McQuay AGZ 026BS Installation Manual

Operation Manual

Air-Cooled Scroll Compressor Chiller Packaged and Remote Evaporator

AGZ 026BS/M through 130BS/M 60 Hertz R-22, R407c

Software Version AGZDU0102C

OM AGZ-1

Group: Chiller Part Number: 331374101 Effective: July 2007 Supercedes: January 2007

Table of Contents

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

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

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

Ambient Air Temperature Limitations.........4

Water Flow Limitations ...............................5

System W ater Volume Considerations.........5 Pre Start-up.................................................54

Variable Speed Pumping..............................5 Start-Up......................................................54

Glycol Solutions ..........................................6 Shutdown ...................................................55

Operating/Standby Limits..........................10 Water Piping Checkout ..............................55

R-407C Units ....................................13

MicroTech II Controller..................15

Controller Section Table of Contents.........15

Overview....................................................16

General Description...................................16

Setpoints ....................................................18

Logging......................................................20

Control Logic............................................. 21

Chilled Water Pump Control......................22

Compressor Control...................................22

Condenser Fan Control..............................26

Low Ambient Startup.................................28

Evaporator Pressure Control......................29

Optional Low Ambient VFD......................29

Using the Controller...................................39

Building Automation System Interface (BAS)

....................................................................53

Startup..............................................54

Refrigerant Piping Checkout......................55

Electrical Check Out..................................56

Operation .........................................56

Hot Gas Bypass (Optional) ........................56

VFD Low Ambient Control (Optional)......57

Filter-Driers................................................57

System Adjustment.....................................57

Liquid Line Sight Glass .............................57

Refrigerant Charging..................................57

Thermostatic Expansion Valve...................58

Crankcase Heaters......................................58

Evaporator..................................................58

Phase Voltage Monitor (Optional)..............58

Our facility is ISO 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.

2 AGZ 026B through 130B OM AGZ-1

Introduction

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 air-cooled condensers with integral subcooler sections, two tandem or triple scroll compressors, brazed-plate or 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 thermal expansion valves. Other features include compressor crankcase heaters, an evaporator heater for chilled water freeze protection, limited pumpdown during “on” or “off” periods, automatic compressor lead-lag to alternate the compressor starting sequence, and sequenced starting of compressors.

The electrical control center includes all equipment protection and operating controls necessary for dependable automatic operation. Condenser fan motors are protected in all three phases and started by their own three-pole contactors.

This manual covers units with software version AGZDU0102C. Installation, maintenance and service information is in IMM AGZ-7 (or current latest dash number) manual.

BOOT Version 3.0F BIOS Version 3.56

Air-Cooled

Global

Scroll Compressor

Nomenclature

A G Z - XXX B S

Application S= Standard Ambient, Packaged M= Standard Ambient, Remote H= High Ambient, Packaged B= High Ambient, Remote

Design Vi ntage

Model Size (Nominal Tons)

OM AGZ-1 AGZ 026B through 130B 3

Ambient Air Temperature Limitations

Standard/High Ambient Panels

Models AGZ-B (26 to 130 tons, two circuit) have electrical data and subsequent field wiring requirements that are tailored to individual applications.

There are many installations where the expected summer ambient air temperatures will be at 105°F (40.1°C) or less, resulting in smaller unit electrical requirements compared to operation at 106°F (41.1) and above. In these lower temperature cases, there can be considerable installation cost savings by using smaller and more appropriate electrical service.

Therefore, the AGZ electrical data is divided into two classifications based on the design ambient temperature where the unit will operate. Standard Ambient unit electrical data (BS and BM models) is for operation in ambient temperatures of 105°F (40.1°C) or less. Units with the High Ambient designation (BH and BB models) are for use above 105°F (40.1°C) to 125°F (51.7°C).

The AGZ-B units for high ambient operation require the addition of the High Ambient Control Panel Option, which includes the addition of a small fan with a filter in the air intake to cool the control panel, and a unit nameplate that lists the larger electrical requirements.

All units with the optional VFD low ambient fan control automatically include the High Ambient Control Panel Option. Operation of the VFD generates a quantity of panel heat best removed by use of a control panel fan.

Winter Operation Temperatures

0°F to 34°F 35°F and Above

Fan Control Optional High VFD (1) Standard FanTrol (2) Design Ambient Air Temperature

Electrical Data (3)

≤105°F >106°F ≤105°F >106°F Standard

Ambient

High Ambient

Standard Ambient

High Ambient

Panel Fan Required (4) Yes Yes No Yes Model Designator (5)

Packaged BS BH BS BH Remote Evaporator BM BB BM BB

NOTES

1. VFD is variable speed, fan control through the MicroTech Ii controller.

2. FanTrol is fan cycling off discharge pressure.

3. Standard Ambient and High Ambient electrical data is located in the installation and

maintenance manual.

4. The VFD option automatically includes the factory-installed panel fan and filter set

5. The designator is the last two characters in the model number, i.e. AGZ 100BS.

Panel Ratings

Vo ltage

208-230

240

380-460

575

Standard

Standard Options

Panel

Optional

VFD

High Short Circuit

Panel (kA)

High Interrupt Panel w/

Disconnect Swt. (kA)

35 5 120 120 35 5 100 100 35 5 65 65

5 5 25 25

4 AGZ 026B through 130B OM AGZ-1

Water Flow Limitations

The evaporator flow rates and pressure drops shown on page 11 are for full load design purposes in order to maintain proper unit control. The maximum flow rate and pressure drop are based on a 6degree temperature drop. Avoid higher flow rates with resulting lower temperature drops to prevent potential control problems resulting from very small control bands and limited start up/shut off temperature changes.

The minimum flow and pressure drop is based on a full load evaporator temperature drop of 16-degrees. Evaporator flow rates below the minimum values can result in laminar flow causing freeze-up problems, scaling and poor control. Flow rates above the maximum values will result in unacceptable pressure drops and can cause excessive erosion, potentially leading to failure.

This full load minimum flow is not to be confused with the part load minimum flow rat e that must be maintained for chillers operating in primary variable flow pumping systems. As chiller capacity drops, the flow rate for this pumping system will reduce proportionally. See the following table for the part load minimum flo w rates.

These minimum flow rates assume that flow will be reduced proportionally to the cooling load.

Table 1, Minimum Part Load Flow Rates

AGZ Model 026 030 035 040 045 050 055 060 065

Minimum Part

Load Flow (GPM)

AGZ Model 070 075 085 090 100 110 120 130

Minimum Part

Load Flow (GPM)

26 29 32 37 41 45 50 55 59

63 71 119 128 146 161 180 194

System Water Volume Considerations

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 not greater than 10 percent of the change per minute.

The water flow through the vessel must remain between the minimum and maximum values listed on

11. If flow drops below the minimum allowable, large reductions in heat transfer can occur. If

page the flow exceeds the maximum rate, excessive pressure drop and tube erosion can occur.

OM AGZ-1 AGZ 026B through 130B 5

Glycol Solutions

The use of a glycol/water mixture in the evaporator to prevent freezing will reduce system capacity and efficiency, as well as 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

Table 2 through Table 5.

from

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

Table 2 through Table 5 to determine the increased evaporator flow due to glycol. If the flow is unknown, it can be calculated from the following equation:

(gpm) Flow Glycol FactorCorrectionFlow

For Metric Applications

– Use the following equation for metric applications:

(l/s) Flow Glycol

CapacitykW

Delta

−×=18.4

3. Pressure drop -- Multiply the water pressure drop from page

correction factor from

Table 2 through Table 5. 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

through

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 or that additional compatible inhibitors be added.

Concentrations above 35 percent do not provide any additional burst protection and should be carefully considered before using.

glycolCapacityTons

)(24

−

TDelta

FactorCorrectionFlow

)

11 by Pressure Drop

Table 2

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.

Table 2, Ethylene Glycol Factors for Models AGZ 026B to 070B

% E.G. Capacity Power Flow PD

10 20 30 40 50

Freeze Point

26 -3.3 0.998 0.998 1.036 1.097 18 -7.8 0.993 0.997 1.060 1.226

7 -13.9 0.987 0.995 1.092 1.369

-7 -21.7 0.980 0.992 1.132 1.557

-28 -33.3 0.973 0.991 1.182 1.791

Table 3, Propylene Glycol Factors for Models AGZ 026B to 070B

% P.G. Capacity Power Flow PD

10 20 30 40 50

Freeze Point

26 -3.3 0.995 0.997 1.016 1.100 19 -7.2 0.987 0.995 1.032 1.211

9 -12.8 0.978 0.992 1.057 1.380

-5 -20.6 0.964 0.987 1.092 1.703

-27 -32.8 0.952 0.983 1.140 2.251

6 AGZ 026B through 130B OM AGZ-1

Table 4, Ethylene Glycol Factors for Models AGZ 075B to 130B

% E.G. Capacity Power Flow PD

10 20 30 40 50

Freeze Point

26 -3.3 0.994 0.998 1.038 1.101 18 -7.8 0.982 0.995 1.063 1.224

7 -13.9 0.970 0.992 1.095 1.358

-7 -21.7 0.955 0.987 1.134 1.536

-28 -33.3 0.939 0.983 1.184 1.755

Table 5, Propylene Glycol Factors for Models AGZ 075B to 130B

% P.G.

10 20 30 40 50

Freeze Point

26 -3.3 0.988 0.996 1.019 1.097 19 -7.2 0.972 0.992 1.035 1.201

9 -12.8 0.951 0.987 1.059 1.351

-5 -20.6 0.926 0.979 1.095 1.598

-27 -32.8 0.906 0.974 1.142 2.039

Capacity Power Flow PD

Altitude Correction Factors

Performance tables are based at sea level. Elevations other than sea level affect the performance of the unit. The decreased air density will reduce condenser capacity consequently reducing the unit's performance. For performance at elevations other than sea level, refer to

Table 6 and Table 7.

Evaporator Temperature Drop Factors

Performance tables are based on a 10°F (5°C) temperature drop through the evaporator. Adjustment factors for applications with temperature ranges from 6°F to 16°F (3.3°C to 8.9°C) are in Table 7.

Table 6 and

Temperature drops outside this 6°F to 16°F (3.3°C to 8.9°C) range can affect the control system's capability to maintain acceptable control and are not recommended.

The maximum water temperature that can be circulated through the evaporator in a non-operating mode is 100°F (37.8°C).

Fouling Factor

Performance tables are based on water with a fouling factor of

As fouling is increased, performance decreases. For performance at other than 0.0001 (0.0176) fouling factor, refer to

Foreign matter in the chilled water system will adversely affect the heat transfer capability of the evaporator and could increase the pressure drop and reduce the water flow. Maintain proper water treatment to provide optimum unit operation.

per ARI 550/590-98.

)/0176.0(/0001.0

kWCmorBTUFhrft °×°××

OM AGZ-1 AGZ 026B through 130B 7

Table 6, Capacity and Power Derates, Models AGZ 026 to 070

Fouling Factor

Altitude

Sea

Level

2000 feet

4000 feet

6000 feet

Chilled Water Delta T

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

6 3.3 0.978 0.993 0.975 0.991 0.963 0.987 0.940 0.980

8 4.4 0.989 0.996 0.986 0.994 0.973 0.990 0.950 0.983 10 5.6 1.000 1.000 0.996 0.999 0.984 0.994 0.961 0.987 12 6.7 1.009 1.003 1.005 1.001 0.993 0.997 0.969 0.990 14 7.7 1.018 1.004 1.014 1.003 1.002 0.999 0.978 0.991 16 8.9 1.025 1.007 1.021 1.006 1.009 1.001 0.985 0.994

6 3.3 0.977 1.001 0.973 1.000 0.961 0.996 0.938 0.989

8 4.4 0.987 1.006 0.984 1.004 0.971 1.000 0.948 0.993 10 5.6 0.998 1.009 0.995 1.007 0.982 1.003 0.959 0.996 12 6.7 1.007 1.011 1.004 1.010 0.991 1.006 0.967 0.998 14 7.7 1.014 1.014 1.011 1.013 0.998 1.009 0.974 1.001 16 8.9 1.022 1.016 1.018 1.014 1.005 1.010 0.981 1.003

6 3.3 0.973 1.011 0.970 1.010 0.957 1.006 0.935 0.998

8 4.4 0.984 1.014 0.980 1.013 0.968 1.009 0.945 1.001 10 5.6 0.995 1.019 0.991 1.017 0.979 1.013 0.955 1.005 12 6.7 1.004 1.021 1.000 1.020 0.987 1.016 0.964 1.008 14 7.7 1.011 1.024 1.007 1.023 0.994 1.018 0.971 1.011 16 8.9 1.018 1.027 1.014 1.026 1.002 1.021 0.978 1.014

6 3.3 0.969 1.021 0.966 1.020 0.954 1.016 0.931 1.008

8 4.4 0.980 1.026 0.977 1.024 0.964 1.020 0.942 1.013 10 5.6 0.989 1.029 0.986 1.027 0.973 1.023 0.950 1.015 12 6.7 0.998 1.033 0.995 1.031 0.982 1.027 0.959 1.020 14 7.7 1.007 1.036 1.004 1.034 0.991 1.030 0.967 1.022 16 8.9 1.014 1.037 1.011 1.036 0.998 1.031 0.974 1.024

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

8 AGZ 026B through 130B OM AGZ-1

Table 7, Capacity and Power Derates, Models AGZ 075 to 130

Fouling Factor

Altitude

Sea

Level

2000 feet

4000 feet

6000 feet

8000 feet

Chilled Water

Delta T

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

6 3.3 0.990 0.997 0.976 0.994 0.937 0.983 0.868 0.964

8 4.4 0.994 0.998 0.981 0.995 0.942 0.984 0.872 0.965 10 5.6 1.000 1.000 0.987 0.996 0.947 0.986 0.877 0.967 12 6.7 1.005 1.001 0.991 0.997 0.951 0.986 0.881 0.968 14 7.7 1.009 1.002 0.995 0.998 0.955 0.987 0.884 0.968 16 8.9 1.013 1.004 1.000 1.000 0.960 0.989 0.889 0.970

6 3.3 0.987 1.005 0.974 1.002 0.934 0.991 0.865 0.972

8 4.4 0.992 1.006 0.979 1.003 0.940 0.992 0.870 0.973 10 5.6 0.997 1.008 0.984 1.004 0.944 0.994 0.875 0.975 12 6.7 1.002 1.009 0.989 1.005 0.949 0.994 0.879 0.975 14 7.7 1.007 1.011 0.993 1.007 0.953 0.996 0.883 0.977 16 8.9 1.011 1.012 0.998 1.008 0.958 0.997 0.887 0.978

6 3.3 0.985 1.014 0.972 1.010 0.933 0.999 0.864 0.980

8 4.4 0.991 1.015 0.977 1.012 0.938 1.001 0.869 0.981 10 5.6 0.995 1.016 0.982 1.013 0.943 1.002 0.873 0.982 12 6.7 1.000 1.018 0.987 1.014 0.947 1.003 0.877 0.984 14 6.8 1.005 1.019 0.991 1.015 0.951 1.004 0.881 0.985 16 8.9 1.009 1.021 0.995 1.017 0.955 1.006 0.884 0.987

6 3.3 0.982 1.023 0.969 1.020 0.930 1.009 0.861 0.989

8 4.4 0.988 1.025 0.975 1.022 0.935 1.010 0.866 0.991 10 5.6 0.992 1.026 0.979 1.022 0.940 1.011 0.870 0.992 12 6.7 0.997 1.028 0.984 1.024 0.944 1.013 0.875 0.994 14 7.7 1.002 1.029 0.989 1.025 0.949 1.014 0.879 0.995 16 8.9 1.006 1.031 0.992 1.027 0.952 1.016 0.882 0.996

6 3.3 0.979 1.034 0.966 1.031 0.927 1.019 0.859 1.000

8 4.4 0.984 1.036 0.971 1.032 0.932 1.021 0.863 1.002 10 5.6 0.990 1.037 0.976 1.033 0.937 1.022 0.868 1.002 12 6.7 0.993 1.039 0.980 1.035 0.941 1.024 0.871 1.004 14 7.7 0.998 1.041 0.985 1.037 0.945 1.026 0.875 1.006 16 8.9 1.003 1.041 0.990 1.038 0.950 1.026 0.879 1.007

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

Evaporator Freeze Protection

Evaporator freeze-up can be a concern in the application of air-cooled water chillers. To protect against freeze-up, insulation and an electric heater cable are furnished with the unit. This protects the evaporator down to -20°F (-29°C) ambient air temperature. Although the evaporator is equipped with freeze protection, it does not protect water piping external to the unit or the evaporator itself if there is a power failure or heater cable burnout. Consider the following recommendations for additional protection.

1. If the unit will not be operated during the winter, drain evaporator and chilled water

piping and flush with glycol. Drain and vent connections are provided on the evaporator to ease draining.

2. Add a glycol solution to the chilled water system to provide freeze protection.

Freeze point should be approximately ten degrees below minimum design ambient temperature.

3. The addition of thermostatically controlled heat and insulation to exposed piping.

4. Continuous circulation of water through the chilled water piping and evaporator.

OM AGZ-1 AGZ 026B through 130B 9

The evaporator heater cable is factory wired to the 115-volt circuit in the control box. This power should be supplied from a separate source, but it can be supplied from the control circuit. Operation of the heater cable is automatic through the ambient sensing thermostat that energizes the evaporator heater cable for protection against freeze-up. Unless the evaporator is drained in the winter, the disconnect switch to the evaporator heater must not be open.

Operating/Standby Limits

Maximum standby ambient air temperature, 130°F (55°C) Maximum operating ambient air temperature Standard Ambient Unit, 105°F (40.6°C) and below, Models BS and BM High Ambient Unit, above 105°F (40.6°C) to 125°F 51.7°C), Models BH and BB Minimum operating ambient temperature (standard), 35°F (2°C) Minimum operating ambient temperature (with optional low-ambient control), 0°F (-

18°C) Leaving chilled water temperature, R-22, 40°F to 60°F (4.4°C to 15.6°C) Leaving chilled water temperature, R-407C, 42°F to 60°F (5.5°C to 15.6°C) Leaving chilled fluid temperatures (with anti-freeze), 20°F to 60°F (-7°C to 16°C Design chilled water Delta-T range, 6 degrees F to 16 degrees F (3.3 degrees C to 8.9

degrees C) Part load minimum flow for variable flow systems, varies with unit size, see table

below. Maximum operating inlet fluid temperature, 76°F (24°C) Maximum non-operating inlet fluid temperature, 100°F (38°C)

Water Flow Limitations, Variable Flow

The full load, minimum flow limitation for constant flow is not to be confused with the part load minimum flow rate that must be maintained for chillers operating in primary variable flow pumping systems. As chiller capacity drops, the flow rate for this pumping system will reduce proportionally. See the following table for the part load minimum flo w rates.

Other design practices for variable flow systems requiring a range of evaporator flow rates can be found below.

These minimum flow rates assume that flow will be reduced proportionally to the cooling load.

Table 8, Minimum Part Load Flow Rates

AGZ Model 010 013 017 020 025 029 034 026 030 035 040 045

Minimum

Part Load

Flow (GPM)

AGZ Model 050 055 060 065 070 075 085 090 100 110 120 130

Minimum

Part Load

Flow (GPM)

10 13 15 20 22 27 33 26 29 32 37 41

45 50 55 59 63 71 119 128 146 161 180 194

10 AGZ 026B through 130B OM AGZ-1

Figure 1, AGZ 026B – 130B, Evaporator Pressure Drop

040

045

050

055

026-030

065-070

035

075-085-090

120-130

060

100-110

AGZ Unit

Model

026B 030B 035B 040B 045B 050B 055B 060B 065B 070B 075B 085B 090B 100B 110B 120B 130B

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

Inch-Pound S.I. Inch-Pound S.I. Inch-Pound S.I.

gpm DP ft. lps DP kpa gpm DP ft. lps DP kpa gpm DP ft. lps DP kpa

41 1.6 2.6 4.7 65 3.9 4.1 11.6 109 10.4 6.9 30.9 45 1.9 2.9 5.7 72 4.7 4.6 14.1 121 12.7 7.6 37.8 50 1.9 3.1 5.6 80 4.6 5.0 13.8 133 12.4 8.4 36.9 58 1.9 3.6 5.7 92 4.7 5.8 14.0 154 12.6 9.7 37.5 64 1.8 4.0 5.4 102 4.5 6.4 13.4 170 12.1 10.7 35.9 71 1.8 4.4 5.4 113 4.5 7.1 13.3 188 12.0 11.9 35.7 78 1.8 4.9 5.3 125 4.4 7.9 13.0 209 11.7 13.2 34.8 86 1.7 5.4 5.2 137 4.3 8.6 12.8 228 11.5 14.4 34.2 92 1.6 5.8 4.9 147 4.1 9.3 12.1 246 10.9 15.5 32.5

98 1.9 6.2 5.6 157 4.6 9.9 13.7 262 12.3 16.5 36.8 111 5.6 7.0 16.5 177 12.5 11.2 37.4 295 30.4 18.6 90.7 119 6.3 7.5 18.9 191 14.3 12.1 42.7 318 34.8 20.1 103.6 128 7.2 8.1 21.4 205 16.2 12.9 48.4 342 39.4 21.6 117.3 146 2.6 9.2 7.7 234 6.1 14.8 18.2 390 15.5 24.6 46.2 161 3.1 10.2 9.2 258 7.3 16.3 21.7 430 18.5 27.1 55.1 180 3.5 11.3 10.4 288 8.9 18.1 26.5 479 24.6 30.2 73.4 194 4.1 12.2 12.1 311 10.4 19.6 30.9 518 28.7 32.7 85.6

proper unit control.

OM AGZ-1 AGZ 026B through 130B 11

Minimum Nominal Maximum

Figure 2, AGZ 026B – AGZ 130B, Typical Field Wiring

3 PHASE

POWER

DISCONNECT

(BY OTHERS)

UNIT MAIN

TERMINAL BLOCK

GND LUG

TO COMPRESSOR(S)

AND FAN MOTORS

NOTE: ALL FIELD WIRING TO BE INSTALLED AS NEC CLASS 1 WIRING SYSTEM WITH CONDUCTOR RATED 600 VOLTS

FIELD SUPPLIED

REMOTE STOP SWITCH

(BY OTHERS)

ICE MODE SWITCH

(BY OTHERS)

ALARM BELL

OPTION

CHW FLOW SWITCH

---MANDATORY–(BY OTHERS)

OPTION

CONTROL POWER

120VAC

FACTORY SUPPLIED ALARM

FIELD WIRED

ALARM BELL RELAY

TIME

CLOCK

FUSED CONTROL

CIRCUIT TRANSFORMER

DISCONNECT (BY OTHERS)

10A

FUSE

(BY OTHERS)

CHW PUMP RELAY

120 VAC 1.0 AMP MAX

OFF

AUTO

MANUAL

OFF

AUTO

MANUAL

(BY OTHERS)

120 VAC

CONTROLLER

TB1

TB2

TB1-20

1 2

CONTROL

CIRCUIT

FUSE

120 VAC

GND

IF REMOTE STOP

52 72

43 83

CONTROL IS USED, REMOVE LEAD 585

585

FROM TERM. 52 TO 72.

BELL

ALARM BELL OPTION

ALARM BELL

RELAY

COM NO

NOR. OPEN PUM P AUX. CONTACTS (OPTIONAL)

44 61

4-20MA FOR

EVAP. WATER RESET

(BY OTHERS)

4-20MA FOR

DEMAND LIMIT

(BY OTHERS)

DWG. 330423101 REV.0A

LESS EVAPORATOR ONLY

LIQUID LINE #1 SOLENOID

24 VAC 1.5 AMP MAX

LIQUID LINE #2 SOLENOID

24 VAC 1.5 AMP MAX

GND

24 VAC

12 AGZ 026B through 130B OM AGZ-1

R-407C Units

AGZ chillers are available with R-407C refrigerant as non-ARI certified units. R-407C is a zeotropic blend of three compounds, and as such exhibits the characteristic of glide. It does not behave as one substance like R-22 does. Glide is the difference (in degrees F) between the beginning and end phase-change process in either the evaporator or condenser. During these processes, different ratios of the refrigerant’s components change phase from the beginning to the end of the process. The following functions, conditions and settings will differ from units charged with R-22.

1. Polyolester lubricants are used instead of mineral oil.

2. The saturated pressure/temperature relationship

3. Control and alarm settings

4. Charging procedures

1. Lubrication. The units are factory-charged with polyoester (POE) lubricant and one of

the following lubricants must be used if lubricant is to be added to the system:

Copeland Ultra 22 CC Mobil EAL™ Arctic 22 CC ICI EMKARATE RL RL™ 32CF

POEs are very hydroscopic and will quickly absorb moisture if exposed to air. Pump the lubricant into the unit through a closed transfer system. Avoid overcharging the unit.

2. Pressure/temperature relationship. See

temperature chart. Due to refrigerant glide, use the following procedures for superheat and subcooling measurement.

To determine superheat, only vapor must be present at the point of measurement, no liquid. Use the temperature reading, the pressure reading and the Saturated P/T Chart. If the pressure is measured at 78 psig, the chart shows the saturated vapor

50.6°F. If the temperature is measured at 60°F, the superheat is 9.4 degrees F. To determine subcooling, only liquid must be present, no vapor. Use the temperature

reading, the pressure reading and the Saturated P/T Chart. If the pressure is measured at 250 psig, the chart shows the saturated liquid temperature is measured at 98°F, the subcooling is 10.2 degrees F.

The P/T relationship between R-407C and R-22 is similar enough to allow the use of R-22 expansion valves. The valves may be marked as “R-22’ or “R-22/R-407C”.

3. Control and alarm settings. The software that controls the operation of the unit is

factory-set for operation with R-407C, taking into account that the pressure/temperature relationship differs from R-22. The software functionality is the same for either refrigerant.

4. Charging procedure. The units are factory-charged with R-407C. Use the following

procedure if recharging in the field is necessary: Whether topping off a charge or replacing the circuit’s entire charge, always remove the

refrigerant from the charging vessel as a liquid. Many of the cylinders for the newer refrigerants have a dip tube so that liquid is drawn off when the cylinder is in the upright position. Do not vapor charge out of a cylinder unless the entire contents will be charged into the system.

Figure 3 on page 14 for the saturated pressure-

temperature to be

temperature to be 108.2°F. If the

With the system in a 250-micron or lower vacuum, liquid can be charged into the high side. Initially charge about 80 percent of the system total charge.

OM AGZ-1 AGZ 026B through 130B 13

Start the system and observe operation. Use standard charging procedures (liquid only) to top off the charge.

It may be necessary to add refrigerant through the compressor suction. Because the refrigerant leaving the cylinder must be a liquid, exercise care to avoid damage to the compressor. A sight glass can be connected between the charging hose and the compressor. It can be adjusted to have liquid leave the cylinder and vapor enter the compressor.

Figure 3, R-407C Saturated Pressure/Temperature Chart

Pressure

(PSIG)

20 -10.7 1.5 150 74.8 84.9 22 -8.2 4.0 155 76.8 86.8 24 -5.7 6.4 160 78.7 88.7 26 -3.4 8.7 165 80.6 90.5 28 -1.1 11.0 170 82.5 92.3 30 1.1 13.1 175 84.3 94.0 32 3.2 15.2 180 86.1 95.8 34 5.3 17.2 185 87.8 97.5 36 7.3 19.2 190 89.6 99.1 38 9.2 21.0 195 91.3 100.7 40 11.1 22.9 200 92.9 102.3 42 12.9 24.7 205 94.6 103.9 44 14.7 26.4 210 96.2 105.4 46 16.4 28.1 215 97.7 107.0 48 18.1 29.7 220 99.3 108.4 50 19.7 31.3 225 100.8 109.9 52 21.3 32.9 230 102.3 111.4 54 22.9 34.4 235 103.8 112.8 56 24.4 35.9 240 105.3 114.2 58 25.9 37.4 245 106.7 115.6 60 27.4 38.8 250 108.2 116.9 62 28.8 40.2 255 109.6 118.2 64 30.2 41.6 260 111.0 119.6 66 31.6 43.0 265 112.3 120.9 68 33.0 44.3 270 113.7 122.1 70 34.3 45.6 275 115.0 123.4 72 35.6 46.9 280 116.3 124.7 74 36.9 48.1 285 117.6 125.9 76 38.2 49.3 290 118.9 127.1 78 39.4 50.6 295 120.2 128.3 80 40.6 51.8 300 121.4 129.5 82 41.9 52.9 305 122.7 130.7 84 43.0 54.1 310 123.9 131.8 86 44.2 55.2 315 125.1 133.0 88 45.4 56.3 320 126.3 134.1 90 46.5 57.4 325 127.5 135.2 92 47.6 58.5 330 128.7 136.3 94 48.7 59.6 335 129.8 137.4 96 49.8 60.7 340 131.0 138.5

98 50.9 61.7 345 132.1 139.6 100 51.9 62.7 350 133.2 140.6 105 54.5 65.2 355 134.3 141.7 110 57.0 67.7 360 135.4 142.7 115 59.5 70.0 365 136.5 143.7 120 61.8 72.3 370 137.6 144.7 125 64.1 74.6 375 138.7 145.7 130 66.4 76.7 380 139.8 146.7 135 68.5 78.8 385 140.8 147.7 140 70.7 80.9 390 141.8 148.7 145 72.8 82.9 395 142.9 149.6

Liquid Temp

(°F)

Vapor Temp

(°F)

Pressure

(PSIG)

Liquid Temp

(°F)

Vapor Temp

(°F)

14 AGZ 026B through 130B OM AGZ-1

MicroTech II Controller

Software Version AGZDU0102B

Controller Section Table of Contents

Overview.............................................................................. 16

Inputs/Outputs ................................................................. 16

Setpoints ......................................................................... 18

Shutdown Alarms ............................................................ 19

Limit Alarms................................................................... 20

Control Logic.................................................................. 21

Compressor Control .......................................................22

Condenser Fan Control.................................................... 26

Using the Controller ............................................................. 30

Getting Started...................................................................... 39

Menu Screens.................................................................. 39

Menu Matrix ................................................................... 42

View Screens Defined ..................................................... 43

Alarm Screens Defined.................................................... 46

Set Screens Defined ........................................................ 46

Building Automation Systems (BAS)...............................53

OM AGZ-1 AGZ 026B through 130B 15

Overview

MicroTech II controller’s state-of-the-art design not only permits the chiller to run more efficiently, but also can simplify troubleshooting if a system failure occurs. Every MicroTech II controller is programmed and tested prior to shipment to facilitate startup.

Operator-friendly

The MicroTech II controller menu structure is separated into three distinct categories that provide the operator or service technician with a full description of 1) current unit status, 2) control parameters, and 3) alarms. Security protection prevents unauthorized changing of the setpoints and control parameters.

MicroTech II control continuously performs self-diagnostic checks, monitoring system temperatures, pressures and protection devices, and will automatically shut down a compressor or the entire unit should a fault occur. The cause of the shutdown will be retained in memory and can be easily displayed in plain English for operator review. The MicroTech II chiller controller will also retain and display the date/time the fault occurred. In addition to displaying alarm diagnostics, the MicroTech II chiller controller also provides the operator with a warning of limit (pre-alarm) conditions.

General Description

AGZ-B Inputs/Outputs

Table 9, Analog Inputs

No. Description Type Signal Source Range

1 Evaporator Refrigerant Pressure #1 C1 0 to 132 psi 2 Evaporator Refrigerant Pressure #2 C2 0 to 132 psi 3 Condenser Refrigerant Pressure #1 C1 3.6 to 410 psi 4 Leaving Evaporator Water Temperature UT NTC Thermister (10k@25°C) -58 to 212°F 5 Outside Ambient Temperature UT NTC Thermister (10k@25°C) -58 to 212°F 6 Condenser Refrigerant Pressure #2 C2 3.6 to 410 psi

7 Reset of Leaving Water Temperature UT 4-20 mA Current 8 Demand Limit UT 4-20 mA Current 0-100 % Load

9 Compressor Suction Temperature #1 C1 NTC Thermister (10k@25°C) -58 to 212°F

10 Compressor Suction Temperature #2 C2 NTC Thermister (10k@25°C) -58 to 212°F

NOTES:

1. C1 = Refrigerant Circuit #1, C2 = Refrigerant Circuit #2, UT = Unit

2. Value at the converter board input. Value at the converter board output is 0.1 VDC – 0.9 VDC.

0.5 - 4.5 VDC (NOTE 2)

0.1 to 0.9 VDC

Table 10, Analog Outputs

No. Description Output Signal Range

1 Fan #1 VFD 0 to 10 VDC 20 to 60 Hz 2 Fan #2 VFD 0 to 10 VDC 20 to 60 Hz

0 to10 degrees

60°F max inlet

16 AGZ 026B through 130B OM AGZ-1

Table 11, Digital Inputs

# Description Type Signal Signal

1 Unit OFF Switch UT 0 VAC (Disable) 24 VAC (Enable) 2 Pump Down Switch #1 C1 0 VAC (Disable) 24 VAC (Enable) 3 Evaporator Water Flow Switch UT 0 VAC (No Flow) 24 VAC (Flow) 4 Open 5 Open 6 Pump Down Switch #2 C2 0 VAC (Disable) 24 VAC (Enable) 7 Open 8 Open

9 Phase Voltage Fault #1 (See Note 1) C1 0 VAC (Fault) 24 VAC (No Fault) 10 Phase Voltage Fault #2 (See Note 1) C2 0 VAC (Fault) 24 VAC (No Fault) 11 Ground Fault Prot. #1 (See Note 2 Below) C1 0 VAC (Fault) 24 VAC (No Fault) 12 Ground Fault Prot. #2 (See Note 2 Below) C2 0 VAC (Fault) 24 VAC (No Fault) 13 Remote Start/Stop UT 0 VAC (Disable) 24 VAC (Enable) 14 Open 15 Mechanical High Pressure/Motor Protect

Circuit 1

16 Mechanical High Pressure/Motor Protect

Circuit 2 17 Ice Mode Switch UT 0 VAC (Cool) 24 VAC (Ice) 18 Open

NOTES:

1. See Safety Alarms Table for “Phase Voltage Protection”. Units with single point electrical connection

will have one PVM with Inputs 9 and 10 wired together. Units with multiple point connection will have two PVM’s with Input 9 for Electrical Circuit #1 and Input 10 for Electrical Circuit #2.

C2 0 VAC (Fault) 24 VAC (No Fault)

2. See Safety Alarms

Table 14 for “Ground Fault Protection”. Units with single point electrical connection will have one GFP with Inputs 11 and 12 wired together. Units with multiple point connection will have two GFP’s with Input 11 for Electrical Circuit #1 and Input 12 for Electrical Circuit #2.

Table 12, Digital Outputs

No. Description Type Load Output OFF Output ON

1 Alarm C1,C2,UT Alarm Indicator Alarm OFF Alarm ON 2 Evaporator Water Pump UT Pump Contactor Pump OFF Pump ON 3 Condenser Fan #1 C1 Fan Contactor Fan OFF Fan ON

Motor Control Relay #1 =

Compr#1 Motor Control Relay #3 =

Compr#3 Motor Control Relay #5 =

Compr#5 7 Liquid Line #1 C1 Solenoid Cooling OFF Cooling ON 8 Condenser Fan #2 C2 Fan Contactor Fan OFF Fan ON

Motor Control Relay #2 =

Compr#2

Motor Control Relay #4 =

Compr#4

Motor Control Relay #6 =

Compr#6

12 Liquid Line #2 C2 Solenoid Cooling OFF Cooling ON 13 Condenser Fan #3 C1 Fan Contactor Fan OFF Fan ON 14 Hot Gas Bypass #1 C1 Solenoid Cooling OFF Cooling ON 15 Hot Gas Bypass #2 C2 Solenoid Cooling OFF Cooling ON 16 Condenser Fan #4 C2 Fan Contactor Fan OFF Fan ON

Condenser Fan #5 ( on 8

Fans Only)

Condenser Fan #6 ( on 8

Fans Only)

C1 Starter Compressor OFF Compressor ON C1 Starter Compressor OFF Compressor ON C1 Starter Compressor OFF Compressor ON

C2 Starter Compressor OFF Compressor ON C2 Starter Compressor OFF Compressor ON C2 Starter Compressor OFF Compressor ON

C1 Fan Contactor Fan OFF Fan ON C2 Fan Contactor Fan OFF Fan ON

OM AGZ-1 AGZ 026B through 130B 17

Setpoints

The setpoints shown in Table 13 are retained by battery-back-up and remembered during power off, are factory set to the Default value, and can be adjusted within the values shown in Range. The PW (password) column indicates the password. Passwords are as follows: O = Operator =0100 M = Manager=2001

Table 13, Setpoints

Description Default Range PW

Unit Enable OFF OFF, ON O Unit Mode COOL COOL, COOL w/Glycol, ICE w/Glycol, TEST O Control source DIGITAL IN KEYPAD, BAS, DIGITAL INPUT O

Available Modes COOL Cool LWT O

Ice LWT O Evap Delta T O Startup Delta T O Stop Delta T O Max Pulldown Rate M Evap Recirculate Timer 30 15 to 300 sec M Low Ambient Lockout M Demand Limit No No,Yes M * Refrigerant Select None R22, R407c -* Multipoint Power No No,Yes M Ice Time Delay 12 1 to 23 hrs. Clear Ice Delay No No, Yes Protocol Modbus BACnet, LonWorks, Modbus M Ident number (Modbus only) 001 001-999 M Baud rate (Modbus only) 9600 1200,2400,4800,9600,19200 M

Compressor

* Number of Compressors 4 4,6 M Stage Up Delay 240 90 to 480 sec M Stage Down Delay 30 20 to 60 sec M Start-Start 15 min 10 to 60 min M Stop-Start 5 min 3 to 20 min M Clear Cycle Timers No No,Yes M

Alarms

Low Evap Pressure-Hold, R22 59 psi Glycol =31 to 65 psi Cool=55 to 65 psi M Low Evap Pressure-Hold,R407c 60 psi Glycol =26 to 75 psi Cool=58 to 75 psi M Low Evap Pressure-Unload,R22 58 psi Glycol =31 to 65 psi Cool=55 to 65 psi M Low Evap Pressure-Unload,R407 59 psi Glycol =26 to 75 psi Cool=58 to 75 psi M High Condenser Stage Down 370 psi 365 to 380 psi M High Condenser Pressure 385 psi 385 to 390 psi M Evaporator Water Freeze M * Phase Voltage Protection No No,Yes M * Ground Fault Protection No No,Yes M Evap Flow Proof 3 sec 1 to 10 sec A

Condenser Fans

VFD Enable No No,Yes M * Number of Fans 4 4,6,8 M

Stage Down 2 Deadband 6 to 10 F M

VFD Max Speed 100% 90 to 110% M VFD Min Speed 25% 25 to 60% M Sat Condenser Temp Target 100 M Forced Fan 1 1 1 to # Fans Per Circuit M Forced Fan 2 2 1 to # Fans Per Circuit M Forced Fan 3 3 1 to # Fans Per Circuit M

(*) These items are factory set prior to shipment.

44. 0°F 20.0(40.0) to 60.0 °F

40. 0°F 20.0 to 40.0 °F

10. 0°F 6.0 to 16.0 °F

10.0°F 1.0 to 15.0 °F

0.5°F 0.5 to 3.0°F

1.0°F 0.2 to 5.0 °F

35 °F –2 to 70°F

38.0 °F 18(37) to 42°F

15°F 10°F 10°F 15°F 15°F 10°F 10°F

COOL, COOL w/GLYCOL, COOL/ICE

w/GLYCOL, ICE w/GLYCOL. TEST

15 to 25oF Stage Up 2 Deadband M 10 to 15oF Stage Up 3 Deadband M 10 to 15oF Stage Up 4 Deadband M 15 to 20oF Stage Down 0 Deadband M 10 to 15oF Stage Down 1 Deadband M

6 to 10oF Stage Down 3 Deadband M

90 to 120°F

18 AGZ 026B through 130B OM AGZ-1

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