McQuay AGS 225D Installation Manual

Installation and Maintenance Manual

IMM AGSD-2

Air-Cooled Screw Compressor Chiller

AGS 225D - AGS 450D 210 to 450 Tons, 740 to 1580 kW

Packaged or with Remote Evaporator

60 Hertz, R-134a

Group: Chiller

Part Number: 331375301

Date: April 2010

Supersedes: January 2010

Recognize Safety Symbols, Words, and Labels

The following symbols and labels are used throughout this manual to indicate immediate or potential hazards. It is the responsibility of the owner and installer to read and comply with all safety information and instructions accompanying these symbols. Failure to heed safety information increases the risk of property damage and/or product damage, serious personal injury or death. Improper installation, operation and maintenance can void the warranty.

CAUTION

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.

WARNING

Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not avoided.

DANGER

Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.

Table of Contents

Introduction........................................4

Weights and Isolator Locations..........5

Standard Efficiency....................................5

Isolator Installation ....................................7

High Efficiency..........................................8

Isolator Dimensions ................................. 11

Installation and Start-up...................12

Handling ..................................................12

Location ...................................................12

Service Access .........................................13

Clearance Requirements ..........................14

Restricted Airflow....................................15

Chilled Water ...........................................21

Operating Limits: .....................................24

Flow Switch .............................................24

Refrigerant Charge................................... 25

Glycol Solutions....................................... 25

Water Flow and Pressure Drop ........26

Physical Data, Standard Efficiency..29

Physical Data, High Efficiency ........31

Component Location........................59

Major Component Location .................... 59

Power Panel............................................. 61

Control Panel........................................... 62

Remote Evaporator ..........................63

Field Wiring ............................................ 63

Refrigerant Piping ................................... 64

Performance Derate Data ........................ 67

Physical Data........................................... 68

Dimensions and Weights ......................... 76

Isolator Installation.................................. 79

Isolator Locations and Kit Numbers........ 79

Isolator Dimensions................................. 82

Evaporators ............................................. 83

System Maintenance ........................84

General .................................................... 84

Compressor Maintenance ........................ 84

Lubrication .............................................. 84

Electrical Terminals................................. 85

Condensers .............................................. 85

Liquid Line Sight Glass........................... 85

Lead-Lag ................................................. 86

Preventative Maintenance Schedule ........ 86

Dimensions ......................................33

Standard Efficiency..................................33

High Efficiency........................................35

Electrical Data..................................37

Field Wiring.............................................37

Standard Efficiency..................................38

High Efficiency........................................43

Field Wiring Diagram ......................48

Circuit Breakers .......................................51

BAS Interface .......................................... 52

Remote Operator Interface Panel .............52

Warranty Statement..........................87

Service..............................................87

Liquid Line Filter-Driers ......................... 87

Compressor Slide Valves......................... 88

Evaporator Expansion Valve (EXV) ....... 88

Economizer Expansion Valve.................. 88

Charging Refrigerant............................... 89

Standard Controls .................................... 90

Controls, Settings and Functions ............. 92

Troubleshooting Chart............................. 93

Periodic Maintenance Log....................... 94

Solid State Starters...........................53

 The following are trademarks or registered trademarks of their respective companies: BACnet from ASHRAE; LONM

Unit controllers are LONM

Manufactured in an ISO Certified Facility

2007 McQuay International

Information covers the McQuay International products at the time of publication and we reserve the right

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

Echelon Corporation; McQuay, MicroTech II, Guardister, and Protocol Selectability from McQuay International.

certified with an optional LONW communications module.



ARK

ORKS

ARK and LONWORKS



from

IMM AGSD-2 3

Introduction

General Description

McQuay air-cooled water chillers are complete, self-contained automatic refrigerating units that include the latest in engineered components arranged to provide a compact and efficient unit. Each unit is completely assembled, factory wired, evacuated, charged, tested and comes complete and ready for installation. Each circuit (two or three, depending on unit size) consists of an air-cooled condenser section with an integral subcooler section, a semi-hermetic, single-screw compressors with starter, a multi-circuit, shell-and-tube, direct expansion evaporator, an economizer and complete refrigerant piping. Each compressor has an independent refrigeration circuit. Liquid line components included are a manual liquid line shutoff valve, charging port, filter-drier, sight-glass/moisture indicator, solenoid valve and electronic expansion valve. A combination discharge check and shutoff valve is included and a compressor suction shutoff valve is optional. Other features include compressor heaters, evaporator heaters for freeze protection, automatic, one-time pumpdown of each refrigerant circuit upon circuit shutdown, and an advanced fully integrated microprocessor control system.

Model AGS D units are available as standard efficiency (DS) or high efficiency (DE)

A high ambient option is required for operation in ambient temperatures above 105°F and up to 125°F and when the VFD low ambient option is selected.

Information on the operation of the unit MicroTech II controller is in the OM AGS manual.

Operation and maintenance of the optional unit-mounted pump package is in IOMM AGSD Pump Pkg, which is included on all units so equipped.

Nomenclature

Rotary Screw Compressor

Air-Cooled

Global

Nominal Tons

A G S - XXX D S

S=Standard Efficiency, Packaged E=High Efficiency, Packaged M=Standard, Remote Evaporator F=High Efficiency, Remote Evaporator

Design Vintage

Inspection

When the equipment is received, carefully check all items against the bill of lading to verify for a complete shipment. Check all units for damage upon arrival. All shipping damage must be reported to the carrier and a claim must be filed with the carrier. Check the unit’s serial plate before unloading the unit to be sure that it agrees with the power supply available. Physical damage to a unit after shipment is not McQuay International’s responsibility.

Note: Unit shipping and operating weights are shown in Physical Data Tables beginning on page 28.

4 IMM AGSD-2

Weights and Isolator Locations

32.6

(826)

25.6

(650)

32.6

(826)

25.6

(650)

300DS

102.1 (2594)

250.1 (6353)

199.7 (5072)

288.6 (7330)

Standard Efficiency

Figure 1, Lifting and Isolator Locations, Model AGS 225DS - 315DS (from above)

84.6

(2150)

L3L5

M7 M3

M8 M4 M2M6

AGS Model

225DS 250DS 275DS

L4L6

in. (mm)

N/A 210.8 (5354) N/A 217.7 (5530)

102.1 (2594) 255.9 (6500) 194.1 (4930) 253.2 (6431)

102.1 (2594) 250.1 (6353) 199.7 (5072) 288.6 (7330)

in. (mm)

Figure 2, Lifting and Isolator Locations, Model AGS 330DS - 450DS (from above)

84.6

(2150)

M10

M7 M3

M8 M4

L3L5

L4L6

AGS MODEL

330DS, 350DS

360DS 390DS 400DS 450DS

in. (mm)

141.2 (3586) 262.0 (6655) 339.3 (8618) 177.0 (4496) 269.3 (6840) 361.6 (9185)

141.2 (3586) 262.0 (6655) 348.3 (8847) 177.0 (4496) 269.3 (6840) 361.6 (9185)

137.6 (3495) 297.4 (7554) 383.8 (9749) 169.3 (4299) 304.7 (7739) 397.0 (10085)

IMM AGSD-2 5

Table 1, Standard Efficiency, Shipping and Lifting Weights, Aluminum Fins

OPERATING.

UNIT SIZE

225DS 250DS 275DS 300DS 330DS 350DS 360DS 390DS 400DS 450DS

WEIGHT

lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg

12007 5451 3743 1699 4059 1843 - - - - 2018 916 2188 993 - - - 12849 5833 2653 1204 2824 1282 2241 1017 2386 1083 1330 603 1416 642 - - - 14053 6380 2642 1199 2780 1262 2381 1081 2505 1137 1825 828.6 1920 871 - - - 14049 6378 2642 1199 2780 1262 2379 1080 2503 1136 1825 828.6 1920 871 - - - 19596 8897 3758 1706 3707 1683 19596 8897 3758 1706 3707 1683 19639 8916 3761 1707 3710 1684 20278 9206 3559 1616 3559 1616 20549 9329 3572 1622 3572 1622 21326 9682 3693 1677 3693 1677

L1 L2 L3 L4 L5 L6 L7 L8

2884 1309 2845 1292 1918 870 1892 859 1305 592 1287 584 2884 1309 2845 1292 1918 870 1892 859 1305 592 1287 584 2892 1313 2853 1295 1926 874 1900 862 1308 593 1290 585 2850 1294 2850 1294 2109 957 2109 957 1621 735 1621 735 2905 1319 2905 1319 2164 982 2164 982 1634 741 1634 741 3094 1405 3094 1405 2184 991 2184 991 1692 768 1692 768

LOCATION SHIPPING

Table 2, Standard Efficiency, Shipping and Lifting Weights, Copper Fins

UNIT SIZE

225DS 250DS 275DS 300DS 330DS 350DS 360DS 390DS 400DS 450DS

WEIGHT.

lbs. kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg

13584 6167 4154 1886 4470 2029 - - - - 2430 1103 2600 1180 - - - 14689 6669 2660 1208 2810 1276 2546 1156 2690 1221 1980 899 2085 947 - - - 15807 7176 2672 1213 2745 1246 2647 1202 2720 1235 2526 1147 2591 1176 - - - 16100 7309 2639 1198 2796 1269 2632 1195 2788 1266 2595 1178 2746 1247 - - - 22224 10090 4086 1855 4035 1832 3213 1459 3174 1441 2247 1020 2221 1008 1633 741 1615 733 22224 10090 4086 1855 4035 1832 3213 1459 3174 1441 2247 1020 2221 1008 1633 741 1615 733 22267 10109 4089 1856 4038 1833 3221 1462 3182 1445 2255 1024 2229 1012 1636 743 1618 735 23169 10519 3920 1780 3920 1780 3212 1458 3212 1458 2470 1121 2470 1121 1982 900 1982 900 23440 10642 3933 1786 3933 1786 3266 1483 3266 1483 2526 1147 2526 1147 1995 906 1995 906 24480 11114 4087 1855 4087 1855 3488 1584 3488 1584 2579 1171 2579 1171 2086 947 2086 947

L1 L2 L3 L4 L5 L6 L7 L8

LOCATION SHIPPING

Table 3, Standard Efficiency, Operating and Mounting Weights, Aluminum Fins

UNIT SIZE

225DS 250DS 275DS 300DS 330DS 350DS 360DS 390DS 400DS 450DS

WEIGHT

lbs. kg lbs. kg lbs. kg lbs. kg lbs. kg lbs. kg lbs. kg lbs. kg lbs. kg lbs. kg lbs. kg

12556 5700 2382 1081 2582 1172 2118 962 2297 1043 - - - - 1525 692 1653 750 - - - 13398 6083 2411 1095 2566 1165 2002 909 2131 967 1243 564 1324 601 834 379 888 403 - - - 14958 6791 2523 1145 2697 1224 2183 991 2333 1059 1519 690 1624 737 1006 457 1073 487 14954 6789 2522 1145 2696 1224 2182 991 2332 1059 1518 689 1623 737 1006 457 1075 488 20507 9310 2818 1279 2780 1262 2535 1151 2500 1135 2095 951 2067 938 1657 752 1634 742 1219 553 1202 546 20507 9310 2818 1279 2780 1262 2535 1151 2500 1135 2095 951 2067 938 1657 752 1634 742 1219 553 1202 546 20517 9315 2818 1279 2780 1262 2537 1152 2502 1136 2097 952 2069 939 1658 753 1635 742 1219 553 1202 546 21156 9605 2678 1216 2678 1216 2488 1130 2488 1130 2112 959 2112 959 1750 795 1750 795 1550 704 1550 704 21708 9855 2678 1216 2678 1216 2488 1130 2488 1130 2192 995 2192 995 1896 861 1896 861 1600 726 1600 726 22485 10208 2721 1235 2721 1235 2558 1161 2558 1161 2323 1055 2323 1055 1948 884 1948 884 1693 769 1693 769

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

LOCATION OPERATING

Table 4, Standard Efficiency, Operating and Mounting Weights, Copper Fins

UNIT SIZE

225DS 250DS 275DS 300DS 330DS 350DS 360DS 390DS 400DS 450DS

WEIGHT

lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg

14133 6416 2642 1199 2843 1291 2379 1080 2571 1167 - - - - 1785 810 1913 869 - - - 15238 6918 2641 1199 2796 1269 2232 1013 2361 1072 1473 669 1554 706 1064 483 1118 507 - - - 17060 7745 2786 1265 2959 1343 2445 1110 2605 1183 1780 808 1883 855 1269 576 1333 605 - - - 17056 7743 2785 1264 2958 1343 2444 1110 2605 1183 1780 808 1883 855 1267 575 1334 606 - - - 23135 10503 3081 1399 3043 1382 2798 1270 2763 1254 2358 1071 2330 1058 1920 872 1897 861 1481 672 1464 665 23135 10503 3081 1399 3043 1382 2798 1270 2763 1254 2358 1071 2330 1058 1920 872 1897 861 1481 672 1464 665 23145 10508 3081 1399 3043 1382 2800 1271 2765 1255 2360 1071 2332 1059 1921 872 1898 862 1481 672 1464 665 24047 10917 2967 1347 2967 1347 2777 1261 2777 1261 2401 1090 2401 1090 2039 926 2039 926 1839 835 1839 835 24599 11168 2967 1347 2967 1347 2777 1261 2777 1261 2481 1126 2481 1126 2185 992 2185 992 1889 858 1889 858 25639 11640 3036 1378 3036 1378 2873 1304 2873 1304 2638 1198 2638 1198 2263 1027 2263 1027 2009 912 2009 912

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

LOCATION

- - - -

6 IMM AGSD-2

Isolator Installation

Transfer the unit as indicated under “Moving the Unit.” In all cases, set the unit in place and level with a spirit level. When spring-type isolators are required, install springs running under the main unit supports. The unit should be set initially on shims or blocks at the listed spring free height. When all piping, wiring, flushing, charging, etc., is completed, the springs are adjusted upward to loosen the blocks or shims that are then removed. A rubber anti-skid pad should be used under isolators if hold-down bolts are not used. Installation of spring isolators requires flexible piping connections and at least three feet of flexible electrical conduit to avoid straining the piping and transmitting vibration and noise.

Standard Efficiency, Isolator Location and Kit Number

Table 5, Packaged, Standard Efficiency, Rubber-in-Shear Isolators, Aluminum Fins

UNIT MODEL

225DS

250DS, 275DS 300DS, 315DS

330DS, 350DS 360DS, 390DS 400DS, 450DS

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

RP-4 RP-4 RP-4 RP-4 RP-4 RP-4

Lime Lime Lime Lime

RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 Lime Lime Lime Lime Brick Red Brick Red Brown Brown

RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4

Lime Lime Lime Lime Lime Lime Brick Red Brick Red Brick Red Brick Red

Table 6, Packaged, Standard Efficiency, Rubber-in-Shear Isolators, Copper Fins

UNIT MODEL

225DS

250DS, 275DS 300DS, 315DS

330DS, 350DS

360DS390DS 400DS450DS

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

RP-4 RP-4 RP-4 RP-4 RP-4 RP-4

Lime Lime Lime Lime

RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4

Lime Lime Lime Lime Brick Red Brick Red Brown Brown

RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4

Charcoal Charcoal Charcoal Charcoal Lime Lime Lime Lime Brick Red Brick Red

RUBBER-IN-SHEAR MOUNTS

- -

RUBBER-IN-SHEAR MOUNTS

- -

Brick Red Brick Red

KIT NUMBER

- - 332325201

- - 332325202

332325203

KIT NUMBER

- - 332325201

- -

332325202

332325205

Table 7, Packaged, Standard Efficiency, Spring Isolators, Aluminum Fins

UNIT MODEL

225DS

250DS, 275DS

300DS

330DS 350DS 360DS

390DS 400DS 450DS

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

1D-3600 -1D-3600 1D-3600 1D-3600

Green Green Green Green

1D-3600 1D-3600 1D-3600 1D-3600 1D 2040 1D 2040 1D-1360 1D-1360

Green Green Green Green Black Black Red Red

1D-3600 1D-3600 1D-3600 1D-3600 1D 3600 1D 3600 1D-2700 1D 2700 1D-2040 1D 2040

Green Green Green Green Green Green Purple Purple Black Black

1D-3600 1D-3600 1D-3600 1D-3600 1D 3600 1D 3600 1D-3600 -1D 3600 1D-2700 1D 2700

Green Green Green Green Green Green Green Green Purple Purple

NOTE: Spring isolators have four same-color springs per housing.

IMM AGSD-2 7

RUBBER-IN-SHEAR MOUNTS

- -

1D-2700 1D 2700

Purple Purple

- - 332320201

- -

KIT NUMBER

332320202

332320204

332320205

Table 8, Packaged, Standard Efficiency, Spring Isolators, Copper Fins

32.6

(826)

25.6

(650)

UNIT SPRING-FLEX MOUNTINGS

SIZE M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

225DS

250DS

275DS

300DS

330DS 350DS 360DS

390DS

400DS

450DS

1D -3600 1D -3600 1D -36000 1D-600 1D -3600 1D -3600

Green Green Green Green

1D -3600 1D -3600 1D -3600 1D -3600 1D-2040 1D-2040 1D-2040 1D-2040

Green Green Green Green Black Black Black Black

1D -3600 1D -3600 1D -3600 1D -3600 1D-2700 1D-2700 1D-2040 1D-2040

Green Green Green Green Purple Purple Black Black

1D 3600 1D -3600 1D -3600 1D -3600 1D-2700 1D-2700 1D-2040 1D-2040

Green Green Green Green Purple Purple Black Black

1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-2700 1D-2700 1D-2040 1D-2040

Green Green Green Green Green Green Purple Purple Black Black

1D-4800 1D-4800 1D-4800 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600

Gray Gray Gray Gray Green Green Green Green Green Green

1D-4800 1D-4800 1D-4800 -1D-4800 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600

Gray Gray Gray Gray Green Green Green Green Green Green

- Purple Purple

- -

- - 332320207

- - 332320208

NOTE: Spring isolators have four (4) same-color springs per housing.

High Efficiency

KIT

NUMBER

332320201

332320204

332320209

Figure 3, Lifting and Isolator Locations, Model AGS 225DE – 300DE

View is looking down at base from above.

L3L5

M7 M3

M8 M4 M2M6

L4L6

84.6

(2150)

AGS MODEL

225DE

250DE

260DE

275DE

300DE

in. (mm)

69.6 (1768) 255.9 (6500) 194.1 (4930) 253.2 (6431)

69.6 (1768) 250.1 (6353) 199.7 (5072) 288.6 (7330)

69.6 (1768) 266.4 (6767) 198.8 (5050) 324.0 (8230)

in. (mm)

8 IMM AGSD-2

Figure 4, Lifting and Isolator Locations, Model AGS 330DE – 450DE

32.6

(826)

25.6

(650)

View is looking down at base from above.

84.6

(2150)

L3L5

M10

AGS MODEL

330DE 350DE 400DE 450DE

M7 M3

M8 M4

in. (mm)

L4L6

in. (mm)

141.2 (3586) 262.0 (6655) 348.3 (8847) 177.0 (4496) 269.3 (6840) 361.6 (9185)

137.6 (3495)) 297.4 (7554) 383.8 (9749) 169.3 (4299) 304.7 (7739) 397.0 (10085)

137.6 (3495) 297.4 (7554) 383.8 (9749) 169.3 (4299) 304.7 (7739) 397.0 (10085)

137.6 (3495) 297.4 (7554) 419.2 (10648) 169.3 (4299) 304.7 (7739) 432.5 (10986)

in. (mm)

Table 9, High Efficiency, Shipping and Lifting Weights, Aluminum Fins

UNIT SIZE

225DE 250DE 260DE 275DE 300DE 330DE 350DE 400DE 450DE

WEIGHT.

L1 L2 L3 L4 L5 L6 L7 L8

lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg

12869 5843 2653 1204 2824 1282 2246 1020 2391 1086 1335 606 1420 645 - - - 13639 6192 2565 1165 2698 1225 2311 1049 2431 1104 1771 804 1863 845.8 14808 6723 2562 1163 2738 1243 2341 1063 2503 1136 1867 848 1997 907 - - - 14766 6704 2615 1187 2737 1243 2470 1121 2586 1174 2129 966.6 2229 1012 14808 6723 2547 1156 2708 1229 2440 1108 2595 1178 2189 994 2329 1057 - - - 20235 9187 3548 1611 3548 1611 2845 1292 2845 1292 2104 955 2104 955 1620 735 1620 735 21040 9552 3661 1662 3661 1662 3055 1387 3055 1387 2144 973 2144 973 1660 754 1660 754 21326 9682 3693 1677 3693 1677 3095 1405 3095 1405 2184 992 2184 992 1691 768 1691 768 22244 10099 3658 1661 3658 1661 3171 1440 3171 1440 2429 1103 2429 1103 1864 846 1864 846

LIFTING WEIGHT LBS (KG) SHIPPING

in. (mm)

- - - -

in. (mm)

Table 10, High Efficiency, Shipping and Lifting Weights, Copper Fins

UNIT SIZE

225DE 250DE 260DE 275DE 300DE 330DE 350DE 400DE 450DE

WEIGHT

L1 L2 L3 L4 L5 L6 L7 L8

lbs. kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg

14709 6678 2660 1208 2810 1276 2550 1158 2695 1224 1986 902 2090 949 - - - 15741 7146 2915 1324 3048 1384 2661 1208 2781 1263 2121 963.1 2213 1005 - - - 16110 7314 2639 1198 2796 1269 2632 1195 2788 1266 2594 1178 2747 1247 - - - 17131 7777 3009 1366 3131 1421 2864 1300 2980 1353 2523 1146 2623 1191 - - - 17173 7797 2707 1229 2854 1296 2747 1247 2898 1316 2957 1342 3119 1416 - - - 23126 10499 3909 1775 3909 1775 3206 1456 3206 1456 2466 1120 2466 1120 1982 900 1982 900 24194 10984 4055 1841 4055 1841 3449 1566 3449 1566 2538 1152 2538 1152 2055 933 2055 933 24480 11114 4087 1855 4087 1855 3489 1584 3489 1584 2578 1170 2578 1170 2086 947 2086 947 25660 11650 4085 1855 4085 1855 3598 1633 3598 1633 2856 1297 2856 1297 2291 1040 2291 1040

IMM AGSD-2 9

LIFTING WEIGHT LBS (KG) SHIPPING

Table 11, High Efficiency, Operating and Mounting Weights, Aluminum Fins

UNIT SIZE

225DE 250DE 260DE 275DE 300DE 330DE 350DE 400DE 450DE

WEIGHT

lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg

13418 6092 2411 1095 2566 1165 2005 910 2134 969 1247 566 1328 603 836 380 891 405 - - - 14544 6603 2513 1141 2643 1200 2160 981 2273 1032 1473 669 1549 703 942 428 991 450 14913 6771 2514 1141 2687 1220 2177 988 2327 1056 1515 688 1620 735 1002 455 1071 486 - - - 15671 7115 2491 1131 2650 1203 2229 1012 2371 1076 1717 780 1826 829 1158 526 1231 559 15669 7114 2491 1131 2650 1203 2228 1012 2370 1076 1717 780 1826 829 1158 526 1231 559 - - - 21146 9600 2678 1216 2678 1216 2488 1130 2488 1130 2109 957 2109 957 1748 794 1748 794 1550 704 1550 704 21918 9951 2716 1233 2716 1233 2470 1121 2470 1121 2230 1012 2230 1012 1850 840 1850 840 1693 769 1693 769 22485 10208 2721 1235 2721 1235 2558 1161 2558 1161 2323 1055 2323 1055 1948 884 1948 884 1693 769 1693 769 23403 10625 2688 1220 2688 1220 2568 1166 2568 1166 2404 1091 2404 1091 2142 972 2142 972 1899 862 1899 862

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

ISOLATOR LOCATION WEIGHT OPERATING

Table 12, High Efficiency, Operating and Mounting Weights, Copper Fins

UNIT SIZE

225DE 250DE 260DE 275DE 300DE 330DE 350DE 400DE 450DE

WEIGHT

lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg

15258 6927 2643 1200 2798 1270 2234 1014 2363 1073 1475 670 1556 706 1068 485 1120 508 - - - 16646 7557 2776 1260 2905 1319 2422 1100 2536 1151 1736 788 1812 823 1205 547 1254 569 17015 7725 2789 1266 2962 1345 2450 1112 2600 1180 1788 812 1893 859 1277 580 1346 611 - - - 18036 8188 2787 1265 2946 1337 2524 1146 2666 1210 2013 914 2122 963 1455 661 1523 691 18034 8187 2787 1265 2946 1337 2524 1146 2666 1210 2013 914 2122 963 1454 660 1522 691 - - - 24037 10913 2967 1347 2967 1347 2777 1261 2777 1261 2398 1089 2398 1089 2037 925 2037 925 1839 835 1839 835 25072 11383 3031 1376 3031 1376 2785 1264 2785 1264 2545 1155 2545 1155 2165 983 2165 983 2010 913 2010 913 25639 11640 3036 1378 3036 1378 2873 1304 2873 1304 2638 1198 2638 1198 2263 1027 2263 1027 2008 912 2008 912 26819 12176 3030 1376 3030 1376 2910 1321 2910 1321 2746 1247 2746 1247 2484 1128 2484 1128 2240 1017 2240 1017

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

ISOLATOR LOCATION WEIGHT LBS (KG) OPERATING

- - - -

High Efficiency, Isolator Identification

Table 13, Packaged, High Efficiency, Rubber-in-Shear Isolators, Aluminum Fins

UNIT MODEL

225DE, 250DE 260DE, 275DE

300DE 330DE

350DE 400DE

450DE 500DE

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 - -

Lime Lime Lime Lime

R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4

Lime Lime Lime Lime Lime Lime

R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4

Lime Lime Lime Lime Lime Lime Lime Lime

Table 14, Packaged, High Efficiency, Rubber-in-Shear Isolators, Copper Fins

UNIT MODEL

225DE, 250DE 260DE, 275DE

300DE

330DE 350DE 400DE

450DE 500DE

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 - -

Lime Lime Lime Lime

R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4

Charcoal Charcoal Charcoal Charcoal Lime Lime Lime Lime

R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4 R-4

Charcoal Charcoal Charcoal Charcoal Charcoal Charcoal Lime Lime Lime Lime

LOCATION

Brick

Red

LOCATION

Brick

Red

Brick

Red

Brown Brown - -

Brick

Red

Brick

Red

Brick

Red

Brown Brown

Brick

Red

Brick

Red

- -

Brick

Red

Brick

Red

Brick

Red

Brick

Red

KIT NUMBER

332325202

332325203

332325204

KIT NUMBER

332325202

332325205

332325206

10 IMM AGSD-2

Table 15, Packaged, High Efficiency, Spring Isolators, Aluminum Fins

NOTES:

3. RP-4 MOUNT VERSION WITH STUD IN PLACE.

ALL DIMENSIONS ARE IN DECIMAL INCHES

3314814

1.13 ± .25

APPROX.

1.63

.38

DURULENE

MATERIAL

3.00

4.63

.28

TYP.

.250

TYP.

R.750 TYP.

RECESSED

.500-13NC-2B

UNIT

SIZE

225DE 250DE 260DE

275DE

300DE

330DE

350DE

400DE

450DE

500DE

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

1D-3600 1D-3600 1D-3600 1D-3600 1D-2040 1D-2040 1D-1360 1D-1360

Green Green Green Green Black Black Red Red

1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-2040 1D-2040

Green Green Green Green Green Green Black Black

1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-2700 1D-2700 1D-2040 1D-2040

Green Green Green Green Green Green Purple Purple Black Black

1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-2700 1D-2700

Green Green Green Green Green Green Green Green Purple Purple

1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600

Green Green Green Green Green Green Green Green Green Green

NOTE: Spring isolators have four, same color springs per housing.

SPRING-FLEX MOUNTINGS, ALUMINUM FINS

Table 16, Packaged, High Efficiency, Spring Isolators, Copper Fins

UNIT SZE

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

225DE

250DE

260DE

275DE 300DE

330DE, 350DE 400DE, 450DE

500DE

1D-3600 1D-3600 1D-3600 1D-3600 1D-2040 1D-2040 1D-2040 1D-2040

Green Green Green Green Black Black Black Black

1D-3600 1D-3600 1D-3600 1D-3600 1D-2700 1D-2700 1D-2040 1D-2040

Green Green Green Green Purple Purple Black Black

1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-2040 1D-2040

Green Green Green Green Green Green Black Black

1D-4800 1D-4800 1D-4800 1D-4800 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600 1D-3600

Gray Gray Gray Gray Green Green Green Green Green Green

NOTE: Spring isolators have four, same color springs per housing.

SPRING-FLEX MOUNTINGS, COPPER FINS

KIT NUMBER

- - 332320202

- - 332320203

332320204

332320205

332320206

KIT NUMBER

- - 332320207

- - 332320208

- - 332320203

332320209

Isolator Dimensions

Figure 5, Four-Spring Mounting Figure 6, RP-4, R-I-S Mounting

6.25

5.00

3.75

3.87 .56 TYP.

VM&C

GRIP RIBS

IMM AGSD-2 11

MOUNT MATERIAL TO BE DURULENE RUBBER.

MOLDED STEEL AND ELASTOMER MOUNT FOR OUTDOOR SERVICE CONDITIONS.

VM&C

RAISED GRIP RIBS

DRAWING NUMBER

Installation and Start-up

WARNING

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

Note: Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment.

Start-up by McQuay Factory Service is included on all units sold for installation within the U.S. and Canada and must be performed by them to initiate the standard Limited Product Warranty. Start-up by any party other than McQuay Factory Service or a McQuay Authorized Service Representative will void the Limited Product Warranty. Two-week prior notification of start-up is required. The contractor should obtain a copy of the Start-up Scheduled Request Form from the sales representative or from the nearest McQuay Factory Service office.

WARNING

Escaping refrigerant can displace air and cause suffocation. Immediately evacuate and ventilate the

equipment area. If the unit is damaged, follow Environmental Protection Agency (EPA) requirements.

Do not expose sparks, arcing equipment, open flame or other ignition source to the refrigerant.

Handling

Avoid rough handling shock due to impact or dropping the unit. Do not push or pull the unit.

Never allow any part of the unit to fall during unloading or moving, as this can result in serious damage.

To lift the unit, lifting tabs with 2½" (64 mm) diameter holes are provided on the base of the unit. All lifting holes must be used when lifting the unit. Spreader bars and cables should be arranged to prevent damage to the condenser coils or unit cabinet (see Figure 7).

DANGER

Improper lifting or moving of a unit can result in property damage, severe personal injury or death. Follow rigging and moving instructions carefully.

Figure 7, Required Lifting Method

NOTES:

1. All rigging points on a unit must be used. See location and weights at lifting points beginning on page 5 for a specific size unit.

2. Crosswise and lengthwise spreader bars must be used to avoid damage to unit. Lifting cables from the unit mounting holes up must be vertical.

3. The number of condenser sections, fans, and lifting points can vary from this diagram.

Location

Locate the unit carefully to provide proper airflow to the condenser. (See Figure 8 on page 14 for required clearances.)

Due to the shape of the condenser coils on the AGS chillers, it is recommended that the unit be oriented

so that prevailing winds blow parallel to the unit length, thus minimizing the wind effect on

12 IMM AGSD-2

condensing pressure and performance. If low ambient temperature operation is expected, optional louvers should be installed if the unit has no protection against prevailing winds.

Using less clearance than shown in Figure 8 can cause discharge air recirculation to the condenser and could have a significant, detrimental effect on unit performance.

See Restricted Airflow beginning on page 15 for further information.

For pad-mounted units, it is recommended that the unit be raised a few inches with suitable supports such as neoprene waffle vibration pads, located at least under the mounting locations. This will allow water to drain from under the unit and facilitate cleaning under it.

Service Access

Compressors, filter-driers, and manual liquid line shutoff valves are accessible on each side or end of the unit. The evaporator heater is located on the barrel.

The control panels are located on the end of the chiller. The left-hand control box contains the unit and circuit microprocessors as well as transformers, fuses and terminal. The right-hand panel has line voltage and contains a circuit breaker and starter for each compressor plus fuses, fan VFD (optional) and fan contactors. A minimum of four feet of clearance is required in front of the panels.

The side clearance required for airflow provides sufficient service clearance.

On all AGS units, the condenser fans and motors can be removed from the top of the unit. The complete fan/motor assembly can be removed for service. The fan blade must be removed for access to wiring terminals at the top of the motor.

WARNING

Disconnect, lockout and tag all power to the unit before servicing condenser fan motors or

compressors. Failure to do so can cause bodily injury or death.

Do not block access to the sides or ends of the unit with piping or conduit. These areas must be open for service access. Do not block any access to the control panels with a field-mounted disconnect switches.

IMM AGSD-2 13

Clearance Requirements

5ft (1.5m)

3ft (1m) for service

Air Flo

No obstructions allowed

above unit at any heigh

See notes 2 & 4

concerning wall

height at unit sides.

6ft (1.8m)

Figure 8, Clearance Requirements

if open fence or 50% open wall if solid wall (see note 3 for pit)

4ft (1.2m) For electric panel access

if open fence or 50% open wall if solid wall (see note 3 for pit)

No obstructions. Recommended area required for unit operation, air flow and maintenance access.

See Note 5

Wall or Fence

Notes:

1. Minimum side clearance between two units is 12 feet (3.7 meters).

2. Unit must not be installed in a pit or enclosure that is deeper or taller than the height of the unit unless extra

clearance is provided per note 4.

3. Minimum clearance on each side is 8 feet (2.4 meters) when installed in a pit no deeper than the unit height.

4. Minimum side clearance to a side wall or building taller than the unit height is 6 feet (1.8 meters), provided

no solid wall above 6 feet (1.8 meters) is closer than 12 feet (3.7 meters) to the opposite side of the unit.

5. Do not mount electrical conduits where they can block service access to compressor controls, refrigerant

driers or valves.

6. There must be no obstruction of the fan discharge.

7. Field installed switches must not interfere with service access or airflow.

8. The evaporator can be removed from the side of the unit and may require the temporary removal of a coil

section support post. See dimension drawings beginning on page 29 for details.

9. If the airflow clearances cannot be met, see the following pages on Restricted Airflow.

14 IMM AGSD-2

Restricted Airflow

General

The clearances required for design operation of AGS air-cooled condensers are described in the previous section. Occasionally, these clearances cannot be maintained due to site restrictions such as units being too close together or a fence or wall restricting airflow, or both.

The McQuay AGS chillers have several features that can mitigate the problems attributable to restricted airflow.

• The shape of the condenser section allows inlet air for these coils to come in from both sides and

the bottom. All the coils on one side serve one compressor. Every compressor always has its own independent refrigerant circuit.

• The MicroTech II control is proactive in response to off-design conditions. In the case of single

or compounded influences restricting airflow to the unit, the microprocessor will act to keep the compressor(s) running (at reduced capacity) as long as possible, rather than allowing a shut-off on high discharge pressure.

Figure 9, Coil and Fan Arrangement

The following sections discuss the most common situations of condenser air restriction and give capacity and power adjustment factors for each. Note that in unusually severe conditions, the MicroTech II controller will adjust the unit operation to remain online until a less severe condition is reached.

IMM AGSD-2 15

Case 1, Building or Wall on One Side of One Unit

5 ft.

(1.5m)

(1.8m)

The existence of a screening wall, or the wall of a building, in close proximity to an air-cooled chiller is common in both rooftop and ground level applications. Hot air recirculation on the coils adjoining the wall will increase compressor discharge pressure, decreasing capacity and increasing power consumption.

When close to a wall, it is desirable to place chillers on the north or east side of them. It is also desirable to have prevailing winds blowing parallel to the unit’s long axis. The worst case is to have wind blowing hot discharge air into the wall.

Figure 10, Unit Adjacent to Wall

Figure 11, Adjustment Factors

(1.5m)

6 ft.

(1.8m)

5 ft.

6 ft.

16 IMM AGSD-2

Case 2, Two Units Side By Side

Two or more units sited side by side are common. If spaced closer than 12 feet (3.7 meters), or 8 feet (2.5 meters), depending on size, it is necessary to adjust the performance of each unit. Circuits adjoining each other are affected. NOTE: This case applies only to two units side by side. See Case 3 for three or more parallel units. If one of the two units also has a wall adjoining it, see Case 1. Add the two adjustment factors together and apply to the unit located between the wall and the other unit.

Mounting units end to end will not necessitate adjusting performance. Depending on the actual arrangement, sufficient space must be left between the units for access to the control panel door opening and/or evaporator tube removal. See “Clearance” section of this guide for requirements for specific units.

Figure 12, Two Units Side by Side

Figure 13, Adjustment Factor

IMM AGSD-2 17

Case 3, Three or More Units Side By Side

When three or more units are side by side, the outside units (chillers 1 and 3 in this case) are influenced by the middle unit only on their inside circuits. Their adjustment factors will be the same as Case 2. All inside units (only chiller 2 in this case) are influenced on both sides and must be adjusted by the factors shown below.

Figure 14, Three or More Units

Chiller 1 Chiller 2 Chiller 3

Figure 15, Adjustment Factor

18 IMM AGSD-2

Case 4, Open Screening Walls

Decorative screening walls are often used to help conceal a unit either on grade or on a rooftop. These walls should be designed such that the combination of their open area and distance from the unit do not require performance adjustment. It is assumed that the wall height is equal to or less than the unit height when mounted on its base support. This is usually satisfactory for concealment. If the wall height is greater than the unit height, see Case 5, Pit Installation.

The distance from the ends of the unit to the end walls must be sufficient for service, opening control panel doors, and pulling evaporator tubes, as applicable.

If each side wall is a different distance from the unit, the distances can be averaged, providing either wall is not less than 8 feet (2.4 meters) from the unit. For example, do not average 4 feet and 20 feet to equal 12 feet.

Figure 16, Open Screening Walls

Figure 17, Wall Free Area vs. Distance

IMM AGSD-2 19

Case 5, Pit/Solid Wall Installation

Pit installations can cause operating problems and great care must be exercised if they are to be used on an installation. Recirculation and restriction can both occur. A solid wall surrounding a unit is substantially the same as a pit and the data presented in this case should be used.

Steel grating is sometimes used to cover a pit to prevent accidental falls or trips into the pit. The grating material and installation design must be strong enough to prevent such accidents, yet provide abundant open area or serious recirculation problems will occur. Have any pit installation reviewed by the McQuay Factory Service prior to installation to discuss whether it has sufficient airflow characteristics. The installation design engineer must approve the work and is responsible for design criteria.

Figure 18, Pit Installation

Figure 19, Adjustment Factor

20 IMM AGSD-2

Chilled Water

It is recommended that the chilled water pumps' starters be wired to, and controlled by, the chiller's microprocessor. The controller will energize the pump whenever at least one circuit on the chiller is enabled to run, whether there is a call for cooling or not. The control will also start the pump when freezing temperatures are approached. Wiring connection points are shown in Figure 28 on page 48.

Water Piping

Due to the variety of piping practices, follow the recommendations of local authorities. They can supply the installer with the proper building and safety codes required for a proper installation.

Design the piping with a minimum number of bends and changes in elevation to keep system cost down and performance up. It should contain:

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 and drains at the low parts in

the system. The evaporator should not be the highest point in the piping system.

4. Some means of maintaining adequate system water pressure (i.e., expansion tank or regulating

valve).

5. Water temperature and pressure indicators located at the evaporator inlet and outlet to aid in unit

servicing. Any connections should be made prior to filling the system with water.

6. A strainer to remove 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 help maintain high system performance levels.

NOTE

evaporator. This will aid in preventing foreign material from entering the evaporator and causing damage or decreasing its performance. Care must also be exercised if welding pipe or flanges to the evaporator connections to prevent any weld slag from entering the vessel. Units equipped with the optional pump package will have a strainer in the pump suction.

7. Any water piping to the unit must be protected to prevent freeze-up if below freezing temperatures

A 20-mesh strainer must also be placed in the supply water line just prior to the inlet of the

are expected.

CAUTION

If a separate disconnect is used for the 115V supply to the unit, it should power the entire control circuit. It should be clearly marked so that it is not accidentally shut off during cold seasons. Freeze damage to the evaporator could result. If the evaporator is drained for winter freeze protection, the heaters must be de-energized to prevent burnout.

8. If the unit is used as a replacement chiller on a previously existing piping system, flush the system

thoroughly prior to unit installation. Perform regular chilled water analysis and chemical water treatment immediately at equipment start-up.

9. In the event glycol is added to the water system as a late addition for freeze protection, recognize

that the refrigerant suction pressure will be lower, cooling performance less, and water side pressure drop greater. If the percentage of glycol is large, or if propylene is employed in lieu of ethylene glycol, the added pressure drop and loss of performance could be substantial.

IMM AGSD-2 21

10. For ice making or low temperature glycol operation, a different freezestat pressure value is usually

required. The freezestat setting can be manually changed through the MicroTech II controller.

Make a preliminary leak check prior to insulating the water piping and filling the system.

Include a vapor barrier with the piping insulation to prevent moisture condensation and possible damage to the building structure. It is important to have the vapor barrier on the outside of the insulation to prevent condensation within the insulation on the cold surface of the pipe.

System Water Volume

All chilled water systems need adequate time to recognize a load change, respond to that load change and stabilize, without undesirable short cycling of the compressors or loss of control. In air conditioning systems, the potential for short cycling usually exists when the building load falls below the minimum chiller plant capacity or on close-coupled systems with very small water volumes.

Some of the things the designer should consider when looking at water volume are the minimum cooling load, the minimum chiller plant capacity during the low load period and the desired cycle time for the compressors.

Assuming that there are no sudden load changes and that the chiller plant has reasonable turndown, a rule of thumb of “gallons of water volume equal to two to three times the chilled water gpm flow rate” is often used.

A properly designed storage tank should be added if the system components do not provide sufficient water volume.

Variable Speed Pumping

Variable water flow involves reducing the water flow through the evaporator as the load decreases. McQuay chillers are designed for this duty, provided that the rate of change in water flow is slow, and the minimum and maximum flow rates for the vessel are not exceeded.

The recommended maximum change in water flow is 10 percent of the change per minute. For example, if the maximum (design) flow is 200 gpm and the flow is reduced to a minimum of 140 gpm, the change in flow is 60 gpm, so the maximum change per minute would be 10% of 60, or 6 gpm per minute. It would take ten minutes to change the flow through the entire range.

The water flow through the vessel must remain between the minimum and maximum values listed on page 27. If flow drops below the minimum allowable, large reductions in heat transfer can occur. If the flow exceeds the maximum rate, excessive pressure drop and tube erosion can occur.

Evaporator Freeze Protection

AGS chillers are equipped with thermostatically controlled evaporator heaters that help protect against freeze-up down to -20°F (-28°C).

NOTE: The heaters come from the factory connected to the control power circuit. The control power can be rewired in the field to a separate 115V supply (do not wire directly to the heater). See the field wiring diagram on page 48. If this is done, mark the disconnect switch clearly to avoid accidental deactivation of the heater during freezing temperatures. Exposed chilled water piping also requires protection.

For additional protection, at least one of the following procedures should be used during periods of sub-freezing temperatures:

1. Adding of a concentration of a glycol anti-freeze with a freeze point 10 degrees F. below the

lowest expected temperature. This will result in decreased capacity and increased pressure drop.

22 IMM AGSD-2

Note: Do not use automotive grade antifreezes as they contain inhibitors harmful to chilled water

systems. Use only glycols specifically designated for use in building cooling systems.

2. Draining the water from outdoor equipment and piping and blowing the chiller tubes dry from the

chiller. Do not energize the chiller heater when water is drained from the vessel.

CAUTION

If fluid is absent from the evaporator, the evaporator heater must be de-energized to avoid burning out the heater or causing damage from the high temperatures.

1. Providing operation of the chilled water pump, circulating water through the chilled water system and through the evaporator.

Table 17, Freeze Protection

Temperature

°°°°F (°°°°C)

20 (6.7) 16 18 11 12

10 (-12.2) 25 29 17 20

0 (-17.8) 33 36 22 24

-10 (-23.3) 39 42 26 28

-20 (-28.9) 44 46 30 30

-30 (-34.4) 48 50 30 33

-40 (-40.0) 52 54 30 35

-50 (-45.6) 56 57 30 35

-60 (-51.1) 60 60 30 35

Notes:

1. These figures are examples only and cannot be appropriate to every situation. Generally, for an extended margin of protection, select a temperature at least 15°F lower than the expected lowest ambient temperature. Inhibitor levels should be adjusted for solutions less than 25% glycol.

2. Glycol of less than 25% concentration is not recommended because of the potential for bacterial growth and loss of heat transfer efficiency.

For Freeze Protection For Burst Protection

Ethylene Glycol Propylene Glycol Ethylene Glycol Propylene Glycol

Percent Volume Glycol Concentration Required

IMM AGSD-2 23

Operating Limits:

Maximum standby ambient temperature, 130°F (55°C)

Maximum operating ambient temperature, 105°F. See High Ambient Option below.

Minimum operating ambient temperature (standard), 35°F (2°C)

Minimum operating ambient temperature (optional low-ambient control), 0°F (-18°C)

Leaving chilled water temperature, 40°F to 60°F (4°C to 16°C)

Leaving chilled fluid range (with anti-freeze), 20°F to 60°F (-7°C to 16°C). Unloading is not permitted with fluid leaving temperatures below 30°F (-1°C).

Operating Delta-T range, 6 degrees F to 16 degrees F (10.8°C to 28.8°C)

Maximum operating inlet fluid temperature, 76°F (24°C)

Maximum startup inlet fluid temperature, 90°F (32°C)

Maximum non-operating inlet fluid temperature, 100°F (38°C)

NOTE: Contact the local McQuay sales office for operation outside any of these limits.

High Ambient Option, A factory-installed option that allows operation in high ambient temperature

locations with operating temperatures above 105°F up to 125°F (40.6°C to 51.7°C).

Flow Switch

A flow switch must be included in the chilled water system to prove that there is adequate water flow to the evaporator before the unit can start. It also serves to shut down the unit in the event that water flow is interrupted in order to guard against evaporator freeze-up. A solid state, thermal dispersion flow switch that is factory-mounted in the chiller leaving water nozzle and factory-wired is available as an option.

Figure 20, Flow Switch

Flow direction marked on switch

1" (25mm) NPT flow switch connection

Tee

A paddle-type flow switch for field mounting and wiring in the leaving chilled water is also available as an option from McQuay under ordering number 017503300. It is

1 1/4" (32mm) pipe

dia. min. after switch

1 1/4" (32mm) pipe

dia. min. before switch

adaptable to any pipe size from 1" (25mm) to 8" (203mm) nominal.

Certain minimum flow rates are required to close the switch and are listed in Table 18. Installation should be as shown in Figure 17.

Electrical connections in the unit control center should be made at terminals 60 and 67 from switch terminals Y and R. The normally open contacts of the flow switch should be wired between these two terminals. Flow switch contact quality must be suitable for 24 VAC, low current (16ma). Flow switch wire must be in separate conduit from any high voltage conductors (115 VAC and higher) and have an insulation rating of 600 volts.

24 IMM AGSD-2

Table 18, Paddle Type Flow Switch Flow Rates

Vent

Valve

Vibration

Valved

Against Freezing

Vibration

Valve

()()(

)

(NOTE !)

Min.

Adjst.

Max.

Adjst.

Flow

Flow Lpm 0.8 1.1 2.2 2.8 4.3 11.4 22.9 35.9 38.6

Flow

Flow Lpm 2.8 4.1 6.1 7.3 11.4 27.7 53.4 81.8 90.8

NOTES:

1. A segmented 3-inch paddle (1, 2, and 3 inches) is furnished mounted, plus a 6-inch paddle loose.

2. Flow rates for a 2-inch paddle trimmed to fit the pipe.

3. Flow rates for a 3-inch paddle trimmed to fit the pipe.

4. Flow rates for a 3-inch paddle.

5. Flow rates for a 6-inch paddle.

inch 1 1/4 1 1/2 2 2 1/2 3 4 5 6 8 Pipe Size

mm 32 (2) 38 (2) 51 63 (3) 76 102 (4) 127 (4) 153 (4) 204 (5)

gpm 5.8 7.5 13.7 18.0 27.5 65.0 125.0 190.0 205.0 Lpm 1.3 1.7 3.1 4.1 6.2 14.8 28.4 43.2 46.6 gpm 3.7 5.0 9.5 12.5 19.0 50.0 101.0 158.0 170.0

gpm 13.3 19.2 29.0 34.5 53.0 128.0 245.0 375.0 415.0 Lpm 3.0 4.4 6.6 7.8 12.0 29.1 55.6 85.2 94.3 gpm 12.5 18.0 27.0 32.0 50.0 122.0 235.0 360.0 400.0

Figure 21, Typical Field Water Piping

Suction

Gauge

Flow

Eliminator

Balancing

Pressure

Out

Liquid

Drain

Notes:

1. Connections for vent and drain fittings are located on the top and bottom of the evaporator.

2. Piping must be supported to avoid putting strain on the evaporator nozzles.

Eliminator

Switch

Water

Strainer

Gate

Flow

Gate

Protect All Field Piping

Flow

Refrigerant Charge

All packaged units are designed for use with R-134a and are shipped with a full operating charge. The operating charge for each unit is shown in the Physical Data Tables beginning on page 28.

Glycol Solutions

When using glycol anti-freeze solutions, the chiller's capacity, glycol solution flow rate, and pressure drop through the evaporator can be calculated using the following formulas and tables.

Note: The procedure below does not specify the type of glycol. Use the derate factors found in Table 19 for corrections when using propylene glycol and those in Table 20 for ethylene glycol.

1. Capacity - Cooling capacity is reduced from that with plain water. To find the reduced value, multiply the chiller’s water system tonnage by the capacity correction factor to find the chiller’s capacity when using glycol.

2. Flow - To determine flow (or Delta-T) knowing Delta-T (or flow) and capacity:

GPM−=

factorflowtons

TDelta

3. Pressure drop - To determine pressure drop through the evaporator when using glycol, enter the water pressure drop curve at the water flow rate. Multiply the water pressure drop found there by the "PD" factor to obtain corrected glycol pressure drop.

IMM AGSD-2 25

4. Power - To determine glycol system kW, multiply the water system kW by the factor designated

"Power".

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. On glycol applications, the supplier normally recommends that a minimum of 25% solution by weight be used for protection against corrosion or that additional inhibitors should be employed.

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

Table 19, Ethylene Glycol Factors

Freeze

E.G.

Point

oF o

26 -3.3 0.996 0.998 1.036 1.097

18 -7.8 0.988 0.994 1.061 1.219

7 -13.9 0.979 0.991 1.092 1.352

-7 -21.7 0.969 0.986 1.132 1.532

-28 -33.3 0.958 0.981 1.182 1.748

Capacity Power Flow PD

Table 20, Propylene Glycol Factors

Freeze

% P.G.

Point

oF o

26 -3.3 0.991 0.996 1.016 1.092

19 -7.2 0.981 0.991 1.032 1.195

9 -12.8 0.966 0.985 1.056 1.345

-5 -20.6 0.947 0.977 1.092 1.544

-27 -32.8 0.932 0.969 1.140 1.906

Capacity Power Flow PD

Water Flow and Pressure Drop

Adjust the chilled water flow through the evaporator to meet specified conditions. The flow rates must fall between the minimum and maximum values shown in the table on the following page. Flow rates below the minimum values shown can result in laminar flow that will reduce efficiency, cause erratic operation of the electronic expansion valve and could cause low temperature cutouts. On the other hand, flow rates exceeding the maximum values shown can cause erosion on the evaporator water connections and tubes.

Measure the chilled water pressure drop through the evaporator at field-installed pressure taps. It is important not to include valve or strainer pressure drops in these readings.

26 IMM AGSD-2

Figure 22, Standard Efficiency, Evaporator Pressure Drop

Standard Efficiency, Minimum/Nominal/Maximum Flow Rates

MODEL

225DS A 250DS A 275DS B 300DS C 330DS D 350DS D 360DS E 390DS E 400DS F 450DS F

CURVE

MINIMUM FLOW NOMINAL FLOW MAXIMUM FLOW AGS

GPM FT L/S KPA GPM FT L/S KPA GPM FT L/S KPA

252 3.9 15.9 11.6 507 14.3 32.0 42.6 845 37.0 53.3 110.3 252 3.9 15.9 11.6 556 17.0 35.1 50.7 926 43.0 58.5 128.1 292 2.2 18.4 6.6 631 9.5 39.8 28.3 1052 26.5 66.4 79.0 355 3.7 22.4 11.0 713 12.2 45.0 36.4 1188 33.3 75.0 99.2 356 2.7 22.5 8.0 765 11.4 48.3 34.0 1275 30.0 80.4 89.4 356 2.7 22.5 8.0 809 12.6 51.1 37.5 1349 34.0 85.1 101.3 407 3.9 25.7 11.6 843 15.4 53.2 45.9 1404 40.0 88.6 119.2 407 3.9 25.7 11.6 896 17.3 56.5 51.6 1493 45.0 94.2 134.1 470 3.3 29.7 9.8 937 12.2 59.1 36.4 1562 32.0 98.6 95.4 470 3.3 29.7 9.8 1044 15.0 65.9 44.7 1740 37.0 109.8 110.3

IMM AGSD-2 27

Figure 23, High Efficiency, Evaporator Pressure Drops

High Efficiency, Minimum/Nominal/Maximum Flow Rates

MODEL

225DE A 250DE A 260DE B 275DE B 300DE C 330DE D 350DE E 400DE F 450DE F

CURVE

MINIMUM FLOW NOMINAL FLOW MAXIMUM FLOW AGS

gpm ft l/s kpa gpm ft l/s kpa gpm ft l/s kpa

260 2.3 16.4 6.9 516 8.7 32.5 25.9 860 23.4 54.2 69.7 260 2.3 16.4 6.9 565 10.4 35.7 31.0 942 28.0 59.4 83.4 292 2.2 18.4 6.6 599 8.7 37.8 25.9 998 23.5 63.0 70.0 292 2.2 18.4 6.6 642 9.8 40.5 29.2 1070 26.5 67.5 79.0 355 3.6 22.4 10.7 719 13.4 45.3 39.9 1198 36.0 75.6 107.3 356 2.6 22.5 7.7 778 11.4 49.1 34.0 1296 28.0 81.8 83.4 407 3.9 25.7 11.6 823 15.0 51.9 34.0 1372 38.4 86.5 114.4 470 3.2 29.7 9.5 953 12.1 60.2 44.7 1589 31.0 100.3 92.4 470 3.2 29.7 9.5 1051 14.5 66.3 36.1 1751 38.1 110.5 113.5

28 IMM AGSD-2

Physical Data, Standard Efficiency

Table 21, Standard Efficiency, AGS 225DS – AGS 275DS

DATA

BASIC DATA

Unit Cap. @ ARI tons (kW) 211.2 (742.6) 231.6 (814.3) 263.1 (925.1) Unit Operating Charge lbs (kg) 185 (84) 185 (84) 210 (95) 210 (95) 210 (95) 240 (109) Cabinet Dimensions

L x W x H, in. (mm) Unit Operating Weight, lbs. (kg) 12556 (5700) 13398 (6069) 14958 (6785) Unit Shipping Weight, lbs (kg) 12007 (5451) 12849 (5821) 14049 (6374)

COMPRESSORS, SCREW, SEMI-HERMETIC

Nominal Capacity, tons (kW) 100 (350) 100 (350) 100 (350) 125 (4370 125 (4370 150 (525) Minimum Capacity (% of Full Load) 15 15 15

CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER

Pumpdown Capacity, lbs (kg) 249 (113) 249 (113) 287 (130) 287 (130) 287 (130) 325 (148) Coil Inlet Face Area, sq. ft. (sq m.) 129.2 (12.0) 129.2 (12.0) 150.8 (14.0) 150.8 (14.0) 150.8 (14.0) 172.5 (16.0)

CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE

No. of Fans/Circuit – 30 in. Fan Dia. 6 6 7 7 8 8 Fan Motor hp (kW) 2.5 (1.8) 2.5 (1.8) 2.5 (1.8) Fan & Motor RPM, 60Hz 1140 1140 1140 60 Hz Fan Tip Speed, fpm (m/s) 60 Hz Total Unit Airflow, cfm (l/s) 137328 (64819) 160216 (75622) 183104 (86425)

EVAPORATOR, DIRECT EXPANSION SHELL AND TUBE

Shell Dia.-Tube Length in.(mm) - in. (mm)

Connection Size, in (mm) 6 (152) 6 (152) 8 (203) Water Volume, gallons (liters) 65.8 (249.4) 65.8 (249.4) 108.5 (411.1) Max. Water Pressure, psi (kPa) 152 (1048) 152 (1048) 152 (1048) Max. Refrigerant Press., psi (kPa) 350 (2413) 350 (2413) 350 (2413)

225DS 250DS 275DS

Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2

243x88x97

(6172x2225x2464)

8954 (45)

16x108 (406x2750) 16x108 (406x2750) 20x108 (508x2750)

AGS-DS MODEL NUMBER

279x88x97

(7087x2225x2464)

8954 (45)

314x88x97

(7984x2225x2464)

8954 (45)

Table 22, Standard Efficiency, AGS 300DS

DATA

BASIC DATA

Unit Cap. @ ARI, tons (kW) 297.0 (1042.5) Unit Operating Charge lbs (kg) 240 (109) 240 (109) Cabinet Dimensions L x W x H, in. (mm) Unit Operating Weight (1), lbs. (kg) 14903 (6751) Unit Shipping Weight(1), lbs (kg) 14954 (6760)

COMPRESSORS, SCREW, SEMI-HERMETIC

Nominal Capacity, tons (kW) 150 (525) 150 (525) Minimum Capacity (% of Full Load) 15

CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE

Pumpdown Capacity, lbs (kg) 325 (148) 325 (148) Coil Inlet Face Area, sq. ft. (sq m.) 172.5 (16.0) 172.5 (16.0)

CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE

No. of Fans/Circuit – 30 in. Fan Dia 8 8 Fan Motor -- hp (kW) 2.5 (1.8) Fan & Motor RPM, 60Hz 1140 60 Hz Fan Tip Speed, fpm (m/s) 60 Hz Total Unit Airflow, cfm (l/s) 183104 (86425)

EVAPORATOR, DIRECT EXPANSION SHELL AND TUBE

Shell Dia.-Tube Length in.(mm) - in. (mm) Connection Size, in (mm) 8 (203) Water Volume, gallons (liters) 103.2 (391.2) Max. Water Pressure, psi (kPa) 152 (1048) Max. Refrigerant Press., psi (kPa) 350 (2413)

AGS MODEL NUMBER

300DS

Ckt 1 Ckt 2

314x88x97

(7984x2225x2464)

8954 (45)

20x108 (508x2750)

IMM AGSD-2 29

Table 23, Standard Efficiency, AGS 330DS – AGS 360DS

DATA

Ckt. 1 Ckt. 2 Ckt. 3 Ckt. 1 Ckt. 2 Ckt. 3 Ckt. 1 Ckt. 2 Ckt. 3

BASIC DATA

Unit Cap. @ ARI, tons (kW) 318.7 (1120.5) 337.2 (1185.6) 351.1 (1234.5) Unit Operating Charge, lbs (kg) 210 (95) 210 (95) 190 (86 210 (95) 210 (95) 190 (86) 210 (95) 210 (95) 190 (86) Cabinet Dim., L x W x H, in. (mm) Operating Weight(1), lbs. (kg) 20507 (9302) 20507 (9302) 20517 (9307) Shipping Weight(1), lbs (kg) 19596 (8889) 19596 (8889) 19639 (8908)

COMPRESSORS, SCREW, SEMI-HERMETIC

Nominal Capacity, tons (kW) 100 (350) 100 (350) 100 (350) 100 (350) 125 (437) 100 (350) 125 (437) 125 (437) 100 (350) Minimum Capacity (% of Full Load)

CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER

Pumpdown Capacity, lbs (kg) 287 (130) 287 (130) 243 (110) 287 (130) 287 (130) 243 (110) 287 (130) 287 (130) 243 (110) Coil Inlet Face Area, sq. ft. (sq m.) 150.8 (14) 150.8 (14) 128.5 (12) 150.8 (14) 150.8 (14) 128.5 (12) 150.8 (14) 150.8 (14) 128.5 (12)

CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE

No. of Fans/Cir, Fan Dia. 30 in 7 7 6 7 7 6 7 7 6 Fan Motor -- hp (kW) 2.5 (1.8) 2.5 (1.8) 2.5 (1.8) Fan & Motor RPM, 60Hz 1140 1140 1140 60 Hz Fan Tip Speed, fpm (m/s) 60 Hz Total Unit Airflow, cfm (l/s) 228880 (108031) 228880 (108031) 228880 (108031)

EVAPORATOR, DIRECT EXPANSION SHELL AND TUBE

Shell Dia.,Tube Length in.(mm) 20x108 (508x2750) 20x108 (508x2750) 20x108 (508x2750) Connection Size, in (mm) 8 (203) 8 (203) 8 (203) Water Volume, gallons (liters) 107.0 (405.4) 107.0 (405.4) 103.2 (391.2) Max. Water Pressure, psi (kPa) 152 (1048) 152 (1048) 152 (1048) Max. Refrigerant Press., psi (kPa) 350 (2413) 350 (2413) 350 (2413)

330DS 350DS 360DS

403x88x97

(10239x2225x2459)

10 10 10

8954 (45)

AGS MODEL NUMBER

403x88x97

(10239x2225x2459)

8954 (45)

403x88x97

(10239x2225x2459)

8954 (45)

Table 24, Standard Efficiency, AGS 390DS – AGS 450DS

AGS MODEL NUMBER

DATA 390DS 400DS 450DS

Ckt. 1 Ckt. 2 Ckt. 3 Ckt. 1 Ckt. 2 Ckt. 3 Ckt. 1 Ckt. 2 Ckt. 3

BASIC DATA

Unit Cap. @ ARI, tons (kW) 373.2 (1311.8) 390.4 (1373.3)) 434.8 (1529.1) Unit Operating Charge, lbs (kg) 210 (95) 210 (95) 230 (104) 215 (97) 215 (97) 235 (106) 240 (109) 240 (109) 240 (109)

Cabinet Dim., L x W x H, in. (mm)

Operating Weight(1), lbs. (kg) 21156 (9596) 21708 (9847) 22485 (10199) Shipping Weight(1), lbs (kg) 20278 (9198) 20549 (9321) 21326 (9674)

COMPRESSORS, SCREW, SEMI-HERMETIC

Nominal Capacity, tons (kW) 125 (437) 125 (437) 125 (437) 125 (437) 125 (437) 150 (525) 150 (525) 150 (525) 150 (525) Minimum Capacity (% of Full Load)

CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER

Pumpdown Capacity, lbs (kg) 287 (130) 287 (130) 316 (144) 287 (130) 287 (130) 316 (144) 325 (147) 325 (147) 316 (144) Coil Inlet Face Area, sq. ft. (sq m.) 150.8 (14) 150.8 (14) 171.7 (16) 150.8 (14) 150.8 (14) 171.7 (16) 172.5 (16) 172.5 (16) 171.7 (16

CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE

No. of Fans/Circuit – 30 in. Fan Dia Fan Motor -- hp (kW) 2.5 (1.8) 2.5 (1.8) 2.5 (1.8) Fan & Motor RPM, 60Hz 1140 1140 1140 60 Hz Fan Tip Speed, fpm (m/s) 60 Hz Total Unit Airflow, cfm (l/s) 251768 (118835) 251768 (118835) 274656 (129637)

EVAPORATOR, DIRECT EXPANSION SHELL AND TUBE

Shell Dia.,Tube Length in.(mm) 20x108 (508x2750) 20x149 (508x3785) 20x149 (508x3785) Connection Size, in (mm) 8 (203) 8 (203) 8 (203) Water Volume, gallons (liters) 103.2 (391.2) 97.2 (368.5) 97.2 (368.5) Max. Water Pressure, psi (kPa) 152 (1048) 152 (1048) 152 (1048) Max. Refrigerant Press., psi (kPa) 350 (2413) 350 (2413) 350 (2413)

439x88x97

11140x2225x2459)

10 10 10

7 7 8 7 7 8 8 8 8

8954 (45)

439x88x97

11140x2225x2459)

8954 (45)

474x88x97

12040x2225x2459)

8954 (45)

30 IMM AGSD-2

+ 68 hidden pages