McQuay AGS 120CS/H Installation And Maintenance Manual
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McQuay AGS 120CS/H Installation And Maintenance Manual

Air-cooled screw compressor chiller 60 hertz, r-134a
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Installation and Maintenance Manual
Air-Cooled Screw Compressor Chiller
AGS 120CS/H - AGS 210CS/H, Packaged
AGS 120CM/B – AHS 210CM/B, Remote Evaporator
60 Hertz, R-134a
IMM AGS-2
Group: Chiller
Part Number: 331373301
Date: July 2008
Supersedes: March 2008

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  • Page 1 Installation and Maintenance Manual IMM AGS-2 Group: Chiller Part Number: 331373301 Date: July 2008 Supersedes: March 2008 Air-Cooled Screw Compressor Chiller AGS 120CS/H - AGS 210CS/H, Packaged AGS 120CM/B – AHS 210CM/B, Remote Evaporator 60 Hertz, R-134a...

  • Page 2: Table Of Contents

    © 2004 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. ®™ The following are trademarks or registered trademarks of their respective companies: BACnet from ASHRAE; L ARK and from Echelon Corporation;...

  • Page 3: Introduction

    Check the unit’s serial plate before unloading the unit to be sure that it agrees with the power supply available. Physical damage to unit after acceptance is not the responsibility of McQuay International.

  • Page 4: Installation And Start-Up

    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 McQuayService is included on all units sold for installation within the USA and Canada and must be performed by them to initiate the standard limited product warranty.

  • Page 5: Location

    Location Locate the unit carefully to provide proper airflow to the condenser. (See Figure 2 on page 6 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 condensing pressure and performance.

  • Page 6: Clearance Requirements

    Clearance Requirements Figure 2, Clearance Requirements, AGS 120C – AGS 210C No obstructions. Recommended area required for unit operation, air flow and maintenance 5ft (1.5m) if open fence or 50% open wall access. 6ft (1.8m) if solid wall (see note 3 for pit) 4ft (1.2m) For electric panel access...

  • Page 7: Restricted Airflow

    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. •...
  • Page 8 Case 1, Building or Wall on One Side of One Unit 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.
  • Page 9 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.
  • Page 10 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.
  • Page 11 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.
  • Page 12 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 sales office 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.

  • Page 13: Vibration Isolators

    Initially installed the unit on shims or blocks at the illustrated "free height" of the isolator that is six inches for the McQuay isolators shown. When all piping, wiring, flushing, charging, etc. is complete, adjust the springs upward to load them and to provide clearance to free the blocks, which are then removed.
  • Page 14 Table 1, Dimensions MODEL 36.00 136.60 12.00 21.00 57.30 174.60 165.60 71.49 186.60 36.00 168.85 12.00 21.00 69.25 212.80 203.80 86.54 224.80 36.00 136.60 12.00 21.00 57.30 174.60 165.60 71.49 186.60 36.00 168.85 12.00 21.00 69.25 212.80 203.80 86.54 224.80 36.00 136.60 12.00...
  • Page 15 Table 4, Lifting & Mounting Weights, Remote Evaporator, Aluminum Fins, AGS-CM/B Lifting Weights Mounting Weights Operating Shipping Weight Weight L1, L2 L3, L4 MM1, MM2 M3, M4 MM5, MM6 3029 1374 1021 1780 1521 8100 3674 8100 3674 3169 1437 1307 1938 1659...
  • Page 16 Table 6, Spring Vibration Isolators, Aluminum Fin, AGS-CS/H Mounting Location Model Kit Number CP2-28 CP2-28 CP2-28 CP2-28 CP2-27 CP2-27 330904101 GREEN GREEN GREEN GREEN ORANGE ORANGE CP2-31 CP2-31 CP2-31 CP2-31 CP2-28 CP2-28 330904102 GRAY GRAY GRAY GRAY GREEN GREEN CP2-28 CP2-28 CP2-28 CP2-28...
  • Page 17 Table 8, Spring Vibration Isolators, Copper Fin, AGS-CS/H Mounting Location Model Kit Number CP2-31 CP2-31 CP2-31 CP2-31 CP2-28 CP2-28 330904102 GRAY GRAY GRAY GRAY GREEN GREEN CP2-32 CP2-32 CP2-31 CP2-31 CP2-31 CP2-31 330904105 WHITE WHITE GRAY GRAY GRAY GRAY CP2-31 CP2-31 CP2-31 CP2-31...
  • Page 18 CP-2-32 White 226103B-00 (2) 226120A-00 (1180) (12.7) (259.1) (228.6) (195.6) (68.6) (146.0) Table 11, Neoprene-in-Shear Isolators Dimensions Max. Load Defl. McQuay In. (mm) Type Each In. (mm) Part Number Lbs. (kg) D (1) 1500 0.25 3.75 0.56 0.25 216398A-04 RP-4...

  • Page 19: Chilled Water Pump

    Chilled Water Pump 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. Wiring connection points are shown in Figure 23 on page 42.

  • Page 20: System Water Volume

    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.

  • Page 21: Evaporator Freeze Protection

    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).

  • Page 22: Operating Limits

    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. Maximum Operating Ambient Temperatures Standard Efficiency, designated by a "0" as the last digit in the model number (such as AGS 170C) are designed for operation up to 125 degrees.

  • Page 23: Refrigerant Charge

    ordering number 017503300. It is a paddle-type switch and 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 13. Installation should be as shown in Figure 18. Electrical connections in the unit control center should be made at terminals 60 and 67 from switch terminals Y and R.

  • Page 24: Water Flow And Pressure Drop

    Note: The procedure below does not specify the type of glycol. Use the derate factors found in Table 14 for corrections when using propylene glycol and those in Table 15 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.
  • Page 25 Figure 19, Evaporator Pressure Drops Flow Rate (L/s) 44 50 57 63 AGS Models 125, 135, 160 AGS Models 120, 130, 140 AGS Models AGS Models 190, 195, 210 AGS Models 165, 170, 175, 180 500 600 1000 Flow Rate (GPM) Minimum/Nominal/Maximum Flow Rates MINIMUM FLOW NOMINAL FLOW...

  • Page 26: Physical Data, Standard Efficiency

    Physical Data, Standard Efficiency Table 16, Physical Data, AGS 120C – AGS 140C AGS MODEL NUMBER DATA 120C 130C 140C Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2 BASIC DATA Unit Cap. @ 44°F LWT, 95°F Ambient 116.7 (410) 125.2 (440) 133.7 (470)

  • Page 27: Physical Data, High Efficiency

    Table 18, Physical Data, AGS 190C – AGS 210C AGS 190C AGS 210C DATA Ckt 1 Ckt 2 Ckt 1 Ckt 2 BASIC DATA Unit Cap. @ 44°F LWT, 95°F Ambient 185.6 (653) 201.2 (707) Temperature kW, (tons) Unit Operating Charge lbs (kg) 172 (78) 172 (78) 201 (91)
  • Page 28 Table 20, Physical Data, AGS 165C – AGS 195C AGS MODEL NUMBER DATA 165C 175C 195C Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2 BASIC DATA Unit Cap. @ 44°F LWT, 95°F Ambient 160.5 (564) 172.5 (607) 190.3 (669) Temperature kW, (tons) Unit Operating Charge lbs (kg)

  • Page 29: Dimensional Data

    Dimensional Data Figure 20, Dimensions, AGS 120CS/H – AGS 160CS/H Note: See page 13 for lifting locations, mounting locations, weights and mounting loads. CONTROL POWER POWER PANEL PANEL PANEL 6.0 (152.4) 8.0 (203.2) 8.5 (215.9) 7.2 (182.9) 0.875 (22.2) OUTLET...
  • Page 30 Figure 21, Dimensions, AGS 125CS/H –190CS/H Note: See page13 for lifting locations, mounting locations, weights and mounting loads. POWER POWER CONTROL PANEL PANEL PANEL 6.0 (152.4) 8.0 (203.2) 8.5 (215.9) 7.2 (182.9) 0.875 (22.2) OUTLET INLET KNOCK OUT 31.5 " D " ( QTY 4 TOTAL) (800.1) FIELD CONTROL...
  • Page 31 Figure 22 , Dimensions, AGS 165CS/H –210CS/H Note: See page 13 for lifting locations, mounting locations, weights and mounting loads. POWER POWER PANEL PANEL 6.0 (152.4) 8.0 (203.2) 8.5 (215.9) 7.2 (182.9) INLET OUTLET 0.875 (22.2) 31.5 KNOCK OUT " D " ( QTY 4 TOTAL) (800.1) FIELD CONTROL...

  • Page 32: Electrical Data

    (or optional circuit breaker disconnects) in power panel. See the dimension drawings beginning on page 29 for entry locations. Separate disconnects are required for each electrical circuit if the McQuay optional factory-mounted disconnects are not ordered.
  • Page 33 Table 21, AGS 120C – AGS 210C, Electrical Data, Single-Point FIELD FUSE SIZE or MINIMUM POWER HACR BREAKER SIZE CIRCUIT SUPPLY UNIT VOLTS AMPACITY (NOTE 1) RECOM- SIZE MAXIMUM (MCA) FIELD WIRE MENDED (2) 350 MCM (2) 300 MCM 120C 400 MCM 300 MCM 4/0 AWG...
  • Page 34 MINIMUM POWER FIELD FUSE SIZE or CIRCUIT SUPPLY HACR BREAKER SIZE UNIT VOLTS AMPACITY (NOTE 1) RECOM- SIZE MAXIMUM (MCA) FIELD WIRE MENDED 208* (2) 2-300 MCM 1000 1000 (2) 2-250 MCM 1000 1000 180C (2)-250 MCM 2-250 MCM 350 MCM 208* (2) 2-300 MCM 1000...
  • Page 35 ELECTRICAL CIRCUIT 1 (COMP 1) ELECTRICAL CIRCUIT 2 (COMP 2) POWER POWER MINIMUM FIELD FUSING MINIMUM FIELD FUSING SUPPLY SUPPLY UNIT VOLTS CIRCUIT CIRCUIT SIZE AMPS AMPS FIELD WIRE FUSE FUSE FIELD WIRE FUSE FUSE (MCA) (MCA) SIZE SIZE SIZE SIZE 2-250 MCM 2-250 MCM...
  • Page 36 Table 23, AGS 120C – AGS 210C, Compressor and Condenser Fan Motor Amp Draw RATED LOAD AMPS L R A NO OF MOTORS UNIT VOLTS MOTORS CIRCUIT #1 CIRCUIT #2 SIZE MOTORS (EACH) (EACH) 40.0 40.0 20.0 20.0 12.8 40.0 40.0 20.0 20.0...
  • Page 37 RATED LOAD AMPS L R A NO OF MOTORS UNIT VOLTS MOTORS CIRCUIT #1 CIRCUIT #2 SIZE MOTORS (EACH) (EACH) 40.0 40.0 20.0 20.0 12.8 40.0 40.0 20.0 20.0 12.8 11.0 46.0 46.0 25.0 23.0 20.0 NOTES: Table based on 75° C field wire. Complete notes are on page on page 47.
  • Page 38 WIRING TO OPTIONAL NONFUSED WIRING TO STANDARD UNIT POWER BLOCK MOLDED CASE SWITCH IN UNIT UNIT VOLTS CONNECTOR WIRE RANGE CONNECTOR WIRE RANGE TERMINAL SIZE SIZE SIZE PER PHASE PER PHASE AMPS AMPS (COPPER WIRE ONLY) (COPPER WIRE ONLY) 1/0 – 750 MCM (4/C) 1/0 –...
  • Page 39 Table 25, AGS 120C – 210C, Wiring Information with Multiple-Point Power w/o Disconnect WIRING TO UNIT POWER BLOCK UNIT VOLTS TERMINAL SIZE (AMPS) CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY) SIZE CKT 1 CKT 2 CKT 1 CKT 2 #6 –...
  • Page 40 WIRING TO UNIT POWER BLOCK UNIT VOLTS TERMINAL SIZE (AMPS) CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY) SIZE CKT 1 CKT 2 CKT 1 CKT 2 1/0 – 750 MCM (4/C) 1/0 – 750 MCM (4/C) 1/0 – 750 MCM (4/C) 1/0 –...
  • Page 41 WIRING TO UNIT DISCONNECT SWITCH UNIT VOLTS TERMINAL SIZE (AMPS) CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY) SIZE CKT 1 CKT 2 CKT 1 CKT 2 3/0 – 500 MCM (2/C) 3/0 – 500 MCM (2/C) 3/0 – 500 MCM (2/C) 3/0 –...

  • Page 42: Field Wiring Diagram

    Field Wiring Diagram Figure 23, Typical Field Wiring Diagram DISCONNECT UNIT MAIN (BY OTHERS) TERMINAL BLOCK GND LUG 3 PHASE TO COMPRESSOR(S) POWER AND FAN MOTORS SUPPLY FUSED CONTROL CIRCUIT TRANSFORMER 120 VAC TB1-2 DISCONNECT ALARM BELL (BY OTHERS) (115 VAC) 15 A RELAY FUSE...
  • Page 43 Figure 24, AGS 120C - 210C Unit Controller Schematic SHIELD OUTSIDE AIR TEMP (S07) DEMAND LIMIT (S10) 4-20MA EVAP. WATER TEMP. RESET (S11) 4-20MA BLACK +VDC WHITE SHIELD GROUND EVAP. LEAVING WATER TEMP (S08) EVAP. ENTERING WATER TEMP (S09) EVAPORATOR PUMP 1 EVAPORATOR PUMP 2...
  • Page 44 Unit Controller Schematic Continued LINE CONTACT TERMINAL BLOCK LOCATION AND LEAD NUMBERS -301 FU12 -302 -303 820, 822, 850 115V OUTLET 853, 890 -304 821, 891 -305 852, 855 -306 HTR-EVAP 801, 807 -307 FU11 897, 830 HEATER -308 -309 800, 802, 813 -310 C-BOX...
  • Page 45 Figure 25, AGS 120C - 210C Circuit Controller Schematic (SEE LINE 693) TO T5 120V 139 (SEE LINE 687) EVAP PRESS TRANSDUCER (S01) 0-5 VDC DISCHARGE PRESS TRANSDUCER (S02) 0-5 VDC BIAS 5 BIAS G SLIDE LOAD 21 VDC INDICATOR DC GROUND SUCTION TEMP.
  • Page 46 Circuit Controller Schematic Continued LINE TERMINAL BLOCK AND LEAD NUMBERS -601 TB*1 -602 105, 114, 116, 160 -603 115V -604 183, 145 -605 147, 149, 151, 153 -606 155, 161, 187, 197 -607 -608 113, 101, 117, 179 181, MHP-1 -609 MHP-2, 182, 184 -610...

  • Page 47: Bas Interface

    Modbus IM 743 IM 735 BACnet IM 736 ORKS Remote Operator Interface Panel The box containing the optional remote interface panel will have installation instructions, IOM MT II Remote, in it. The manual is also available for downloading from www.mcquay.com. IMM AGS-2...

  • Page 48: Remote Evaporator

    Remote Evaporator This section contains data that is unique to AGS-CM/B remote evaporator models including: • Refrigerant piping on page 49. • Dimensions on page 51. • Vibration isolators on page 58. • Physical data on page 60. Data common to both packaged and remote evaporator models are: •...

  • Page 49: Field Wiring (Remote Evaporator)

    Liquid line connection at the evaporator = 1 5/8. • A piping drawing showing altitudes, line lengths, slopes and all fittings, using Form SF 99006 (Revised 5/02), must be sent to the McQuay Technical Response Center for review prior to entering a unit order. •...
  • Page 50 Table 27, Fitting Equivalent Feet of Pipe Line Size 90 Degree Std. 90 Degree Long Angle Valve Globe Valve Ball Valve In. OD Radius Elbow Radius Elbow 2 5/8 29.00 69.0 3 1/8 35.0 84.0 3 5/8 41.0 100.0 4 1/8 47.0 120.0 10.0...

  • Page 51: Dimensions, Unit With Remote Evaporator

    Dimensions, Unit with Remote Evaporator Figure 27, Models AGS 120CM/B, 130CM/B, 140CM/B, 160CM/B Circuit SUCTION CONNECTION LIQUID ( 3.62 O.D.) CONNECTION ( 1.38 O.D.) Circuit 0.875 KNOCK-OUT ( QTY 4 TOTAL) FIELD CONTROL (2) POWER ENTRY (2) CONNECTIONS 100.4 (2550.2) 88.5 (2247.9) 186.6 (4739.6) LIQUID CONNECTIONS...
  • Page 52 Figure 29, AGS 165CM/B – AGS 175CM/B (with Remote Evaporator) SUCTION LIQUID CONNECTION CONNECTION (3.12 O.D.) ( 1.38 O.D.) 0.875 KNOCK OUT ( QTY 4 TOTAL) FIELD CONTROL (2) POWER (2) CONNECTIONS ENTRY 100.4 (2550.2) 88.5 (2247.9) 263.0 (6680.2) 330712801D030A AGS-C-165-175 Figure 30, AGS 180CM/B - AGS 190CM/B (with Remote Evaporator) SUCTION...
  • Page 53 Figure 31, AGS 195CM/B - AGS 210CM/B (with Remote Evaporator) SUCTION CONNECTION LIQUID CONNECTION (3.62 O.D.) ( 1.38 O.D.) 0.875 KNOCK OUT ( QTY 4 TOTAL) FIELD CONTROL (2) POWER (2) CONNECTIONS ENTRY 100.4 (2550.2) 88.5 (2247.9) 263.0 (6680.2) 330712801D030C LIQUID CONNECTIONS AGS-C-195-210 IMM AGS-2...
  • Page 54 Evaporators Figure 32, Evaporator for AGS 120C - 140C 11.9 HEATER (302.3) LEADS (76.2) (76.2) 04.125 IDS. FLANGE (QTY. 2) 18.2 (462.3) 1/4" NPTF (QTY. 2) LIQUID 12.4 (315.0) 3.9 (99.1) 1/2" NPTF HEATER (QTY. 2) 72.3 (1836.4) LEADS MTG. 85.6 (2174.2) 92.2 (2341.9) 2.8 (71.1)
  • Page 55 Figure 34, Evaporator for AGS 145C 11.9 HEATER (48.3) LEADS. 3.0 (76.2) (76.2) 04.125 IDS. FLANGE 18.2 (QTY. 2) (462.3) 1/4" NPTF LIQUID (QTY. 2) 12.4 3.9 (99.1) 1/2" NPTF (315.0) (QTY. 2) 95.0 (2413.0) HEATER 108.3 (2750.8) LEADS. MTG. 114.9 (2918.5) 2.8 (71.1) (40.6)
  • Page 56 Lifting and Mounting Dimensions and Weights, Remote Evaporator Figure 36, Mounting and Lifting Dimensions " G " " E " " F " " D " " C " 44.00 " A " 3307127-00-04 " B " DIMENSIONS IN INCHES MODEL 36.00 136.60...
  • Page 57 Table 31, Lifting and Mounting Weights, Aluminum Fins (Remote Evaporator) Operating & Lifting Weights Mounting Weights Shipping L1 & L2 L3 & L4 M1 & M2 M3 & M4 M5 & M6 Weights MODEL lbs. lbs. lbs. lbs. lbs. lbs. 3029 1375 1021...

  • Page 58: Vibration Isolators, Remote Evaporator

    Vibration Isolators, Remote Evaporator The vibration isolator specific locations and the kit numbers shown on the following two pages are based on Figure 36 and the weights shown on the previous page. Table 33, Spring Vibration Isolators, AGS 120C – 210C, Aluminum Fin Mounting Location Model Kit Number...
  • Page 59 Table 35, Spring Vibration Isolators, AGS 120C – 210C, Copper Fin (Remote Evaporator) Mounting Location Model Kit Number CP2-31 CP2-31 CP2-28 CP2-28 CP1-31 CP1-31 330904122 GRAY GRAY GREEN GREEN WHITE WHITE CP2-31 CP2-31 CP2-31 CP2-31 CP2-31 CP2-31 330904123 GRAY GRAY GRAY GRAY GRAY...

  • Page 60: Physical Data, Standard Efficiency

    Physical Data, Standard Efficiency Table 37, Physical Data, AGS 120C – AGS 140C (Remote Evaporator) AGS MODEL NUMBER DATA 120C 130C 140C Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2 BASIC DATA Unit Operating Charge lbs (kg), Note 1 131 (59) 131 (59) 131 (59)

  • Page 61: Physical Data, High Efficiency

    Table 39, Physical Data, AGS 190C – AGS 210C (Remote Evaporator) AGS 190C AGS 210C DATA Ckt 1 Ckt 2 Ckt 1 Ckt 2 BASIC DATA Unit Operating Charge lbs (kg) 172 (78) 172 (78) 201 (91) 201 (91) Cabinet Dimensions 225 x 89 x 101 263 x 89 x 101 L x W x H, in.
  • Page 62 Table 41, Physical Data, AGS 165C – AGS 195C (Remote Evaporator) AGS MODEL NUMBER DATA 165C 175C 195C Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2 BASIC DATA Unit Operating Charge lbs (kg) 186 (84) 186 (84) 186 (84) 186 (84) 201 (91)

  • Page 63: Solid State Starters

    (SCR) power section to allow a motor to be brought to full speed with a reduced initial voltage that increases to full line voltage over a given time. The McQuay motor starter, custom designed for this specific application, is microprocessor controlled.
  • Page 64 OL will alternately blink with the normal display on the LED display when motor thermal overload content has reached 90% to 99% of its capacity. The motor thermal overload content has reached 100%, and the motor has stopped. The motor cannot be restarted until the overloaded motor has cooled and OLt is displayed.
  • Page 65 Controlled Auto Number Description Stop Reset Current Sensor Offset Error Burden Switch Error Thermistor Trip Stack OT Switch Trip Analog Input Trip Modbus Time-out CPU Error – Software Fault CPU Error – Parameter Storage Fault CPU Error – Illegal Instruction Trap CPU Error –...
  • Page 66 Figure 37, Trouble Shooting Guide Start Low or Missing Line? Phase Order Fuses OK? Fault Swap Any Circuit Replace Thermal Trip? 2 Power Breaker OK? Fuses Leads Replace Interlock Circuit In-Line OK? Open? Breaker Correct Power Correct High Source Wiring OK? Inline Fault Ambient? Problem...
  • Page 67 Repair or Switches Set Pulses Present? Defective SCRs Replace Motor Correctly? Contact Check Jumpers Replace Replace Benshaw Parameters Control Card Control Card For Assistance and CTs Return to Does Problem Normal Still Exist? Operation Contact McQuay For Assistance IMM AGS-2...
  • Page 68 FLOW CHART DETAILS: Fuses Determine if power line fuses have been installed, and if they are operating properly. Circuit Breaker Determine if the circuit breaker is off, or has tripped and disconnected the line from the starter. Power Line Voltage Verify that line voltage is present, and that it is the correct voltage.
  • Page 69 Solid State Starter Settings Operating Parameters Settings for Default Value and Settable Range: Table 43, Starter Settings Operating Parameter Default Range of Setting Motor Full Load Amps (FLA) 1 to 9999A Motor Rated Load Amps (RLA) 1 to 9999A Motor Service Factor 1.25 1-1.99 Motor Overload Class...

  • Page 70: Component Location

    Component Location Major Component Location Figure 38, Unit Cutaway View Power Panel Control Panel Suction Connection for Remote Evaporators (2) Filter-drier (2) Chilled Water Inlet Electronic Expansion Valve (2) Two-circuit DX Evaporator Liquid Connection for Remote Chilled Water Outlet Evaporators, Models AGS 120C – 175C IMM AGS-2...
  • Page 71 Figure 39, Piping Schematic, One of Two Circuits SCHRADER VALVE DISCHARGE (HEADER) TUBING SCHRADER VALVE SUCTION FRAME 3200 SHUT-OFF FLOW COMPRESSOR VALVE (OPTIONAL) CHARGING VALVE RELIEF VALVE FLOW FLOW SUCTION TUBING CONDENSOR ASSEMBLY LIQUID TUBING RELIEF CHARGING VALVE VALVE SCHRADER FILTER SOLENOID VALVE...

  • Page 72: Power Panel

    Power Panel The power panel is located on the front of the unit, to the right of the control panel. Figure 41, Power Panel Components (Single Point Power) Primary Control Power Fuses Control Transformer Cir#2 Circuit Breaker, Single Point Power Only Cir#1 Circuit Breaker, Single Point Power Only Line...

  • Page 73: Control Panel

    Control Panel The control panel is located on the front of the unit, to the left of the power panel. Distributed control architecture enhances unit reliability. Each compressor circuit has its own microprocessor controller so that if one circuit controller is inoperative, the other circuit controller will still be able to run its compressor and circuit components.

  • Page 74: System Maintenance

    No further lubrication is required. Excessive fan motor bearing noise is an indication of a potential bearing failure. Figure 43, Compressor Oil Filter Compressor oil must be ICI RL68HB, McQuay Part Number 735030446 in a 1-gallon container. This is synthetic polyolester oil with anti-wear additives and is highly hygroscopic.

  • Page 75: Electrical Terminals

    McQuay recommends the use of non-caustic, non-acidic, foaming coil cleaners available at most air conditioning supply outlets. Flush the coil from the inside out.

  • Page 76: Lead-Lag

    Lead-Lag A feature on all McQuay AGS air-cooled chillers is a system for alternating the sequence in which the compressors start to balance the number of starts and run hours. Lead-Lag of the refrigerant circuits is accomplished automatically through the MicroTech II controller.

  • Page 77: Warranty Statement

    Limited Warranty McQuay’s written Limited Product Warranty, along with any extended warranty expressly purchased is the only warranty. Consult your local McQuay Representative for warranty details. Refer to Form 430285Y. To find your local McQuay Representative, go to www.mcquay.com. Service CAUTION 1.

  • Page 78: Compressor Slide Valves

    The following is the procedure for changing the filter-drier core: The standard unit pumpdown is set to stop pumpdown when 20 psig (138 kPa) suction pressure is reached. To fully pump down a circuit beyond 20 psig (138 kPa) for service purposes, a "Full Pumpdown"...

  • Page 79: Evaporator

    Note: It is a good idea to record the normal values of refrigerant pressures, subcooling, superheat, and evaporator and condenser approach temperatures during startup by the McQuay service technician. This makes it easier to spot errant unit behavior. Indications of a low refrigerant R-134a charge: •...

  • Page 80: Standard Controls

    4. Add sufficient charge to clear the conditions listed above under “Indications of a low refrigerant R-134a charge”. 5. Overcharging of refrigerant will raise the condenser pressure and increase the condenser subcooling. Standard Controls NOTE: A complete explanation of the MicroTech II controller and unit operation is contained in the Operation Manual OM AGS.
  • Page 81 Mechanical high pressure equipment protection control The high pressure equipment protection control is a single pole, pressure-activated switch that opens on a pressure rise. When the switch opens, the control circuit is de-energized, dropping power to the compressor and fan motor contactors. The switch is factory set (non- adjustable) to open at 310 psig (2137 kPa) ±7 psig and reclose at 200 psig (1379 kPa) ±7 psig.

  • Page 82: Controls, Settings And Functions

    Controls, Settings and Functions Table 44, Controls DESCRIPTION FUNCTION SYMBOL SETTING RESET LOCATION Compressor To provide heat to drive off liquid On, when On the HTR1-COMPR Heaters refrigerant when compressor is off. compressor is off. Compressor Compressor On the Loads compressor LOAD Solenoid - Load Compressor...

  • Page 83: Troubleshooting Chart

    Troubleshooting Chart Table 45, Troubleshooting PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS Main power switch open. Close switch. Unit S1 system switch open. Check unit status on MicroTech II display. Close switch. Circuit switch, CS in pumpdown position. Check circuit status on MicroTech II display. Close switch. Check pump operation for flow.

  • Page 84: Periodic Maintenance Log

    Periodic Maintenance Log Date of inspection: Address: Facility/job name: City/State: Unit model number: Physical location of unit: Unit serial number: Service technical (name): Software identification: Operating hours: Compressor #1 Compressor #2 Number of starts Compressor #1 Compressor #2 Follow up service required: General Actions to be Taken Upper part of report completed: Fill in above...
  • Page 85 IMM AGS-2...
  • Page 86 IMM AGS-2...
  • Page 88 This document contains the most current product information as of this printing. For the most up-to- date product information, please go to www.mcquay.com (800) 432-1342 • www.mcquay.com IMM AGS-2 (07/08)

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