McQuay MAC 150 CR, MAC 080 CR, MAC 120 CR, MAC 150 C, MAC 100 C User Manual

...

Air-Cooled Mini Chiller

MAC-C-2004

Models: MAC 080 C/CR

MAC 100 C/CR MAC 120 C/CR MAC 150 C/CR

M4AC 080 C/CR M4AC 100 C/CR M4AC 120 C/CR M4AC 150 C/CR

Contents

Nomenclature.................................................................................................................. 2

General Features and Specifications...................................................................... 2 - 3

Chiller Panel Controller .......................................................................................... 4 - 35

Specifications ........................................................................................................ 36 - 39

Performance Table ................................................................................................ 40 - 45

Technical Data ....................................................................................................... 46 - 47

Outlines and Dimensions...................................................................................... 48 - 50

Wiring Diagrams .................................................................................................... 51 - 54

Special Precautions for R407C............................................................................. 55 - 56

Installation ............................................................................................................. 57 - 61

Servicing and Maintenance ......................................................................................... 62

Troubleshooting ........................................................................................................... 63

Schematic Diagram ...................................................................................................... 64

Parts List and Exploded View............................................................................... 65 - 66

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,

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

Warning: Moving machinery and electrical power hazards. May cause severe personal injury or death.

Disconnect and lock off power before servicing equipment.

2003 McQuay International

"Bulletin illustrations cover the general appearance of McQuay International products at the time of publication

and we reserve the right to make changes in design and construction at any time without notice."

Nomenclature

M 4AC080 C R

Brand Name _ R22 Equipment Air Cooled Norminal Generation (McQuay) 4 R407C Equipment Chiller Cooling _ Cooling

Capacity R Heating

General Features and Specifications

Refrigerant circuit

The unit has been designed with two separate refrigerant circuits, i.e. it has two compressors. By doing so, the unit has part loading capabilities, i.e. 0-50-100% of rated capacity. This will improve the reliability and energy efficiency of the unit, especially during low loading operations. Each circuit is factory brazed and evacuated before accurately charged with refrigerant to ensure optimum performance. Because each circuit is separated, there is no danger of crosscontamination should either one of the compressors experiences a burnt-up. Each circuit is also equipped with a carefully sized thermostatic expansion valve (for cooling only units) to give optimum performance characteristics. For the heat pump versions, the expansion process is done with capillary tubes.

Scroll compressors are used in the unit to give quiet and reliable performance over a wide operating temperature range. However, in order to protect the compressors from damage, a phase protector is provided to prevent the compressors from rotating in the wrong direction.

Condenser Fan Motor

The unit is equipped with two high air flow propeller fan blades which are made of metal. The fans are directly driven by weather proof motors, the motors are of single phase type.

Evaporator

The heat exchanger is made of stainless steel plates closely arranged and brazed together (BPHE) to ensure high heat exchange efficiency. The water flows through the BPHE in a channel on its own, while because of the two compressors, the refrigerant flows through another two separate channels. The refrigerant will either be in a counter-flow or parallel-flow with respect to the water, depending on the mode of operation (cooling or heating).

Safety Protection

The safety protections provided for in the chiller unit are:

a) High and low pressure switches b) Differential water flow switch c) Compressor, water pump and fan motor overload protectors d) Anti-freeze protection sensor

During abnormal condition, the electronic controller will turn off the unit and then display the fault of operation.

Other than that, the unit also has pressure gauges (analog) for each compressor suction and discharge pipes. These are useful for detecting abnormal operating conditions, especially during maintenance services.

Water buffer tank & pipe connection

The unit does not come with a water buffer tank. However, the unit does come with an 8 liters expansion tank. (A 135L water tank is available as optional item)

The external water piping connection can be made either from the left or right side of the unit. Connection is done with I1-1/4” female thread couplings for both supply and return pipes.

Anti-freeze protection

The chiller unit has several anti-freeze protection features:

1. Brazed plate heat exchanger anti-freeze The BPHE has a strip heater around it to prevent water freezing inside.

2. Auto mode The chiller controller will force-on the unit to the heat mode if the outdoor ambient air temperature

becomes too cold.

Maintenance

In order to facilitate maintenance of the controller, a rocker switch is provided to power-off the supply to the PCB. However, switching off this switch will not disconnect the main incoming power supply to the chiller unit.

Coil Guard

The unit also comes with two sets of coil guards (i.e. on the left and right side coils). Each guard is basically a metal mesh which protects the coil from damage due to a side impact on the coil surface itself.

Fin Coating

The finned tube heat exchanger coil used on the chiller unit is made of staggered rows of 3/8” seamless copper tubes, mechanically expanded into die-formed louvered fins. The slit openings on the fins enhance the heat transfer coefficient between the fin surfaces and air.

In order to protect these fins from corrosion, a special fin coating (gold fin) is applied on the surface. This coating is standard on the heat pump version, whereas it is an option on the cooling only model.

Chiller Panel Controller

1. SAFETY CONSIDERATION

Only specially trained and qualified technicians and installers are authorized to install and service this equipment.

1.1 General Installation Recommendations

x Only supply DC voltage (9-17V, typically 12V, maximum current 200mA) as a power source to the device. x Input contact voltage supply should limit to 12VDC or 24VAC. x Isolated all the low voltage wiring (communication bus, etc.) from high voltage power supply wiring.

2. GENERAL DESCRIPTION

2.1 General

The Chiller Panel Controller is designed to control the Chiller operation. This device allows the user to have customized control for each connected unit.

2.2 Features

The requirements of user friendly and easy to use have been taken into account in designing this Chiller Panel Controller. It can do the task as follow:

x Whole system configuration x Unique parameter settings x Operation status display x Tracing fault record (easy in hardware troubleshooting)

The display is shown in an 8-line graphical LCD display. There are 8 dedicated keys available in the panel, which allow user to do the following task:

x Menu selection x Navigation on the screen x Modification of the selected value

During first start-up, the panel will have a default configuration (timer schedule, set point, miscellaneous settings, etc). User can do the changes on that particular configuration later.

2.3 Panel Position

The Chiller Panel Controller can be installed anywhere, as long as it is easy to accessed by authorized personnel. The requirements of installation are:

x Avoid exposure to shocks x Avoid any source of electromagnetic pollution x Avoid installation on uneven vertical surface

2.4 Operation Environmental Condition

x Temperature:

-10ºC to 65ºC Operating Temperature

-20ºC to 85ºC Storage Temperature

x Relative Humidity:

0 to 95% Non - Condensing

3. HARDWARE DESCRIPTION

Legend

Front View

Back View

1 & 2 Navigation key

3 Execute instruction key

4 Cancel instruction key

5 Switching to Heat mode shortcut key

6 Switching to Cool mode shortcut key

7 Toggle ON/OFF shortcut key

8 Show alarm key

9 Graphical LCD display

10 ON/OFF indicator

Legend

Chiller terminal unit connection

1 & 2

Not available

CMOS reset jumper (JH2)

4 5

Chiller bus resistor configuration (JH3)

Not available

Backup battery

3.1 Key Explanation

The 2 navigation keys permit item selection and modifying the selected value.

ENTER key is used to execute the navigation instruction

ESC key is used to cancel the navigation instruction

Shortcut key to switch the operation mode in the Summary Pages

Shortcut key to trigger ON/OFF in the Summary Pages

Shortcut key to show fault / alarm in the Summary Pages

4. INSTALLATION

4.1 Chiller Bus

orted up to 50 units of Chille

Chiller 0 Chiller 1 Chiller 2

Chiller Panel 0

(Master)

Chille

(Slave)

Panel 1

5 way wire (CN8)

Chille Communication bus

CHILLER NETWORK

Chiller panel needs to be energized with +12Vdc. The 5 way wires that provided is once on the easiest solution to establish a communication between the panel and chiller main board (CN8-CN8). If the 5-way wires socket has been occupied in main board, just using 2 insulation wires connected to the +12Vdc and GND terminal block from main board to panel can still energize a panel. Beside that, another 2 insulation wired are needed to establish a communication between panel and chiller main board.

Chiller panel can support maximum up to 50 units of chiller. In the chiller network, duplication of main board unit address is not allowed. Each chiller main board should have their unique unit address (0 – 50). For first time running, user need to assign a unique unit address to each main board in the chiller network. User should follow the procedure below:

x Only power ON one main board at once time. Make sure not others main boards are energized. x By using the panel connected to the main board.

Summary Pages Main Menu Settings Menu

<ENTER>

1. General Set ParameterG7 Unit No

<ENTER>

Key in a unique unit address and press ENTER to execute.

x x De-energized the main board and repeat the procedures again until all the main boards have been assigned a unique unit

<ENTER> Key in “0001” as password

address

IMP ORT A NT : Do not assign a same unit address to more than one chiller main board.

RECOMMENDATION: Please select a coherent model (G1 Model) to all the chiller main boards in the same network

4.2 Others Configuration

x JH2 in Chiller panel should let it open (put the jumper header on one pin only) all the time unless user need to

do CMOS reset to that particular panel.

x JH3 should let it open (put the jumper header on one pin only) all the time as well. x Remember to put in the coin cell battery on the panel. Without the backup battery, the panel will always reset

the time to 12:00am, 1st Jan 2000.

4.3 Installation of the Chiller Panel Controller

x Disconnect the unit and ensure no others unit energy source that supplies the panel. x Open the rear panel of the Chiller Panel (insert a ‘flat-head’ screwdriver in the top joint of main casing with

rear panel to open the rear panel)

x Pass the necessary wires of the panel across the large opening in the rear panel. Place the rear panel flat

support against the wall and make marks on the wall through the four installation holes (inner or outer).

x Drill four appropriate holes in the marked places. x Attach the rear panel to the wall and put on the screws on it. Ensure that all cables are passed through the

hole of the rear panel.

x Connect the wires to the corresponding terminal according to the wiring bus network. The power supply and

communication wires must be correctly connected to ensure that the panel works.

x Close the Chiller panel (ensure the bottom joint is aligned for the casing, then complete others joint part.

Ensure that the contacts at the back of the panel are aligned with each others)

BUS WIRING NETWORK

5. SOFTWARE DESCRIPTION

5.1 Introduction

The Chiller Panel Controller can be used to control/display the status of Chiller.

Status viewing:

x ON/OFF status x Mode (Cooling/Heating/Boiling) x Mode set temperature x Compressor status (ON/OFF/DEFROST) x Water in, Water out, Outdoor air and Panel temperature x Chiller Model (Chiller, Heat Pump, Chiller/Boiler, Chiller+Boiler, Heat Pump/Boiler, Heat Pump+Boiler) x Advance Parameter settings x Defrost sensor temperatures x Compressor Discharge sensor temperatures x Compressor run times x Incoming alarm/fault/error

Status settings:

x ON/OFF switching x Mode setting (Cooling/Heating/Boiling) x Mode set temperature x Manual entering defrost x Advance Parameter settings x Password changing x Panel Option setting (Backlight, Alarm Buzzer, Screen saver, Contrast, Brightness, temperature unit) x Time and Date settings x 7 day programmable settings x Clearing compressor run time

5.2 Menu Structure

Menu Structure Diagram for Chiller

5.3 Chiller Menu Structures

[00]

5.3.1 Summary Pages There are 4 pages in [Summary Pages]. Press UP or DOWN for page scrolling. Press ENTER to go into [Main Menu].

Time and date are shown on top of each page. Beside that, the bottom of each page shows current control unit of the Chiller.

For example: [00] – Chiller Panel controls Chiller ID 0 currently

[03] – Chiller Panel controls Chiller ID 3 currently [All] – Chiller Panel controls all Chiller currently

1st page: Display ON/OFF status, Mode Settings and Temperature settings.

01/01/2000 12:00am

Status : ON

Mode : Cooling

Cool Temp : 12.0ºC

2nd page: Display Compressor status.

01/01/2000 12:00am

Compressor 1 : ON

3rd page : Display Water In, Water Out, Outdoor Air and Panel temperatures.

01/01/2000 12:00am

Water In : 19.8ºC Water Out : 25.6ºC Outdoor Air : 32.2ºC Panel : 20.5ºC

4th page : Display Chiller model, Compressor No. and Chiller ID.

01/01/2000 12:00am

Model : Chiller

No. Comp : 1 Comp

Unit No. : 0

5.3.2 Main Menu

Press ENTER in [Summary Pages] to go into this menu.

Operating Menu

Setting Menu Timer Menu Alarm Menu Displa

MAIN MENU

Operation Menu MAIN MENU

There are 5 sub menus in [Main Menu]. Press UP or DOWN to select sub menus, ENTER to enter into the sub menu or press ESC to exit to [Summary Pages].

5.3.2.1 Operation Menu Select [Operation Menu] in [Main Menu] and press ENTER to go into this menu.

OPERATION MENU

Status :ON

Mode : Cooling Cool Temp : 12.0ºC Heat Temp : 40.0ºC

OPERATION MENU

Some normal settings can be found here. Press UP or DOWN to select each settings, ENTER to start the setting or press ESC here to exit to [Main Menu].

Settings: - ON/OFF unit

- Mode changing (Cooling/Heating/Boiling)

- Cooling temperature setting

- Heating temperature setting

- Manual Defrost Selection

Comp 1

5.3.2.1.1 Manual Defrost

Select [Manual Defrost] in [Operation Menu] and press ENTER to go into this menu.

Defrost Compressor

Comp 1

This menu lets user select one compressor to enter into defrost cycle manually, as long as the environment fulfill the defrost requirement.

5.3.2.2 Settings Menu

Select [Settings Menu] in [Main Menu] and press ENTER to go into this menu.

SETTINGS MENU Set Parameter

Change Password Panel Option Set Panel ID

Operation Menu MAIN MENU

Some advance settings can be found here. Press UP or DOWN to select each settings, ENTER to start the setting or press ESC here to exit to [Main Menu].

Settings: - Set Parameter

- Password Changing

- Panel Option

- Set Panel ID

5.3.2.2.1 Set Parameter

Select [Set Parameter] in [Settings Menu] and press ENTER to go into this menu.

1.General

2. Sensor

3. Regulator

4. Compressor

5. Defrost

6. Antifreeze

7. Alarm and Contact

Comp 1

There are 7 groups of advance parameters for user to set in this menu. Press UP or DOWN to select the group, ENTER to go into the group or ESC to exit to [Setting Menu].

Settings: - General

- Sensor

- Regulator

- Compressor

- Defrost

- Antifreeze

- Alarm and Contact

5.3.2.2.2 Password Changing

Select [Password Changing] in [Settings Menu] and press ENTER to go into this menu.

Please enter the old password………

- - - -

User can change the old password in this menu.

Press ESC to exit to [Settings Menu].

5.3.2.2.3 Panel Option Select [Panel Option] in [Settings Menu] and press ENTER to go into this menu.

Operation Menu MAIN MENU

User can do some miscellaneous settings for the panel. These settings would not affect whole system performance.

Settings - toggle Backlight

Press ESC to exit to [Settings Menu].

5.3.2.2.4 Set Panel ID Select [Set Panel ID] in [Settings Menu] and press ENTER to go into this menu.

Backlight : Normal

Buzzer : On Screen Saver : Disable Timeout : 5m Contrast : 50% Brightness : Medium Temp Unit : ºC

- Alarm Buzzer

- Enable/Disable Screen Saver

- Screen Saver timeout

- Contrast display

- Backlight brightness

- Temperature unit

Please enter the0 Panel ID...

=> Unit 0

User can assign the ID no. to the panel. Example: If ID no. 0 has been assigned, the panel acts like Master Panel Unit. It can choose to control each

Chiller in the network.

If other ID no. (1-50) has been assigned, the panel acts like Slave Panel Unit. It is dedicated to one particular Chiller. It can only control the Chiller with same ID in the network.

Press [ESC] to exit to [Settings Menu].

5.3.2.3 Timer Menu Select [Timer Menu] in [Main Menu] and press ENTER to go into this menu.

TIMER MENU

Clock Setting

Date Setting Timer Schedule Timer : Disable

Operation Menu MAIN MENU

All the timer/schedule settings are included in this menu. Press UP or DOWN to select each settings, ENTER to start the setting or press ESC here to exit to [Main Menu].

Settings: - Set Clock

- Set Date

- Set Schedule (7 days Programmable Timer)

- Enable/Disable Timer Schedule

5.3.2.3.1 Set Clock Select [Clock Setting] in [Timer Menu] and press ENTER to go into this menu.

Set Time :

hh mm

00 : 00

User can set the time in this menu. The time setting is in 24-hour format.

Press [ESC] to exit to [Timer Menu].

5.3.2.3.2 Set Date Select [Date Setting] in [Timer Menu] and press ENTER to go into this menu.

Operation Menu MAIN MENU

User can set the date in this menu. The date is set according to sequence below:

Press [ESC] to exit to [Timer Menu].

5.3.2.3.3 Set Schedule Select [Schedule Timer] in [Timer Menu] and press ENTER to go into this menu.

Set Date :

yyyy mm dd

2000 / 01 / 01

(year) / (month) / (day)

Timer 1 Timer 2

ON OFF ON OFF

Sun 0800 1600 - - - - - - - - -

Mon 0800 1600 - - - - - - - - Tue 0800 1600 - - - - - - - - Wed 0800 1600 - - - - - - - - -

This is the 7 days programmable timer schedule menu. There are 2 ON/OFF events in one day. User can choose to set each day of week (Sunday – Saturday) ON/OFF timer. Before this schedule carry their effect to the Chiller, user need to set the [Timer] in [Timer Menu] to enable.

Press [ESC] to exit to [Timer Menu].

5.3.2.4 Alarm Menu Select [Alarm Menu] in [Main Menu] and press ENTER to go into this menu.

ALARM MENU

Show Alarms

Erase All Alarms

This place keeps records for all previous occurred fault/alarms. User can view the alarm history and clear that record (alarm history) as well. The panel can keep up to 20 fault/alarm records.

Press ESC to exit to [Main Menu].

5.3.2.4.1 Show Alarms Select [Show Alarms] in [Alarm Menu] and press ENTER to go into this menu.

Operation Menu MAIN MENU

Alarm 1

[Ch 0]

Comp 1 overload

01/ 01 / 00 12:00am

User can view all the fault/alarm records in this menu.

The record shows - Alarm type

- Alarm occurred date

- Alarm occurred time

- Alarm occurred unit (Chiller ID)

Beside that, user can erase the alarm record in this menu.

Press [ESC] to exit to [Alarm Menu].

5.3.2.4.2 Erase All Alarms Select [Erase All Alarms] in [Alarm Menu] and press ENTER to go into this menu.

Are you sure ?

Press Enter to erase, or ESC to exit

User can erase all the alarm/fault records at once in this menu.

Press [ESC] to exit to [Alarm Menu].

5.3.2.5 Display Menu Select [Display Menu] in [Main Menu] and press ENTER to go into this menu.

DISPLAY MENU

Detrost Sensor

Discharge Sensor Comp Run Time

This menu displays Defrost Sensor temperature, Compressor Discharge sensor temperature and Compressor Run Time. Beside that, user can clear each Compressor Run Time for Chiller.

Press ESC to exit to [Main Menu].

Operation Menu MAIN MENU

5.3.2.5.1 Defrost Sensor Select [Defrost Sensor] in [Display Menu] and press ENTER to go into this menu.

Defrost Sensor

Cimo 1 : 12.8ºC

User can view the defrost sensor temperature for each compressor in the Chiller.

Press [ESC] to exit to [Display Menu].

5.3.2.5.2 Discharge Sensor Select [Discharge Sensor] in [Display Menu] and press ENTER to go into this menu.

Discharges Sensor

Comp 1 : 36.5ºC

User can view the discharge sensor temperature for each compressor in the Chiller.

Press [ESC] to exit to [Display Menu].

5.3.2.5.3 Comp Run Time

Select [Comp Run Time] in [Display Menu] and press ENTER to go into this menu.

Comp Run Time

Comp 1 : 13579h

User can view the compressor run time for each compressor in the Chiller. Beside that, user can clear each compressor run time in this menu. User needs to key in the correct password before clearing the compressor run time.

Press [ESC] to exit to [Display Menu].

6. OPERATION USER MANUAL

6.1 Starting

Chiller panel can be set as Master or Slave panel unit. When the Panel ID is set to ‘0’, it acts like a Master panel, whereas it is Slave panel if Panel ID is set to others number (1-50).

Chiller panel can control the Chiller if both ID no. (Panel ID and Chiller ID) are same.

For example: Panel ID 1 can only control Chiller ID 1

Master Panel can choose to control each Chiller or control all Chiller at once in the network.

For example: Panel ID 0 (master) can control Chiller ID 0 / ID 1 / ID 32…. or all Chillers at once.

Panel ID can be set in Set Panel ID in Settings Menu:

Please enter the Panel ID….

=> Unit 0

6.2 Chiller Operation Control

[00]

6.2.1 Starting

During power on for the Chiller Panel, it needs to take several times to collect information from the Chiller. At this time, all the status will show ‘--’. Please ensure the particular Chiller exists in the network. When the process is completed, user can start to control the Chiller using the panel.

01 / 01 /2000 12:00am

Status : --

Mode : --

Cool Temp : --

01 / 01 /2000 12:00am

Status : ON

Mode : Cooling

Cool Temp : 12.0ºC

In gathering information process Gathering information completed

6.2.2 Changing Display Unit

Chiller Panel (Master) can choose to control/display each Chiller status. This can be done in [Summary Pages] only.

01 / 01 /2000 12:00am

Status : ON

Mode : Cooling

Cool Temp : 12.0ºC

In [Summary Pages], press and hold ENTER button (1 second) to go into [Unit Selection] menu.

Unit Selection :

Select All

Select One : 0

Unit Selection :

Select All

Select One : 0

Select “Select All” and press ENTER if user want to control all Chiller in the network, or select

“Select One” to control a particular Chiller. Press ESC to exit to [Summary Pages].

Select a Chiller ID via UP or DOWN and press ENTER to confirm or ESC to cancel.

6.2.3 Switching ON/OFF

There are several ways to switch ON/OFF for the Chiller.

i) [Summary Pages]

Press and hold ON/OFF button (hold 1 second). Please note that the ON/OFF button will only function in [Summary Pages].

ii) [Operation Menu]

Summary Pages Main Menu Operation Menu

OPERATION MENU

Status :ON

Mode : Cooling Cool Temp : 12.0ºC Heat Temp : 40.0ºC

OPERATION MENU

Status : ON

Mode : Cooling Cool Temp : 12.0ºC Heat Temp : 40.0ºC

iii) [Timer Menu]

In [Operation Menu], select “Status” and press ENTER.

Toggle ON/OFF via UP or DOWN button, and then press ENTER to confirm the change or ESC to cancel.

Main Menu Timer MenuSummary Pages

7 days programmable timer can turn chiller ON/OFF. User can set the schedule in this [Timer Menu]. Please refer 6.2.11 (page 27) for schedule settings.

+ 47 hidden pages

McQuay MAC 150 CR, MAC 080 CR, MAC 120 CR, MAC 150 C, MAC 100 C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual