOMM AGZ-1

Figure 5, Typical Field Evaporator Water Piping

Flow Switch

Mount a water flow switch in either the entering or leaving water line to shut down the unit when water flow is interrupted. A flow switch is a safety control and should never be used to cycle a unit.

A flow switch is available from McQuay (part number 017503300). It is a “paddle” type switch and adaptable to any pipe size from 3” (76mm) to 8” (203mm) nominal. Certain minimum flow rates are required to close the switch and are listed in Table 3. Installation should be as shown in Figure 6. Connect the normally open contacts of the flow switch in the unit control center at terminals 5 and 6. There is also a set of normally closed contacts on the switch that can be used for an indicator light or an alarm to indicate when a “no flow” condition exists. Freeze protect any flow switch that is installed outdoors.

NOTE: Differential pressure switches are not recommended for outdoor installation.

Table 3, Flow Switch Minimum Flow Rates

NOMINAL PIPE SIZE MINIMUM REQUIRED FLOW TO

INCHES (MM) ACTIVATE SWITCH - GPM (L/S)

2 (50.8) 18.80 (1.20)

2 1/2 (63.50 24.30 (1.50)

3 (76.20 30.00 (1.90) 4 (101.6) 39.70 (2.50) 5 (127.0) 58.70 (3.70) 6 (152.4) 79.20 (5.00)

Figure 6, Flow Switch Installation

Flow direction marked

on switch

1" (25mm) NPT flow

switch connection

Tee

IOMM AGZ-1 AGZ 035A through 065A 9

Note: The procedure does not specify the type of glycol. Use the derate factors found in Table 4 for corrections when using ethylene glycol and those in Table 5 for propylene glycol.

Water Connections

Bring water piping to the evaporator through the side between the vertical supports. Provide taps for the connection of pressure gauges and thermometers in the inlet and outlet lines.

Glycol Solutions

The use of a glycol/water mixture in the CDE evaporator to prevent freezing will reduce system capacity and efficiency and increase pressure drop. The system capacity, required glycol solution flow rate, and pressure drop with glycol may be calculated using the following formulas and tables.

1. Capacity – Multiply the capacity based on water by the Capacity correction factor from Table 5.

2. Flow – Multiply the water evaporator flow by the Flow correction factor from Table 5 determine

the increased evaporator flow due to glycol. If the flow is unknown, it can be calculated from the following equation:

)(24

(gpm) Flow Glycol FactorCorrectionFlow

For Metric Applications – Use the following equation for metric applications:

(l/s) Flow Glycol

3. Pressure drop -- Multiply the water pressure drop from Figure 7 by Pressure Drop correction

factor from Table 4 or Table 5 to obtain corrected glycol pressure drop. High concentrations of propylene glycol at low temperatures may cause unacceptably high pressure drops.

4. Power -- Multiply the water system power by Power correction factor from Table 4 or Table 5. Test coolant with a clean, accurate glycol solution hydrometer (similar to that found in service

stations) to determine the freezing point. Obtain percent glycol from the freezing point table below. It is recommended that a minimum of 25% solution by weight be used for protection against corrosion.

CapacitykW

TDelta

−×=18.4

glycolCapacityTons

TDelta

−

FactorCorrectionFlow

)

CAUTION

Do not use an automotive grade antifreeze. Industrial grade glycols must be used. Automotive antifreeze contains inhibitors which will cause plating on the copper tubes within the chiller evaporator. The type and handling of glycol used must be consistent with local codes.

10 AGZ 035A through 065A IOMM AGZ-1

Table 4, Ethylene Glycol Correction Factors

Freeze Point%

E.G.

°F °C

10 26 -3 0.991 0.996 1.013 1.070 20 18 -8 0.982 0.992 1.040 1.129 30 7 -14 0.972 0.986 1.074 1.181 40 -7 -22 0.961 0.976 1.121 1.263 50 -28 -33 0.946 0.966 1.178 1.308

Capacity Power Flow Pressure Drop

Table 5, Propylene Glycol Correction Factors

Freeze Point%

P.G.

°F °C

10 26 -3 0.987 0.992 1.010 1.068 20 19 -7 0.975 0.985 1.028 1.147 30 9 -13 0.962 0.978 1.050 1.248 40 -5 -21 0.946 0.971 1.078 1.366 50 -27 -33 0.929 0.965 1.116 1.481

Capacity Power Flow Pressure Drop

Table 6, Capacity and Power Derates

Fouling Factor

SEA

LEVEL

2000 feet

(610 m)

4000 feet

(1220 m)

6000 feet

(1830 m)

Chilled Water

Delta-T

°F °C Cap. Power Cap. Power Cap. Power Cap. Power

6 3.3 0.992 0.995 0.985 0.993 0.962 0.986 0.919 0.972

8 4.4 0.995 0.997 0.988 0.995 0.965 0.988 0.922 0.974 10 5.6 1.000 1.000 0.993 0.998 0.970 0.991 0.927 0.977 12 6.7 1.005 1.002 0.998 1.000 0.975 0.993 0.932 0.979 14 6.8 1.010 1.005 1.003 1.003 0.980 0.996 0.936 0.982 16 8.9 1.014 1.007 1.007 1.005 0.984 0.998 0.940 0.984

6 3.3 0.978 1.005 0.971 1.003 0.949 0.996 0.906 0.982

8 4.4 0.982 1.007 0.975 1.005 0.953 0.998 0.910 0.984 10 5.6 0.986 1.009 0.979 1.007 0.956 1.000 0.914 0.986 12 6.7 0.992 1.011 0.985 1.009 0.962 1.002 0.919 0.988 14 6.8 0.997 1.014 0.990 1.012 0.967 1.005 0.924 0.991 16 8.9 1.000 1.016 0.993 1.014 0.970 1.007 0.927 0.993

6 3.3 0.966 1.016 0.959 1.014 0.937 1.007 0.895 0.993

8 4.4 0.969 1.018 0.962 1.016 0.940 1.009 0.898 0.995 10 5.6 0.973 1.021 0.966 1.019 0.944 1.012 0.902 0.998 12 6.7 0.978 1.025 0.971 1.023 0.949 1.016 0.906 1.002 14 6.8 0.982 1.027 0.975 1.025 0.953 1.018 0.910 1.004 16 8.9 0.986 1.028 0.979 1.026 0.956 1.019 0.914 1.005

6 3.3 0.953 1.025 0.946 1.023 0.924 1.016 0.883 1.002

8 4.4 0.955 1.028 0.948 1.026 0.926 1.019 0.885 1.005 10 5.6 0.959 1.031 0.952 1.029 0.930 1.022 0.889 1.008 12 6.7 0.963 1.034 0.956 1.032 0.934 1.024 0.893 1.011 14 6.8 0.968 1.036 0.961 1.034 0.939 1.026 0.897 1.013 16 8.9 0.972 1.037 0.965 1.035 0.943 1.027 0.901 1.014

0.0001 (0.0176) 0.00025 (0.044) 0.00075 (0.132) 0.00175 (0.308)ALTITUDE

Evaporator Flow and Pressure Drop

Evaporator flow rate must fall between the minimum and maximum values shown in the evaporator pressure drop table on Figure 7.

Measure the chilled water pressure drop through the evaporator at factory installed pressure taps. It is important not to include the effect of valves or strainers in these readings.

Varying chilled water flow through the evaporator while the compressor(s) are operating is not recommended.

IOMM AGZ-1 AGZ 035A through 065A 11

Figure 7, Pressure Drop Curve

045A - 060A

030A- 040A

065A

AGZ Unit Size

035AS 9.2 82 5.17 23.1 137 8.62 3.9 51 3.23 040AS 11.5 93 5.87 28.8 155 9.78 4.9 58 3.67 045AS 11.2 106 6.69 28.2 177 11.15 4.8 66 4.18 050AS 13.4 117 7.38 33.6 195 12.30 5.7 73 4.61 055AS 16.2 129 8.14 40.0 215 13.56 7.0 81 5.09 060AS 18.0 138 8.71 45.0 230 14.51 7.7 86 5.44 065AS 10.0 146 9.21 25.1 243 15.35 4.3 91 5.76

Minimum and maximum flows are established to ensure the Delta-T for each unit size falls within the 6 - 16°F range for proper unit control.

Pressure Drop Flow Pressure Drop Flow Pressure Drop Flow

(ft) of Water (gpm) (lps) (ft) of Water (gpm) (lps) (ft) of Water (gpm) (lps)

NOMINAL MAXIMUM MINIMUM

12 AGZ 035A through 065A IOMM AGZ-1

Physical Data

Table 7, AGZ 035AS Through 045AS

STANDARD EFFICIENCY 035AS 040AS 045AS

BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2

Unit Capacity @ ARI Conditions (1), Tons (kW) 34.3 (120.5) 38.9 (136.7) 44.3 (156.0)

Number Of Refrigerant Circuits 2 2 2

Unit Operating Charge, R-22, lb. 36 36 40 40 42 42

Unit Operating Charge, R-22, (kg) (16.3) (16.3) (18.1) (18.1) (19.0) (19.0)

Cabinet Dimensions, LxWxH, In. 94.0 x 88.2 x 86.2 94.0 x 88.2 x 86.2 94.0 x 88.2 x 86.2

Cabinet Dimensions, LxWxH, (mm) 2388 x 2241 x 2190 2388 x 2241 x 2190 2388 x 2241 x 2190

Unit Operating Weight, lb (kg) 3480 (1580) 3535 (1605) 3800 (1725)

Unit Shipping Weight, lb (kg) 3405 (1545) 3460 (1570) 3695 (1675)

Add'l Weight If Copper Finned Coils, lb (kg) 445 (200) 445 (200) 445 (200)

COMPRESSORS

Nominal tonnage of each Compressor 9.0 9.0 10.0 10.0 10.0 13.0

Number Of Compressors per Circuit 2 2 2 2 2 2

Oil Charge Per Compressor, oz. 140 140 140 140 140 140

Oil Charge Per Compressor, (g) (496) (496) (496) (496) (496) (496)

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

Standard Staging - Circuit #1 in Lead

Standard Staging - Circuit #2 in Lead

CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING

Coil Face Area, sq. ft. 46.4 46.4 46.4 46.4 46.4 46.4

Coil Face Area, (m2) (4.3) (4.3) (4.3) (4.3) (4.3) (4.3)

Finned Height x Finned Length, In. 80 x 83.5 80 x 83.5 80 x 83.5 80 x 83.5 80 x 83.5 80 x 83.5

Finned Height x Finned Length, (mm) (2032 x

Fins Per Inch x Rows Deep 16 x 2 16 x 2 16 x 2 16 x 2 16 x 2 16 x 2

Maximum Relief Valve Pressure Setting, psig (kPa) 450

CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE

Number Of Fans - Fan Diameter, In. (mm) 4 - 28 (712) 4 - 28 (712) 4 - 28 (712)

Number Of Motors - HP (kW) (2) 4 - 1.0 (0.7) 4 - 1.0 (0.7) 4 - 1.5 (1.1)

Fan And Motor rpm, 60Hz 1140 1140 1140

60 Hz Fan Tip Speed, fpm (m/Sec) 8357 (35.4) 8357 (35.4) 8357 (35.4)

60 Hz Total Unit Airflow, cfm (m3/sec) 34400 (16.2) 34400 (16.2) 38000 (17.9)

DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE

Diameter, in. - Length, ft. 10 - 04 10 - 04 12 - 04

Diameter, (mm) - Length, (mm) (254) - (1220) (254) - (1220) (305) - (1220)

Water Volume, Gallons, (l) 9.1 (34.5) 9.1 (34.5) 12.8 (48.5)

Maximum Water Pressure, psig (kPa) 175 (1207) 175 (1207) 175 (1207)

Maximum Refrigerant Working Pressure, psig (kPa) 225 (1552) 225 (1552) 225 (1552)

Water Inlet / Outlet Victaulic Connections, In.

Drain - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5)

Vent - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5)

NOTES:

1. Nominal capacity based on 95°F ambient air and 54°F/44°F water range.

2. Units with 1.0 Hp Fan Motors, Uses 1.5 Hp Fan Motors when unit is 380V / 60 Hz and 575V / 60Hz.

PHYSICAL DATA AGZ MODEL NUMBER

Type Tandem Scrolls Tandem Scrolls Tandem Scrolls

Standard 4 Stages 0-25-50-75-100 0-25-50-75-100 0-22-50-72-100

Standard 4 Stages 0-25-50-75-100 0-25-50-75-100 0-28-50-78-100

(mm)

2121)

(3103)

(2032 x

2121)

450 (3103) 450 (3103) 450

4 (101.6) 4 (101.6) 4 (101.6)

(2032 x

2121)

(2032 x

2121)

(3103)

(2032 x

2121)

450 (3103) 450

(2032 x

2121)

(3103)

IOMM AGZ-1 AGZ 035A through 065A 13

Table 8, AGZ 050AS Through 065AS

PHYSICAL DATA AGZ MODEL NUMBER

BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2

Unit Capacity @ ARI Conditions (1), Tons (kW) 48.9 (172.2) 54.1 (190.1) 58.9 (207.4) 61.6 (216.5)

COMPRESSORS

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING

Maximum Relief Valve Pressure Setting, psig (kPa) 450 (3103) 450 (3103) 450 (3103) 450

CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE

DIRECT EXPANSION EVAPORATOR – BAFFLED SHELL AND THRU-TUBE

Maximum Refrigerant Working Pressure, psig (kPa) 225 (1552) 225 (1552) 225 (1552) 225 (1552)

Water Inlet / Outlet Victaulic Connections, In. (mm) 4 (101.6) 4 (101.6) 4 (101.6) 5 (127.0)

NOTE: Nominal capacity based on 95°F ambient air and 54°F/44°F water range.

STANDARD EFFICIENCY 050AS 055AS 060AS 065AS

Number of Refrigerant Circuits 2 2 2 2

Unit Operating Charge, R-22, Lb. 44 44 54 54 56 56 62 62

Unit Operating Charge, R-22, (kg) (18.1) (18.1) (22.6) (22.6) (23.5) (23.5) (28.1) (28.1)

Cabinet Dimensions, LxWxH, In. 94.0 x 88.2 x 86.2 94.0 x 88.2 x 86.2 94.0 x 88.2 x 86.2 94.0 x 88.2 x 96.2

Cabinet Dimensions, LxWxH, (mm) 2388 x 2241 x 2190 2388 x 2241 x 2190 2388 x 2241 x 2190 2388 x 2241 x 2444

Unit Operating Weight, lb. (kg) 3850 (1745) 4055 (1840) 4115 (1865) 4295 (1950)

Unit Shipping Weight, lb. (kg) 3745 (1700) 3950 (1790) 4010 (1820) 4190 (1900)

Add'l Weight If Copper Finned Coils, lb. (kg) 445 (200) 665 (300) 665 (300) 830 (375)

Nominal Horsepower of each Compressor 13.0 13.0 13.0 15.0 15.0 15.0 15.0 15.0

Number of Compressors per Circuit 2 2 2 2 2 2 2 2

Oil Charge Per Compressor, o. 140 140 140 140 140 140 140 140

Oil Charge Per Compressor, (g) (496) (496) (496) (496) (496) (496) (496) (496)

Standard Staging - Circuit #1 in Lead

Standard Staging - Circuit #2 in Lead

Finned Height x Finned Length, In. 80 x 83.5 80 x 83.5 80 x 83.5 80 x 83.5 80 x 83.5 80 x 83.5 100x 83.5 100x 83.5

Finned Height x Finned Length, (mm) (2032 x

Fins Per Inch x Rows Deep 16 x 2 16 x 2 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3

Number of Fans - Fan Diameter, In. (mm) 4 - 28 (712) 4 - 28 (712) 4 - 28 (712) 4 - 28(712)

Number of Motors - HP (kW) 4 - 1.5 (1.1) 4 - 1.5 (1.1) 4 - 1.5 (1.1) 4 - 1.5 (1.1)

Fan And Motor rpm, 60Hz 1140 1140 1140 1140

60 Hz Fan Tip Speed, fpm (m/Sec) 8357 (35.4) 8357 (35.4) 8357 (35.4) 8357 (35.4)

60 Hz Total Unit Airflow, cfm (m3/sec) 38000 (17.9) 36800 (17.4) 36800 (17.4) 38400 (18.1)

Diameter, in. - Length, ft. 12 - 04 12 - 04 12 - 04 12 - 04

Diameter, (mm) - Length, (mm) (305) - (1220) (305) - (1220) (305) - (1220) (305) - (1220)

Water Volume, gallons, (l) 12.8 (48.5) 12.8 (48.5) 2.8 (48.5) 12.8 (48.5)

Maximum Water Pressure, psig (kPa) 175 (1207) 175 (1207) 175 (1207) 175 (1207)

Drain - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5) .375 (9.5)

Vent - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5) .375 (9.5)

Type Tandem Scrolls Tandem Scrolls Tandem Scrolls Tandem Scrolls

Standard 4 Stages 0-25-50-75-100 0-23-50-73-100 0-25-50-75-100 0-25-50-75-100

Standard 4 Stages 0-25-50-75-100 0-27-50-77-100 0-25-50-75-100 0-25-50-75-100

Coil Face Area, sq ft 46.4 46.4 46.4 46.4 46.4 46.4 58.0 58.0

Coil Face Area, (m2) (4.3) (4.3) (4.3) (4.3) (4.3) (4.3) (5.4) (5.4)

2121)

(2032 x

2121)

(2032 x

2121)

(2032 x

2121)

(3103)

(2032 x

2121)

450 (3103) 450

(2032 x

2121)

(3103)

(2540 x

2121)

450

(3103)

(2540 x

2121)

450 (3103)

14 AGZ 035A through 065A IOMM AGZ-1

Electrical Data

Field Wiring

Internal power wiring to the compressors for single and multiple point option are different. Field wiring must be installed according to unit wiring diagram.

Wiring must comply with all applicable codes and ordinances. Warranty is void if wiring is not in accordance with specifications. Copper wire is required for all power lead terminations at the unit. Aluminum or copper can be used for all other wiring.

AGZ units have internal power wiring for single point power connection. A single large power terminal block is provided and wiring within the unit is sized in accordance with the National Electrical Code. A single field supplied fused disconnect is required. An optional factory mounted transformer may be installed. If the evaporator heater is on a separate disconnect switch from the main unit power supply, the unit may be shut down without defeating the freeze protection provided by the cooler heater.

Table 9, AGZ 035A - 065A, 60 Hz, Single Point Power Electrical Data

AGZ Unit Size

035A

040A

045A

050A

055A

060A

065A

CAUTION

Minimum

Volts

208 143 3 1/0 1 1.50 (38) 150 230 143 3 1/0 1 1.50 (38) 150 380 93 3 3 1 1.25 (32) 110 460 73 3 4 1 1.00 (25) 80 575 58 3 6 1 1.00 (25) 70

208 159 3 2/0 1 1.50 (38) 175 230 159 3 2/0 1 1.50 (38) 175 380 111 3 2 1 1.25 (32) 125 460 78 3 4 1 1.00 (25) 90 575 67 3 4 1 1.00 (25) 80

208 183 3 3/0 1 2.00 (51) 200 230 183 3 3/0 1 2.00 (51) 200 380 116 3 1 1 1.25 (32) 125 460 94 3 3 1 1.25 (32) 110 575 76 3 4 1 1.00 (25) 90

208 198 3 3/0 1 2.00 (51) 225 230 198 3 3/0 1 2.00 (51) 225 380 120 3 1 1 1.25 (32) 125 460 104 3 2 1 1.25 (32) 125 575 83 3 4 1 1.00 (25) 100

208 214 3 4/0 1 2.00 (51) 250 230 214 3 4/0 1 2.00 (51) 250 380 138 3 1/0 1 1.50 (38) 150 460 109 3 2 1 1.25 (32) 125 575 92 3 3 1 1.25 (32) 110

208 228 3 4/0 1 2.50 (64) 300 230 228 3 4/0 1 2.50 (64) 300 380 153 3 2/0 1 1.50 (38) 175 460 112 3 2 1 1.25 (32) 125 575 100 3 3 1 1.25 (32) 110

Circuit

Ampacity

(MCA)

Field Wire Hub

Quantity

POWER SUPPLY

Wire

Gauge

Quantity

Nominal

Size

Max. Fuse

HACR

Breaker

Size

IOMM AGZ-1 AGZ 035A through 065A 15

Table 10, AGZ 035A - 065A, 60 Hz, Compressor and Condenser Fan Motor Amp Draw

Rated Load Amps Locked Rotor Amps

AGZ Unit Size

035A

040A

045A

050A

055A

060A

065A

Volts

208 29.9 29.9 4.0 4 17.0 232 232 230 29.9 29.9 4.0 4 17.0 232 232 380 18.6 18.6 3.4 4 14.4 144 144 460 15.3 15.3 2.0 4 8.5 125 125 575 11.6 11.6 2.2 4 10.3 100 100

208 33.6 33.6 4.0 4 17.0 255 255 230 33.6 33.6 4.0 4 17.0 255 255 380 22.8 22.8 3.4 4 14.4 151 151 460 16.5 16.5 2.0 4 8.5 127 127 575 13.7 13.7 2.2 4 10.3 100 100

208 33.6 41.0 5.8 4 23.7 255 318 230 33.6 41.0 5.8 4 23.7 255 318 380 22.8 25.0 3.4 4 14.4 151 195 460 16.5 21.8 2.8 4 10.7 127 158 575 13.7 17.3 2.3 4 11.5 100 125

208 41.0 41.0 5.8 4 23.7 318 318 230 41.0 41.0 5.8 4 23.7 318 318 380 25.0 25.0 3.4 4 14.4 195 195 460 21.8 21.8 2.8 4 10.7 158 158 575 17.3 17.3 2.3 4 11.5 125 125

208 41.0 52.6 5.8 4 23.7 318 411 230 41.0 52.6 5.8 4 23.7 318 411 380 25.0 33.3 3.4 4 14.4 195 222 460 21.8 23.7 2.8 4 10.7 158 187 575 17.3 20.5 2.3 4 11.5 125 148

208 48.1 48.1 5.8 4 23.7 425 425 230 48.1 48.1 5.8 4 23.7 425 425 380 32.7 32.7 3.4 4 14.4 239 239 460 23.7 23.7 2.8 4 10.7 187 187 575 21.2 21.2 2.3 4 11.5 148 148

Compressors Compressors

No.

1 & 3

(Each)

No.

2 & 4

(Each)

Fan

Motors

(Each)

No. Of

Fan

Motors

Fan

Motors

(Each)

Across-The-Line

No.1 & 3

(Each)

No.2 & 4

(Each)

Table 11, AGZ035A - 065A, 60 Hz Single Point Power, Field Wiring Data

AGZ

Unit Size

035A

040A

045A

Table continued on next page

Volts

208 335 # 4 - 400 MCM 225 # 3 - 300 MCM 230 335 # 4 - 400 MCM 225 # 3 - 300 MCM 380 175 #12 - 2/0 100 #14 - 1/0 460 175 #12 - 2/0 100 #14 - 1/0 575 175 #12 - 2/0 100 #14 - 1/0

208 335 # 4 - 400 MCM 225 # 3 - 300 MCM 230 335 # 4 - 400 MCM 225 # 3 - 300 MCM 380 175 #12 - 2/0 150 #4 - 4/0 460 175 #12 - 2/0 100 #14 - 1/0 575 175 #12 - 2/0 100 #14 - 1/0

Wiring to Standard

Power Block

Terminal

Amps

Connector Wire Range

(Copper Wire Only)

16 AGZ 035A through 065A IOMM AGZ-1

Wiring to Optional

Non-Fused Disconnect Switch

Terminal

Amps

Connector Wire Range

(Copper Wire Only)

Table 11, AGZ035A - 065A, 60 Hz Single Point Power, Field Wiring Data (continued)

AGZ Unit Size

050E

055A

060A

065A

Wiring to Standard

Volts

208 335 # 4 - 400 MCM 225 # 3 - 300 MCM 230 335 # 4 - 400 MCM 225 # 3 - 300 MCM 380 335 # 4 - 400 MCM 150 #4 - 4/0 460 175 #12 - 2/0 150 #4 - 4/0 575 175 #12 - 2/0 150 #4 - 4/0

208 335 # 4 - 400 MCM 400 250 - 500 MCM 230 335 # 4 - 400 MCM 400 250 - 500 MCM 380 335 # 4 - 400 MCM 250 #4 - 350 MCM 460 175 #12 - 2/0 150 #4 - 4/0 575 175 #12 - 2/0 150 #4 - 4/0

Terminal

Amps

Power Block

Connector Wire Range

(Copper Wire Only)

Wiring to Optional

Non-Fused Disconnect Switch

Terminal

Amps

Connector Wire Range

(Copper Wire Only)

Notes for “Electrical Data Single Point” Power:

1. Unit wire size ampacity (MCA) is equal to 125% of the largest compressor-motor RLA plus 100% of RLA

of all other loads in the circuit including the control transformer.

2. If the control transformer option is furnished, no separate 115V power is required.

3. If a separate 115V power supply is used for the control circuit, then the wire sizing amps is 10 amps for all

unit sizes.

4. Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductor ampacity

in accordance with NEC. Voltage drop has not been included. Therefore, it is recommended that power leads be kept short. All terminal block connections must be made with copper (type THW) wire.

5. “Recommended Fuse Sizes” are selected at approximately 150% to 175% of the largest compressor RLA,

plus 100% of all other loads in the circuit.

6. “Maximum Fuse Sizes” are selected at approximately 225% of the largest compressor RLA, plus 100% of

all other loads in the circuit.

7. The recommended power lead wire sizes are based on an ambient temperature of 86°F. Ampacity

correction factors must be applied for other ambient temperatures. Refer to the National Electrical Code Handbook.

8. The MCA may vary slightly depending on fan motor options such as SpeedTrol, TEFC.

Power Limitations:

Volts within ± 10 percent of nameplate rating. Phase unbalance maximum of 3 percent.

Notes for “Compressor and Condenser Fan Amp Draw”:

1. Compressor RLA values are for wiring sizing purposes only but do not reflect normal operating current

draw at rated capacity. If unit is equipped with SpeedTrol condenser fan motors, the first motor on each refrigerant circuit is a single phase, 1hp motor, with a FLA of 2.8 amps at 460 volts, 5.6 amps at 208, 230, 380, and 575 volts.

2. Compressor LRA for reduced inrush start are for the first winding only. If the unit is equipped with

SpeedTrol motors, the first motor is a single phase, 1 hp motor, with a LRA of 7.3 amps at 460 volts, 14.5 amps at 208, 230, 380, and 575 volts.

Notes for “Field Wiring Data”

1. Requires a single disconnect to supply electrical power to the unit. This power must be fused.

2. All field wiring to unit power block or optional non-fused disconnect switch must be copper.

3. All field wire size values given in table apply to 75°C rated wire per NEC.

IOMM AGZ-1 AGZ 035A through 065A 17

Electrical Legend

Figure 8, Electrical Legend

18 AGZ 035A through 065A IOMM AGZ-1

Figure 9, Typical Field Wiring with Global UNT Controller

IOMM AGZ-1 AGZ 035A through 065A 19

Figure 10, Typical Field Wiring Diagram with MicroTech Controller

20 AGZ 035A through 065A IOMM AGZ-1

Figure 11, Single-point Connection with FanTrol

IOMM AGZ-1 AGZ 035A through 065A 21

Figure 12, Single-point Connection with SpeedTrol

22 AGZ 035A through 065A IOMM AGZ-1

Figure 13, Unit Control Schematic (UNT)

IOMM AGZ-1 AGZ 035A through 065A 23

Figure 14, Staging Schematic (UNT)

24 AGZ 035A through 065A IOMM AGZ-1

Figure 15, MicroTech Controller Schematic

IOMM AGZ-1 AGZ 035A through 065A 25

Figure 16, Unit Control Schematic (MicroTech)

26 AGZ 035A through 065A IOMM AGZ-1

Figure 17, Staging Schematic (MicroTech)

IOMM AGZ-1 AGZ 035A through 065A 27

Dimensional Data

Figure 18, Dimensions AGZ 035A - 065A

AGZ

Model

Number

035AS

040AS

045AS

050AS

055AS

060AS

065AS

Dimensions inches (mm)

A B C D E F X Y Z Operating Shippin

86.2

96.2

81.7

91.7

61.6

22.3

5.3

4.3

15.0

16.0

Center Of Gravity

inches (mm)

43.9

44.2

44.6

45.0

40.2

40.8

41.2

41.8

36.2

35.6

36.4

38.8

Unit Weights

lb (kg)

3480

3535

3800

3850

4055

4115

4295

3405

3460

3695

3745

3950

4010

4190

Additional Weight

For Copper

Fin Coils lb (kg)

445

665

830

28 AGZ 035A through 065A IOMM AGZ-1

Startup

Pre Start-up

The chiller must be inspected to ensure no components became loose or damaged during shipping or installation.

Start-Up

Refer to the Global UNT Controller section to become familiar with its operation before starting chiller. There should be adequate building load (at least 50 percent of the unit full load capacity) to properly

check the operation of the chiller refrigerant circuits. Be prepared to record all operating parameters required by the “Compressorized Equipment Warranty

Form”. Return this information within 10 working days to McQuay International as instructed on the form to obtain full warranty benefits.

1. Verify chilled water flow.

2. Verify remote start / stop or time clock has requested the chiller to start.

3. Set the chilled water setpoint to required temperature. (The system water temperature must be

greater than the total of the leaving water temperature setpoint plus 1/2 the control band before the Global UNT controller will stage on cooling.)

4. Set the control band to 4°F as a starting point.

5. Put both circuit switches to the AUTO position.

6. Put switch S1 to AUTO position.

7. There will be a delay of 2 minutes after closing S1. The time delay is due to the compressor

inherent motor protection. This may allow more than one compressor to start after this time period. This should only occur on initial start-up or when power to the chiller has been turned off and back on. The panel Alarm Light will turn off.

8. After the chiller has been operating for a period of time and has become stable, check the

following:

§ Compressor oil level. (Some Scroll compressors do not have oil sight glasses)

§ Refrigerant sight glass for flashing.

§ Rotation of condenser fans.

9. Complete the “Compressorized Equipment Warranty Form”.

Shutdown

Temporary

1. Put both circuit switches to Pumpdown and Stop.

2. After compressors have stopped, put System Switch (S1) to Emergency Stop.

3. Turn off chilled water pump. Chilled water pump to operate while compressors are pumping

down.

To start the chiller after a temporary shutdown follow the start up instructions.

IOMM AGZ-1 AGZ 035A through 065A 29

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