ag ha iom eng

7/29/2019 AG HA IOM Eng

1/8

303 C - 99/04 AInstallation manual

Date: April 1999

AG HA 030.2110.2

Air cooled water chillers

Serial number:

Supersedes: None


2/8

303 C - 99/04 A - pag. 2

Index

Chapter 1 - Introduction1.1.0. Purpose of the manual1.2.0. Responsabilities declined

Chapter 2 - Manual content2.1.0. General description2.2.0. Characteristics2.2.1. Technical characteristics2.2.2. Electrical characteristics2.2.3. Water flow limits2.2.4. Water temperature limits2.2.5. Pressure limits2.2.6. Drawings and wiring diagrams2.3.0. Safety measures2.3.1. General cautions2.3.2. Cautions and specific warnings2.3.2.1. Lifting2.3.2.2. Access to the unit2.4.0. Installation

2.4.1. Warnings2.4.1.1. Transport2.4.1.2. Inspection2.4.2. Handling

2.4.3. Location2.4.3.1. Clearance requirements2.4.4. Water piping2.4.4.1. General2.4.4.2 Chilled water piping2.4.4.3. Condenser water piping2.4.5. Testing2.4.6. Electrical f ield wiring

2.4.6.1. Field wiring2.5.0. Start up and shut down2.5.1. Control centre layout2.5.2. Pre start-up2.5.3. Start-up2.5.3.1. Warning2.5.3.2. Sequence of start-up2.5.3.3. Warning2.5.4. Emergency stop2.5.5. Temporary shut down2.5.5.1 Warning2.6.0. System maintenance2.7.0. Problems: causes and possible steps

Chapter 1 - Introduction

1.1.0. Purpose of the manualThis manual allows both the installer and the operator to

perform correctly all the operations referring to the installa-

tion and maintenance of the chiller without provoking anydamages to the unit or the qualified personnel.

Therefore the manual is of great help for the qualified per-

sonnel that have to arrange the equipment for providing the

correct installation in accordance with local codes and regu-

lations.

1.2.0. Resposibilities declinedMcQuay Italia declines all present and future resposibilities

referring to injuries to people and damage to things and

unit, coming from negligence of the operators, from the un-

respected installation/maintenance data carried in this ma-

nual, the non-persuance of the current regulations referredto the safety of both the equipment and the qualified per-

sonnel in charge for the installation and maintenance.

Chapter 2 - Manual content

2.1.0. General descriptionMcQuay AG HA air cooled water chillers are manufactured

in order to produce chilled water. Each unit is factory as-

sembled and wired: then it is vacuued, charged with R22,R407C or R134a refrigerant and tested.

The refrigerant circuit consists of a air condenser, scroll

compressors for units from 030.2 to 045.2 and semiherme-

tic compressors from 050.2 to 110.2 C, including a subcoo-

ler, and a shell and tube evaporator. The standard compo-

nents of the liquid line are: stop valve, discharge valve,

dehydrator filters, solenoid valve, sight glass moisture indi-

cator, thermostatic expansion valve.

Morever the following components are included: compres-

sor crankcase heater, pump-down system, microprocessor

with key pad display to control and set up all unit running

conditions. The electrical panel is equipped with all the sa-

fety systems that ensure reliable automatic workings. Themotors of the compressors are equipped with fuses on three

phases and are started by threepole contactors.


3/8

303 C - 99/04 A - pag. 3

2.2.1. Technical characteristics

2.2.0. Characteristics

"AGZ HA ST, CN" unit size 030.2 035.2 040.2 045.2Cooling capacity (HCFC 22) (1)Power input (HCFC 22) (1)

kWkW

97,0

30,0

101,8

40,8

115,8

45,8

128,1

50,8

Cooling capacity (HFC 407C) (1)Power input (HFC 407C) (1)

kWkW

Cooling capacity (HFC 134a) (1)Power input (HFC 134a) (1)

kWkW

94,0

30,0

98,7

40,8

66,0

18,5

69,2

25,1

112,4

45,8

124,3

50,8

78,8

28,2

87,1

31,2

Compressor type/No. of compressorNo. of circuitNo. of reduction steps StandardCondenser fansNo. of fans/Fan motorTotal air flow

kWm3/s

EvaporatorNo. of evaporator

scroll/4

2

scroll/4

2

4 4

scroll/4

2

scroll/4

2

4 4

2/2,1

12,6

2/2,1

12,6

1 1

2/2,1

12,2

2/2,1

12,2

1 1

Max operating pressureWater volume

barl

Condenser coilNo. of coilWeightOperating weight kgShipping weight kg

16

40

16

40

2 2

16

40

16

40

2 2

1520 1520

1480 1480

1520 1520

1480 1480

"AGR HA ST, CN" unit size 050.2 055.2 060.2 065.2 070.2 075.2Cooling capacity (HCFC 22) (1)Power input (HCFC 22) (1)

kWkW

172,7

60,2

185,7

66,3

198,7

72,4

229,2

80,6

260,1

88,8

270,3

89,8


kWkW


kWkW

167,5

60,2

180,1

66,3

117,437,0

126,340,8

192,7

72,4

222,3

80,6

135,144,5

156,049,6

252,3

88,8

262,2

89,8

177,054,6

183,855,2

Compressor type/No. of compressorNo. of circuitNo. of reduction steps StandardCondenser fansNo. of fans/Fan motorTotal air flow

kWm3/s


recip/2

2

recip/2

2

4 4

recip/2

2

recip/2

2

4 4

4/2,1

25,2

4/2,1

25,2

1 1

4/2,1

25,2

4/2,1

25,2

1 1

recip/2

2

recip/2

2

4 4

4/2,1

25,2

4/2,1

25,2

1 1


barl


16

60

16

60

4 4

16

60

16

100

4 4

2310 2310

2245 2245

2310 2310

2245 2245

16

100

16

90

4 4

2310 2310

2245 2245

Note: (1) Nominal cooling capacity are based on: 12/7 C entering/leaving evaporator water temperature; 46C ambient temperature.


4/8

303 C - 99/04 - pag. 4

"AGR HA ST, CN" unit size 080.2 085.2 090.2 095.2 100.2 110.2Cooling capacity (HCFC 22) (1)Power input (HCFC 22) (1)

kWkW

278,0

96,3

295,7

103,8

307,5

104,8

326,1

112,0

336,3

117,4

346,4

122,8


kWkW


kWkW

269,7

96,3

286,8

103,8

189,0

59,2

201,1

63,8

298,3

104,8

316,3

112,0

209,1

64,5

221,7

68,9

326,2

117,4

336,0

122,8

228,7

72,2

235,6

75,5

Compressor type/No. of compressorNo. of circuit

No. of reduction steps StandardCondenser fansNo. of fans/Fan motorTotal air flow

kWm3/s


recip/2

2

recip/2

2

4 4

recip/2

2

recip/2

2

4 4

6/2,1

37,75

6/2,1

37,75

1 1

6/2,1

37,75

6/2,1

37,75

1 1

recip/2

2

recip/2

2

4 4

6/2,1

37,2

6/2,1

36,7

1 1


barl


16

90

10,5

90

4 4

10,5

90

10,5

90

4 4

3110 3110

3025 3025

3110 3500

3025 3415

10,5

90

10,5

90

4 4

3500 3500

3415 3415

Note: (1) Nominal cooling capacity are based on: 12/7 C entering/leaving evaporator water temperature; 46C ambient temperature.

2.2.2. Electrical data

Notes: (1) Allowed voltage tollerance 10%.(2) Absorbed current max. condition.

"AGZ HA ST, CN" (HCFC 22, HFC 407C) 030.2 035.2 040.2 045.2Standard voltageMax absorbed current compressor (FLA) (2) A 53,0

400 V - 3f - 50 Hz (1)72,0 81,0 90,0

Max inrush current bigger compressor ALMax inrush current bigger compressor PW

AA

Total fans absorbed currentMax unit absorbed current

AA

116,0

NA

128,0

NA

7,660,6

7,679,6

159,0

NA

159,0

NA

7,688,6

7,697,6

Max unit inrush current ALMax unit inrush current PW

AA

165,3

NA

186,8

NA

222,0

NA

227,0

NA

"AGR HA ST, CN" (HCFC 22, HFC 407C) 080.2 085.2 090.2 095.2 100.2 110.2Standard voltageMax absorbed current compressor (FLA) (2) A 170,2 183,5

400 V - 3f - 50 Hz (1)185,4 198,0 207,7 217,2


AA


AA

NA

347,0

NA

347,0

22,8

193,0

22,8

206,3

NA

347,0

NA

345,0

22,8

208,2

22,8

220,8

NA

537,0

NA

537,0

22,8

230,5

22,8

240,0


AA

NA

462,5

NA

470,0

NA

470,5

NA

474,5

NA

671,0

NA

676,0

"AGR HA ST, CN" (HCFC 22, HFC 407C) 050.2 055.2 060.2 065.2 070.2 075.2Standard voltageMax absorbed current compressor (FLA) (2) A 106,5 117,3

400 V - 3f - 50 Hz (1)128,0 142,5 157,0 158,8


AA


AA

NA

202,0

NA

247,0

15,2

121,7

15,2

132,5

NA

247,0

NA

286,0

15,2

143,2

15,2

157,7

NA

286,0

NA

286,0

15,2

172,2

15,2

173,0

Max unit inrush current AL

Max unit inrush current PW

A

A

NA

282,0

NA

332,0

NA

337,6

NA

384,0

NA

391,0

NA

392,0


5/8

303 C - 99/04 A - pag. 5

Max operat. press.bar

Pressure testbar

Max operat. press.bar

Pressure testbar

Refrigerant side:

ISPESLTVService des MinesS.A.

16,5 21,516,513,016,5

21,526,021,5

-30,0

-30,0

-37,6

-39,0

Water side:ISPESLTVService des MinesS.A.

10,5 14,010,510,510,5

14,014,014,0

----

----

EVAPORATOR

2.2.5. Pressure limitsCONDENSER COIL

Min. outletwtr temp. - C

Max. inletwtr temp. - C

Standard unitUnit with glycole and low temperature kitUnit with water inlet max. temperature thermostatUnit off

5-8-

191932

- 40

EVAPORATOR

2.2.4. Water temperature limits

See Product Manual 303 B

2.2.3. Water flow limits

"AGZ HA ST, CN" (HFC 134a) 030.2 035.2 040.2 045.2Standard voltageMax absorbed current compressor (FLA) (2) A 32,7

400 V - 3f - 50 Hz (1)44,3 49,9 55,3


AA


AA

116,0

NA

128,0

NA

7,6

40,3

7,6

51,9

159,0

NA

159,0

NA

7,6

57,5

7,6

62,9


AA

155,0

NA

173,0

NA

206,7

NA

209,5

NA

"AGR HA ST, CN" (HFC 134a) 080.2 085.2 090.2 095.2 100.2 110.2Standard voltageMax absorbed current compressor (FLA) (2) A 104,6 112,8

400 V - 3f - 50 Hz (1)114,0 121,7 127,6 133,5


AA


AA

NA

315,0

NA

315,0

22,8

127,4

22,8

135,6

NA

315,0

NA

345,0

22,8

136,8

22,8

144,5

NA

345,0

NA

345,0

22,8

150,4

22,8

156,3


AA

NA

398,0

NA

402,0

NA

402,5

NA

436,3

NA

439,2

NA

442,2

"AGR HA ST, CN" (HFC 134a) 050.2 055.2 060.2 065.2 070.2 075.2Standard voltageMax absorbed current compressor (FLA) (2) A 65,5 72,2

400 V - 3f - 50 Hz (1)78,7 87,6 96,6 97,6


AA


AA

NA

114,0

NA

155,0

15,2

80,7

15,2

87,4

NA

155,0

NA

247,0

15,2

93,9

15,2

102,8

NA

247,0

NA

247,0

15,2

111,8

15,2

112,8


AA

NA

173,4

NA

217,7

NA

221,0

NA

317,5

NA

322,0

NA

322,5

Notes: (1) Allowed voltage tollerance 10%.(2) Absorbed current max. condition.


6/8

303 C - 99/04 A - pag. 6

2.2.6. Drawings and wiring diagramsThe overall dimensional drawings and electrical drawings

are here attached and their reference numbers are those li-

sted on the cover of this manual.

2.3.0. Safety measures

2.3.1. General precautionsThe unit must be placed internally arranged for the clam-

ping to heart of the chiller and if necessary must be equip-ped with anti vibrations shock absorbers. "Warning and

Danger" notices are supplied on the following parts: electri-

cal panel, compressors, safety valves, expansion valves,

compressors liquid line shutoff valves.

2.3.2. Cautions and specific warnings

2.4.0. InstallationBefore any operation please check the instruction for use.

2.4.1. WarningInstallation and maintenance are to be performed only by

qualified personnel who are familiar with local codes and re-

gulations, and experienced with this type of equipment. Theinstallation of the unit in places that could be considered

dangerous for all the maintenance operations must be avoi-

ded.

2.4.1.1. TransportIn order to avoid problems it's necessary to be sure of the

stability of the unit during transportation. This is why the unit

is supplied with a transversal wooden beam placed at the

base that have to be removed only when the unit has arri-

ved at final destination. In case the unit has to be moved

again, it's necessary to adapt a similar solution.

2.4.1.2. InspectionAll units are factory assembled and equipped. Before ship-

ment, units are charged with the necessary quantity of refri-

gerant and oil and tested at working conditions requested

by the client. When the equipment is received, all items

should be carefully checked against the bill of lading to insu-

re a complete shipment. All units should be carefully inspec-

ted for damage upon arrival. All shipping damage should be

reported to carrier and a claim form should be filled.

2.4.2. HandlingIf the unit must be hoisted, it is necessary to lift the unit by

attaching cables or chains at the lifting holes in the evapora-

tor tube sheets. Spreader bars must be used to protect the

fig.1

Size the cables and spreader bars in conjunction with liftingweight.

Use spreader barto avoid damage

to the unit

Use only these rigging holes

WARNING !

Before switching off the power supply performe the stop

procedure reported on paragraph 2.5.5.

DANGER !

No admittance to unauthorized or unqualified personnel.

DANGER !

No operation on electrical components is allowed without

having switched off electricity supply.

DANGER !

Convey the discharge of the safety valves outside the

room

DANGER !

The substitution or addition of oil in the compressors

must be performed by qualified personnel only

DANGER !

No operation is allowed without using insulated platforms

No water or moisture is should be present.

DANGER !

All the operations to refrigerant circuit and vessels, and

all pressurised parts are to be performed by qualified

personnel only

DANGER !

The unit must be lifted only by using the proper tools

able to support the weight of the unit locking it through

the lifting holes

DANGER !

Sharp edges and coil surface are a potential injury ha-

zard. Avoid contact with them

WARNING !

Avoid unrelated bodies into the water piping during the

connection of the unit to the water system

WARNING !

Forsee a mechanical filter for the piping connected to the

entry of the exchangers of the unit

DANGER !

Disconnect all power to the unit while servicing conden-

ser fan motors. Failure to do so may cause bodly injury

or death


7/8

2.4.3.0. LocationA reasonably level and sufficiently strong floor is required in

order to bear the weight of the chiller. If necessary, additio-

nal structural members should be provided to transfer the

weight of the unit to the nearest beams. Rubber-in-shear

isolator (see enclosure drawings) can be furnished and field

placed under each corner of the package. Set the unit in

place and level with a spirit level. Vibration eliminators in all

water piping connected to the chiller are recommended to

avoid straining the piping and transmitting vibrations andnoise.

2.4.3.1. Clearance requirementsEach side of the unit must be accessible after installation

for periodic service work. Clearance should be provided for

cleaning evaporator tubes or for removing compressors. Mi-

nimum recommanded clearance requirements (see enclo-

sure drawings).

2.4.4.0. Water piping

2.4.4.1 General1 - Select piping according to local codes of praticies andsecurity norms.

2 - Shut off valves should be provided at the unit so that

normal servicing can be accomplished without draining the

system.

3 - It's recommended that temperature and pressure indica-

tors be installed at the inlet and outlet of the heat excha-

ngers to and in the normal checking and servicing the unit.

4 - It's recommended the installation of a wire mesh strainer

at the pump suction to protect the pump and the and the ex-

changers from foreign matter.

5 - Before insulating the piping and filling the system, a pre-liminary leak check should be made.

6 - Vibration eliminators are recommended in all lines con-

nected to the unit.

7 - Automatic flow control devices, although not furnished

with the chiller as they are plant components, must be in-

stalled.

8 - Drawings enclosure shows pipe connection sizes.

2.4.4.2. Chilled water piping(Evaporator)The water flow entering the evaporator on the connection

close the electrical panel and leaving on opposite connec-tion. Design the piping so that it has a minimum number of

elevation changes.

Include manual or automatic vent valves at the high points

of the chilled water piping, so that air can be sented from

the water circuit. System pressure can be maintened by

using an expantion tank or a combination pressure relief

and reducing valve. (see par. 2.2.5).

All chilled water piping should be insulated to prevent con-

densation on the lines. If insulation is not of the self contai-

ned vapor barrier type, it should be covered with a vapor

seal. Piping should not be insulated until completly leak te-

sted.

2.4.5 Testing

Check the proper installation of the unit respecting the regu-

lations referred to safety. Check the proper lead of the pi-

ping considering the water inlet/outlet of the evaporator, on

the condensers

2.4.6 Electrical Field wiring(see wiring diagram enclosure)

2.4.6.1 Field wiring

The unit's electrical panel has a terminal block board to lead

a 3-pole cable with ground of adequate gross section for the

motor rating, to the main cutout switches. If the main cutout

switch is installed the line must be connected to its terminal

block board. To provide power to the main cutout, if there is

no transformer, it's necessary to provide monophase power

to terminal block 1 a 2.

Power inlet must be effected on the upper side of the elec-

trical panel through a plate with references for the cables.

2.5.0. Start up and shut down

2.5.1. Control centre layout(see wiring diagram enclosure)

2.5.2. Pre start-up

1 - With main disconnect switch Q10 open, check all the

electric connection in control panel and starter to be sure

they are fight and provide good electrical contact. Althoughs

connections are thightned at the factory, they many have

last enough in shipment to cause a malfunction.

2 - Verify that the switches Q10, are to the OFF position.

3 - Check and inspect all water piping. Make sure flow di-

rection is correct and piping is made to correct connectionon evaporator and condenser.

4 - Check for inlet/outlet piping proper connections as indi-

cated on the exchangers.

5 - Open all water flow valves to the condenser and evapo-

rator.

6 - Start pumps (evaporator) and flush the piping to be sure

the system is clear.

7 - Check all pipings for leaks. Vent the air from the evapo-

rator and condenser water circuit. The cooler circuit should

contain clean, non corrosive water.

8 - Is water regulating valves are provided, connect their ca-pillary to the manual valves provided on the condensers

and open the manual valves.

303 C - 99/04 A - pag.

WARNING !

Inside the electrical panel there is a yellow/green termi-

nal block to lead the unit to the ground. Perform the con-

nection in accordance with the local regulations.

WARNING !

The power tension must fluctuate more than 10%. The

balance between the phases must not be greater than

3%. Condenser and evaporator flow switches must be

connected to the following terminals:

Evaporator flow switch: terminal 5 and 6.


8/8

303 C - 99/04 A - pag. 8

9 - Check pressure drop across evaporator and condenser,

and see that water flow is correct for the design flow rates

and date.

10 - Only for AG 050.2110.2. Check compressor oil level.

Prior to start-up the oil level should cover at least one - third

of the sightglass.

11 - check the actual line voltage to the unit to make sure it

is the same as called for on the compressor nameplate wi-

thin 10% and that the phase voltage unbalance doesn't exceed 3%.

12 - Verify that adeguate power supply and capacity is avai-

lable to handle load.

13 - Make sure all wiring and fuses are of the proper size.

Also make sure all interlock wiring is completed per

McQuay diagrams.

14 - Make sure all auxiliary load and control equipment is

operative and that an adeguate cooling load is available for

initial start-up.

2.5.3.0. Start-up

2.5.3.1. WarningInitial start-up to be performed only by McQuay autorized

Service organization. This is a must to obtain full warranty

benefits.

2.5.3.2. Start-up sequences

2.5.3.3.1 - Open the compressors suction (if available) and dischar-

ge shut-off valves (until backseated) always replace sealcaps.

2 - Open the manual liquid line shut-off valve.

3 - Check to see that the unit circuit breakers are is the OFF

position.

4 - Check to see that the switch Q0 is in the OFF position.

5 - Check to see that the switches Q1 and Q2 are in OFF

position.

6 - Put the main switch in ON position

7 - Put the switch Q12 to ON position in order to power the

crankcase electric motors.

8 - Verify crankcase heaters have operated for at least 8

hours prior to start-up. Crankcase should be warm.

9 - Verify the chilled water temperature set point on the mi-

croprocessor controller by the following procedure: press

the push button "SET" on the key pad. Select on the display

the "chilled water" function by using the UP/DOWN cursor.

Push the "ENTER" button, check if the set point of the lea-

ving water temperature is OK. If you need to adjust the va-

lue use the "UP/DOWN" cursor to increase/decrease the

value. Push "ENTER" button and "MENU" button to return

the first menu.

10 - Switch the Q1 and Q2 switches on ON.

11 - Start the system by pushing the system switch Q0 to

the ON position on local or remote control (position I or II).

12 - After running the unit for a short time, check the level in

each compressor crankcase, and check for flashing in the

refrigerant sightglass.

2.5.3.4 Microprocessor informationFor further informations about all the function and set point

available on the microprocessor controller see the operating

manual.

2.5.4.0 Emergency stop

A red switch Q11 is provided on control box, to allow the

unit emergency stop in case of false alarm, the unit be re-

started following this procedure:

1 - Move switch Q10 to the OFF position.

2 - Reset emergency stop switch Q11.

3 - Repeat start-up procedure from beginning.

2.5.5.0. Temporary shut-down

Move switchs Q1 and Q2 to the OFF position. After pump

down, turn OFF the chilled water pump.

2.5.5.1.2.6.0. Maintenancefor maintenance please refer only to the McQuay authori-

zed Service organization.

2.7.0. Trouble shooting:causes and corrective stepsIn case the chiller should not work, verify the following:

1 if the power is on

2 if the water flow is on

3 if the cooling capacity is on

Refer to the authorized personnel is none of the abovementioned points are the cause of the troubleshooting.

McQuay Italia S.p.A. - S.S. Nettunense, km 12+300 - 00040 Cecchina (Roma) Italia - Tel. (06) 93 7311- Fax (06) 93 74 014

WARNING !

Start-up must be performed by specialized personnel.

WARNING !

By this operation compressors heaters de-energized. It is

important to complete compressors pump-down cycle

prior to close the chiller water flow to avoid freezing.

ag ha iom eng

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