Daikin McQuay AGZ-D 25, Operating And Maintenance Manual

Page 1: ...d Maintenance Manual OMM 1087 1 Group Chiller Part Number OMM 1087 Effective August 2012 Supersedes May 2012 Air Cooled Scroll Compressor Chiller AGZ D 25 to 190 Tons 50 60 Hertz R 410A Software Versi...

Page 2: ...ng the Controller 44 Navigating 45 Menus 47 Optional Low Ambient Fan VFD 60 VFD Interface HMI 61 Recommended Periodic Inspection 65 Optional BAS Interface 65 Startup 66 Operation 68 Unit Maintenance 7...

Page 3: ...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...

Page 4: ...ter flow through the evaporator as the load changes Daikin 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...

Page 5: ...glycol from the freezing point tables 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 Concent...

Page 6: ...han 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 wi...

Page 7: ...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 00...

Page 8: ...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 8000 feet 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...

Page 9: ...eze 15 F to 60 F 9 4 C to 15 6 C 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...

Page 10: ...ge for curve cross reference See following page for curve cross reference and min max flow rates AGZ Water Pressure Drop A B B C C D D E E F F G G H H I I J J K K L L M M N N O O P P Q Q R R S S T T U...

Page 11: ...84 2 5 1 5 3 15 3 134 6 12 5 8 5 37 3 215 4 30 5 13 6 91 0 H 065D 87 2 4 5 5 5 13 4 139 4 11 0 8 8 32 8 223 1 26 9 14 1 80 1 I 070D 96 2 5 4 6 1 16 2 153 8 13 3 9 7 39 6 246 1 32 5 15 5 96 8 J 075D 10...

Page 12: ...12 AGZ 025D through 190D OMM 1087 1 Figure 2 Typical Field Control Wiring...

Page 13: ...election 22 Unit States 22 Start Delays 23 Evaporator Pump Control 24 Leaving Water Temperature LWT Reset Target 25 Unit Capacity Control 26 Unit Capacity Overrides 27 Circuit Control Functions 29 Cir...

Page 14: ...n memory and can be easily displayed in plain English for operator review The MicroTech III chiller controller will also retain and display the date time the fault occurred In addition to displaying a...

Page 15: ...it Enable X7 Circuit 1 MHP Switch Fault No fault X8 Circuit 1 Motor Protection Fault No fault DI1 Circuit 1 or Unit PVM GFP Fault No fault Digital Outputs Description Output Off Output On DO1 Compress...

Page 16: ...1 M1 EXV Stepper Coil 1 M2 M2 EXV Stepper Coil 2 Sensor Information Temperature All temperature sensors will be McQuay part number 1934146 Pressure Pressure inputs will be read using 0 to 5 volt ratio...

Page 17: ...Demand Limit Enable Off Off On Network Capacity Limit 100 0 to 100 LWT Reset Enable Off Off On Configuration Power Input Single Point Single Point Multi Point Evap Control 1 Only 1 Only 2 Only Auto 1...

Page 18: ...Target 100 37 8 C 100 F 32 22 to 48 9 C 90 to 120 F Condenser Target 67 32 2 C 90 F 32 22 to 48 9 C 90 to 120 F Condenser Target 50 32 2 C 90 F 29 44 to 43 3 C 85 to 110 F Condenser Target 33 29 4 C...

Page 19: ...to 115 PSI Special Set Point Operations The following setpoints are not changeable unless the unit switch is off Available Modes Number of Compressors Expansion Valve Type Number of Fans Fan VFD Enabl...

Page 20: ...roller setpoints may be changed If the operator attempts to edit a setpoint for which the necessary password level is not active no action will be taken Once a password has been entered it remains val...

Page 21: ...ature LWT target Control Band LWT target 3 9 C If the unit is configured for use with glycol the compressor staging temperatures are calculated as shown below Stage Up Temperature LWT target Control B...

Page 22: ...changing modes of operation inadvertently while the chiller is running Unit Mode is set according to the following table Control Source Set Point Mode Input BAS Request Available Modes Set Point Unit...

Page 23: ...avoid tripping a false alarm Ice Mode Start Delay An adjustable start to start ice delay timer will limit the frequency with which the chiller may start in Ice mode The timer starts when the first com...

Page 24: ...o max pulldown rate has been met or exceeded 16 Auto Unit Cap Limit Unit State Auto unit capacity limit has been met or exceeded 17 Auto High Ambient Limit 18 Config Changed Reboot Required A configur...

Page 25: ...e greater than the recirculate timeout set point and there is no flow then the primary pump will shut off and the standby pump will start When the evaporator is in the run state if flow is lost for mo...

Page 26: ...bed in following sections must be applied as described Compressor Staging in Cool Mode The first compressor on the unit should be started when evaporator LWT is higher than the Startup Temperature Add...

Page 27: ...art Within that circuit the available compressor with the least starts will be next to start if starts are equal the one with the least run hours will be next to start if run hours are equal the lowes...

Page 28: ...0 Limit 83 3 5 83 3 Limit 66 7 4 66 7 Limit 50 3 50 Limit 33 3 2 33 3 Limit 1 Maximum LWT Pulldown Rate The maximum rate at which the leaving water temperature can drop shall be limited by the Maximum...

Page 29: ...ow Evaporator Pressure Unload set point The equation is as follows Pumpdown pressure Low Evap Pressure Unload set point 103KPA 15 PSI Circuit Control Logic Circuit Enabling A circuit should be enabled...

Page 30: ...commanded to stop Unit State Pumpdown Circuit switch is open Circuit mode is disable Circuit Pumpdown alarm is active T4 Pumpdown to Off Any of the following are required Evaporator Pressure Pumpdown...

Page 31: ...hutdown Multiple Low Ambient Start attempts are allowed On the third failed Low Ambient Start attempt the Restart Alarm is triggered and the circuit will not attempt to restart until the Restart alarm...

Page 32: ...ling of power to the chiller This means that if power is cycled the cycle timers should not be active These timers may be cleared via a setting on the human machine interface HMI Condenser Fan Control...

Page 33: ...one through four should use their respective dead bands Stages five through seven should all use Stage Down Dead Band 4 When the saturated condenser refrigerant temperature is below the target the act...

Page 34: ...ll and tube type evaporator When staging down a compressor the maximum position is reduced by 10 for one minute to prevent liquid from getting to compressors After this initial one minute delay the va...

Page 35: ...arms are classified in the following sections per the Global Chiller Protocol Standard using the Fault Problem Warning scheme When any Unit Fault Alarm is active the alarm digital output should be tur...

Page 36: ...conditions no longer exist Evaporator LWT Sensor Fault Trigger Sensor shorted or open Action Taken Normal stop all circuits Reset This alarm can be cleared manually via the keypad or BAS command but o...

Page 37: ...e keypad or BAS command when communication between main controller and the extension module is working for 5 seconds or Expansion Valve Type Thermal Unit Problem Alarms Low Ambient Lockout No longer a...

Page 38: ...reset is enabled For this alarm out of range is considered to be a signal less than 3mA or more than 21mA Action Taken Cannot use LWT reset function Reset Auto clear when LWT reset is disabled or LWT...

Page 39: ...he evaporator pressure sensor fault is active Action Taken Rapid stop circuit Reset This alarm can be cleared manually via the keypad if the evaporator pressure is above 137 9 KPA 20 PSI High Condense...

Page 40: ...s alarm can be cleared manually via the keypad or BAS command but only if the sensor is back in range Suction Temperature Sensor Fault Trigger Sensor shorted or open and Expansion Valve Type Electroni...

Page 41: ...if the circuit is no longer in the run state High Condenser Pressure Unload Trigger This event is triggered if all of the following are true circuit state Run more than one compressor is running on th...

Page 42: ...porator Pressure Unload set point for a time greater than half of the current freezestat time circuit is not currently in a low OAT start it has been at least 30 seconds since a compressor has started...

Page 43: ...t Log An Event Log similar to the Alarm Log stores the last 50 event occurrences Each Event Log entry includes an event description and a time and date stamp for the event occurrence plus the count of...

Page 44: ...ins a menu title a parameter such as a value or a setpoint or a link which will have an arrow in the right of the line to a further menu The first line visible on each display includes the menu title...

Page 45: ...which can also be accessed by pressing the Menu Button The navigating wheel is the only navigating device necessary although the MENU ALARM and BACK buttons can provide shortcuts as explained later Pa...

Page 46: ...the wheel again cause the new value to be saved and the keypad display to leave the edit mode and return to the navigation mode A parameter with an R is read only it is giving a value or description...

Page 47: ...creen the linked screen is indicated in the rightmost column Example the Enter Password screen links to screen U 2 For each screen the screen s from which you can navigate to it is also shown on the s...

Page 48: ...3 Set Up R U 14 Temperatures R U 15 Date Time Schedules R U 16 Power Conservation R U 17 LON Setup R U 18 BACnet IP Setup R U 19 BACnet MSTP Setup R U 20 Modbus Setup R U 21 AWM Setup R U 22 Configura...

Page 49: ...ervice Support Reference R R Screen U 9 From Screen U 1 Review Operation No password Operator Links to screen Alarm Active U 30 Alarm Log U 31 Unit Status Settings U 33 Circuit 1 Status Settings Cx 2...

Page 50: ...sion R R Application Version R R HMI GUID R R OBH GUID R R Screen U 13 From Screen U 4 Status Settings No password Operator Links to screen Unit Status R Next Compressor On R Next Compressor Off R Chi...

Page 51: ...elta T R Active Set Point R Start Up Temperature R Shut Down Temperature R Stage Up Temperature R Stage Down Temperature R Pulldown Rate Outside Air Temperature R Cool LWT Setpoint 1 R W Cool LWT Setp...

Page 52: ...sk R Actual Gateway R Given IP Address R W Given Mask R W Given Gateway R W Unit Support R W NC Dev 1 R W NC Dev 2 R W BACnet BSP R Screen U 20 From Screen U 4 U 11 BACnet MSTP Setup No password Opera...

Page 53: ...ssword Operator Links to screen Apply Changes Number Of Compressors Expansion Valve Type Number Of Fans Fan VFD Enable Power Configuration Comm Module 1 Type Comm Module 2 Type Comm Module 3 Type Scre...

Page 54: ...re Shutdown Setpoint Low Ambient Start Time Evaporator Water Freeze Evaporator Flow Proof Evap Recirculate Timeout Screen U 27 From Screen U 4 U 11 Calibrate Sensors No password Operator Links to scre...

Page 55: ...nit Status Settings No password Operator Links to screen Actual Time Actual Date Unit Status Unit Mode Unit Capacity Evap Leaving Water Temp Evap Entering Water Temp Active Set Point Pulldown Rate Out...

Page 56: ...reen U 37 From Screen U 32 Circuit 1 Event Log No password Operator Links to screen Event Selection R W Day Selection R W Count R Last Occurrence R Screen U 38 From Screen U 32 Circuit 1 Event Log No...

Page 57: ...n Hours Number Of Starts Last Compressor Start Last Compressor Stop Compressor 5 6 Run Hours Number Of Starts Last Compressor Start Last Compressor Stop Condenser Number of Fans Running Stage Up Error...

Page 58: ...olenoid Output State Hot Gas Bypass Output State Fan Output 1 State Fan Output 2 State Fan Output 3 State Fan Output 4 State Fan Output 5 State Fan VFD Speed Screen Cx 4 From Screen Cx 1 Data No passw...

Page 59: ...et 100 Cond Target 67 Cond Target 50 Cond Target 33 Screen Cx 7 From Screen Cx 1 EXV No password Operator Links to screen EXV State Suction Superheat Superheat Target EXV Control Mode EXV Position Eva...

Page 60: ...the Motor WARNING Avoid swapping any 2 of the 3 motor lead connections which will cause reversal of the motor direction In applications where reversed rotation could cause equipment damage or personne...

Page 61: ...button will return to the Frequency Reference display 3 Moves the cursor to the right Resets the drive to clear a fault situation 4 RUN Key Starts the drive in LOCAL mode 5 Up Arrow Key Scrolls up to...

Page 62: ...d to the MEMOBUS Modbus CommunicationInputs of the drive OP Displayed when the frequency reference is assigned to an Option Unit of the drive RP Displayed when the frequency reference is assigned to t...

Page 63: ...an the operator is selected for Run command and frequency reference control REMOTE During run During deceleration to stop When a Run command is input and frequency reference is 0 Hz While the drive wa...

Page 64: ...i function contact outputs do not operate The drive will not operate the motor until the error has been reset Correct the settings that caused the operation error to clear the error Tuning Errors Tuni...

Page 65: ...ntactors and relays for excessive noise Check for over or undervoltage Inspect for signs of overheating such as melted or cracked insulation Replace damaged parts Optional BAS Interface The AGZ chille...

Page 66: ...control band before the MicroTech III controller will stage on cooling 4 Set the Evap Delta T and the Start Delta T as a starting point 5 Put both pumpdown switches PS1 and PS2 to the ON position 6 P...

Page 67: ...ll water strainers before placing the chiller into service Pre Startup Refrigerant Piping Checkout 1 Check all exposed brazed joints for evidence of leaks Joints may have been damaged during shipping...

Page 68: ...air handler load Note The hot gas bypass valve cannot generate a 100 false load The pressure regulating valves are a Sporlan HGBE 8 75 150 7 8 ODF on models AGZ 025 to 065 and Sporlan HGBE 8 75 150 1...

Page 69: ...element may indicate a wet condition It is recommended that the equipment operate for about 12 hours to allow the system to reach equilibrium before deciding if the system requires a change of drier c...

Page 70: ...ultant should administer the proper testing and evaluate compatibility Models AGZ 140C through 180C The evaporator is direct expansion shell and tube type with water flowing in the baffled shell side...

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Page 72: ...tlets Use caution when applying such cleaners as they can contain potentially harmful chemicals Care should be taken not to damage the fins during cleaning The coils should be thoroughly rinsed to rem...

Page 73: ...ement color If the sight glass does not indicate a dry condition after about 12 hours of operation the circuit should be pumped down and the filter drier changed or verify moisture content by performi...

Page 74: ...es all weekly and monthly operations 3 Log readings can be taken daily for a higher level of unit observation 4 Coil cleaning can be required more frequently in areas with a high level of airborne par...

Page 75: ...proved R 410A with 400 psig rating Open cylinders slowly Avoid rough handling of cylinders and secure as appropriate Cap when not in use Do not overfill recovery cylinders or overcharge units Check ga...

Page 76: ...rge the unit Locate and repair any refrigerant leaks Soap works well to show bubbles at medium size leaks but electronic leak detectors are needed to locate small leaks Charging or check valves should...

Page 77: ...e the same as R 22 Cooling the recovery cylinder will speed recovery and lessen stress on recovery equipment WARNING Service on this equipment is to be performed by qualified refrigeration personnel f...

Page 78: ...78 AGZ 025D through 190D OMM 1087 1 Table 22 Filter Drier Pressure Drop PERCENT CIRCUIT LOADING MAXIMUM RECOMMENDED PRESSUREDROP ACROSS FILTER DRIER PSIG KPA 100 10 69 75 8 55 2 50 5 34 5 25 4 27 6...

Page 79: ...ere is no power to the coil The solenoid coil can be removed from the valve body without opening the refrigerant piping after pumpdown For personal safety shut off and lock out the unit power The coil...

Page 80: ...recirculation 6 Clean coil 7 Correct Low Discharge Pressure 1 Refrigerant flood back 1 Correct 2 Wind blowing into coil at low ambient 2 Shield coil from direct wind Wind guards are available 3 Faulty...

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Page 82: ...e line drop 2 Defective or grounded wiring in motor 2 Replace compressor motor 3 Loose power wiring or burnt contactors 4 High condenser temperature 5 Power line fault causing unbalanced voltage 3 Che...

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Page 84: ...ing or call 540 248 9646 to speak with the Training Department Warranty All Daikin McQuay equipment is sold pursuant to McQuay International standard terms and conditions of sale including Limited Pro...