Air-Cooled Global Chiller

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1 Product Manual PM 970 Group: Chiller Effective: June 1997 Supersedes: None Air-Cooled Global Chiller Type AGR 055AS through 100AS Reciprocating Compressor with R hertz 1997 McQuay International

2 Table of Contents Introduction...3 Nomenclature... 3 Features and Benefits...3 Design Advantages...4 Selection Procedure...7 Selection Procedure 60Hertz English units... 7 Selection Procedure 60Hertz Metric Units... 8 Application Adjustment Factors...9 Ethylene And Propylene Glycol Factors... 9 Altitude Correction Factors... 9 Evaporator Temperature Drop Factors... 9 Performance Data...11 Part Load Data...13 Pressure Drop Curves...14 Electrical Data...15 Physical Data...23 Dimensional Data...26 Application Data...28 Unit Placement Clearances Sound Isolation Typical Chilled Water Piping Chilled Water Piping Series Compared to Parallel Operation Temperature and Water Flow Limitations Evaporator Freeze Protection Optional Features...31 Product Specification...34 "McQuay" is a registered trademark of McQuay International 1997 McQuay International "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 anytime without notice" 2 AGR 055AS through 100AS Product Manual 970

3 Introduction The McQuay AGR SeasonPak air-cooled chiller is part of the Global Chiller Line and a product of McQuay International s commitment to offer quiet, reliable, energy efficient chillers. A design approach incorporating high quality compressors, state of the art coil design, and well thought out innovative packaging. Nomenclature A G R - XXX A S Air-Cooled Global Reciprocating Compressor Application S= Standard Cooling Design Vintage Nominal Tons Features and Benefits Efficiency Cross-circuit compressor staging Copeland Discus compressors Exceeds ASHRAE Standard 90.1 for efficiency Reliability Rugged, proven compressor design Factory installed operating and safety controls Code and agency approval Flexibility Complete factory assembly and testing Sizes available in convenient 5 ton increments Multiple control options Serviceability Dual refrigerant circuits Easy servicing -- All electrical and refrigerant components are readily accessible Small footprint Product Manual 970 AGR 055AS through 100AS 3

4 Design Advantages Construction Factory assembled and mounted on heavy-gauge painted phosphatized galvenized steel channel base. This base distributes the unit weight for roof loading. Flexible installation is possible by virtue of the unit s small footprint and low sound level. Compressors The AGR product line uses Copeland DISCUS valve semi-hermetic compressors. These rugged compressors are designed for Refrigerant 22 and the high loading associated with air-cooled applications. Semi-hermetic, 1750 rpm induction type motors are used. The motors are refrigerant-gas cooled. Solid-state modules in the motor terminal box respond to temperature sensors imbedded in all three motor windings, providing inherent thermal overload protection for all run and start conditions. The compressor housing is constructed from closed grained, high nickel content, alloy cast-iron with no bolted joint between the motor and compressor. The housing includes a cast-iron cylinder head and stator cover, and a crankcase oil sightglass. A suction strainer built into the compressor in the gas stream between the suction service valve and the motor, filters out foreign and abrasive particles. An internal relief valve relieves discharge pressure to the suction side for safety protection at high compression ratios as required by ANSI/ASHRAE 15 Safety Code Main bearings are solid cast bronze insert type with oversized bearing areas that result in ultra-low bearing loading. The crankshaft is die-forged, high strength iron alloy with integral counterweights, statically and dynamically balanced for smooth operation. Connecting rods are lightweight aluminum with integral bearing surfaces on the crankshaft and piston ends. Pistons are close grain cast iron with oil and compression rings. Piston pins are full floating type for long life. Compressors have a force-feed lubrication system with positive oil displacement, a reversible oil pump, and an operating oil charge. The pump feeds oil through rifle drilled passages in the crankshaft to all bearing surfaces. Magnetic plugs trap magnetic particles that enter the crankcase. The oil supply filters through a large area oil strainer. A crankcase heater minimizes oil dilution by refrigerant at start Condenser Coils Condenser coils have internally enhanced seamless copper tubes arranged in a staggered row pattern. The coils are mechanically expanded into McQuay lanced and rippled aluminum fins with full fin collars. An integral subcooler circuit provides subcooling to effectively eliminate the possibility of liquid line flashing. 4 AGR 055AS through 100AS Product Manual 970

5 Condenser Fans and Motors Multiple direct drive dynamically balanced propeller fans operate in formed venturi openings at low tip speeds for maximum efficiency and minimum noise and vibration. A heavy-gauge vinyl-coated fan guard protects each fan. Each condenser fan motor is heavy-duty, 3-phase with permanently lubricated ball bearings and inherent overload protection. SpeedTrol option includes a single-phase motor with fan speed control on the lead fan per circuit. Fan motors on the AGR A are totally enclosed construction providing optimum environmental protection. Totally enclosed fan motors are available as an option on AGR 55-65A. Evaporator The evaporator is direct expansion, shell-and-tube type with water flowing in the baffled shell side and refrigerant flowing through the tubes. Two independent refrigerant circuits within the evaporator serve the units dual refrigerant circuits. The evaporator has a carbon steel shell and seamless high efficiency copper tubes roller expanded into a carbon steel tube sheet. Water baffles are polypropylene to resist corrosion. Refrigerant heads are carbon steel with multi-pass baffles to ensure oil return and are removable to permit access to the tubes from either end. For water removal, 3/8" (10mm) vent and drain plugs are provided on the top and bottom of the shell. The evaporator is wrapped with an electric resistance heater cable and insulated with 3/4" (19mm) thick vinyl nitrate polymer sheet insulation, protecting against water freeze-up at ambient air temperatures to -20 F (-29 C). An ambient thermostat controls the heater cable. The fitted and glued in place insulation has a K factor of 0.28 at 75 F (23 C). The refrigerant (tube) side maximum working pressure is 225 psig (1552 kpa). The water side working pressure is 175 psig (1207 kpa). Each evaporator is designed, constructed, inspected, and stamped according to the requirements of the ASME Boiler and Pressure Vessel Code. Double thickness insulation is available as an option. NOTE: A water flow switch or both water flow switch and water pump starter interlock, must be field installed to protect against evaporator freeze-up under low water flow conditions. Electrical Control Center Operating and safety controls and motor starting components are separately housed in a centrally located, weatherproof control panel with hinged and keylocked doors. Three levels of control are available: Global UNT Microprocessor based control that accomplishes unit capacity control by 4 to 6-stage cross-circuit compressor cycling and unloading based on leaving chilled water temperature. Setpoint and control band are easily field adjusted. Anti-cycling and stage delay timers are included. Safety controls include low and mechanical high refrigerant pressure, low evaporator flow (field installed flow switch), low oil pressure, sensor failures, and evaporator freeze protection. Motor protection includes phase voltage, volts ratio, and solid state compressor motor protection. Outside air temperature is standard. Outside air reset is adjustable with the zone terminal display. Return water reset, demand limit reset and remote reset using a 4-20 ma signal are available options instead of outside air.. Product Manual 970 AGR 055AS through 100AS 5

6 Figure 1, Standard Global UNT Controller Global UNT with Zone Terminal (optional) Provides an onboard (or remotely wired) display of unit operating parameters and adjustment of certain control options. MicroTech (optional) Exclusive microprocessor control common throughout McQuay equipment. The interface is a 12 key keypad and 4-line, 40 character backlit liquid crystal display. The MicroTech continuously performs self diagnostic checks on all system temperatures, pressures, and safeties, and will automatically shut down a circuit or the entire unit at fault conditions. The cause, time, and date of the occurrence is recorded and can be displayed. The seven previous incidents are kept in memory for service reference. If a fault occurs, the controller takes preventive measures in an effort to keep the unit operating; staging down capacity, activating a pre-alarm signal, and automatically switching to the alarm menu on the display. Pre-alarms are self clearing when the fault condition is no longer present. Critical shutdown alarms such as high condenser pressure (with mechanical back up), freeze protection, oil pressure (with mechanical back up), and low evaporator pressure are manual reset and must be cleared at the keypad to resume operation. Choose the MicroTech control and Open Protocol options to interface with virtually any building management system and perform remote monitoring and control by hard wiring or modem. The standard FanTrol system controls fan staging for control of refrigerant discharge pressure. The FanTrol system cycles condenser fans based on discharge pressure and outdoor temperature and is suited for operation to 40 F (4.4 C). The optional SpeedTrol control uses both fan cycling and fan speed control on the lead fan per circuit and allows operation to 0 F (-18 C) outdoor temperature. Figure 2, Optional MicroTech Control Panel 6 AGR 055AS through 100AS Product Manual 970

7 Selection Procedure Selection Procedure 60 hertz English Units Table 4, 60 Hz, R-22 English Units, cover the range of leaving evaporator water temperatures and outside ambient temperatures included under ARI 590. The tables are based on a 10 F temperature drop through the evaporator. Adjustment factors for applications having other than a 10 F drop can be found in Table 3. The minimum leaving chilled water temperature setpoint without glycol is 40 F. For glycol selections, see Table 1 for ethylene or Table 2 for propylene glycol adjustment factors. Ratings are based on a fouling factor in the evaporator at sea level operation. For other fouling factors, derates (for different delta-ts), or altitude correction factors, see Table 3. For applications outside the catalog ratings contact your local McQuay sales representative. Selection example Given: 67 tons minimum 95 F ambient temperature 44 F chilled water temperature fouling factor 1. From Performance Table 4, an AGR 070AS at the given conditions will produce 67.3 tons with a compressor kw input of 80.9 and a unit EER of Calculate the evaporator GPM: GPM = 67. 3tons F = GPM 3 Determine the evaporator pressure drop. Using Figure 3, enter at GPM and follow up to the AGR 070AS line intersect. Read horizontally to obtain an evaporator pressure drop of 15.0 feet of water. Selection example using ethylene glycol Given: 64 tons minimum 95 F ambient temperature 54 F to 44 F chilled fluid fouling factor Protect from freezing down to 0 F 1. From Table 1, select an ethylene glycol concentration of 40% to protect against freezing at 0 F. 2. At 40% ethylene glycol, the adjustment factors are: Capacity =0.961, kw = 0.976, GPM = 1.121, pressure drop = Consider the AGR 070AS and correct with 40% ethylene glycol factors. 4. Correct capacity = X 67.3 tons = 64.7 tons 5. Correct compressor kw = X 80.9 = 78.9 kw Product Manual 970 AGR 055AS through 100AS 7

8 6. Correct chilled water flow: Water flow (at corrected capacity) = 64.7tons F = GPM Water flow (at 40% solution) = X GPM = GPM Determine the evaporator pressure drop. Using Figure 3, enter at GPM and follow up to the AGR 070AS line intersect. Read horizontally to obtain an evaporator pressure drop of 14 feet. The pressure drop for 40% solution = X 14 feet = 17.7 feet of water Selection Procedure 60Hertz Metric Units Table 5, 60 Hz, R-22 Metric Units, covers a range of leaving evaporator water temperatures and outside ambient temperatures. The tables are based on a 5 C temperature drop through the evaporator. The minimum leaving chilled water temperature setpoint without glycol is 4.5 C. For brine selections, see Table 1 for ethylene or Table 2 for propylene glycol adjustment factors. Ratings are based on a fouling factor in the evaporator at sea level operation. For other fouling factors, derates (for different Delta-Ts), or altitude correction factors, see Table 3. For applications outside the catalog ratings contact your local McQuay sales representative. Selection Example Given: 235 kw minimum 35 C ambient air temperature 12 C - 7 C chilled water temperature evaporator fouling factor 1. From Table 5, an AGR 070AS at the given conditions will produce kw with a unit kw input of 81.1 and a COP of Calculate the evaporator L/s: 239.3kW C = 114. L / s 3. Determine the evaporator pressure drop. Using Figure 3, enter at L/s and follow to the AGR 070AS line intersect. Read horizontally to obtain an evaporator pressure drop of 55.5 kpa of water. Selection Example Using Ethylene Glycol Given: 225 kw minimum 35 C ambient air temperature 12 C - 7 C chilled water temperature evaporator fouling factor Protect against freezing down to -18 C 1. From Table 1, select an ethylene glycol concentration of 40% to protect against freezing at -18 C 2. At 40% ethylene glycol, the adjustment factors are: Capacity = 0.961, kw = 0.976, GPM = 1.121, pressure drop = Consider the AGR 070AS and correct with 40% ethylene glycol factors. 4. Correct capacity = X kw = kw 5. Correct compressor kw = X 81.1 kw = 79.1 kw 8 AGR 055AS through 100AS Product Manual 970

9 6. Correct chilled water flow: Water flow (at corrected capacity) = 229.9kW C = 110. L / s Water flow (at 40% solution) = X 11.0 L/s = 12.3 L/s 7. Determine the evaporator pressure drop. Using Figure 3, enter at 11.0 L/s and follow to the AGR 070AS line intersect. Read horizontally to obtain an evaporator pressure drop of 57 kpa of water. The pressure drop for 40% solution = X 57 kpa = 71.9 kpa Application Adjustment Factors Ethylene and Propylene Glycol Factors AGR units can operate with a leaving chilled fluid temperature range of 20 F (-6 C) to 50 F (10 C). A glycol solution is required when leaving chilled fluid temperature is below 40 F (4.6 C). The use of glycol will reduce the performance of the unit depending on concentration. Altitude Correction Factors Performance tables are based at sea level. Elevations other than sea level affect the performance of the unit. The decreased air density will reduce condenser capacity and reduce the unit's performance. For performance at elevations other than sea level refer to Table 3. Evaporator Temperature Drop Factors Performance tables are based on a 10 F (5 C) temperature drop through the evaporator. Adjustment factors for applications having temperature drops from 6 F to 16 F (3.3 C to 8.9 C) are in Table 3. Temperature drops outside this 6 F to 16 F (3.3 C to 8.9 C) range may affect the control system's capability to maintain acceptable control and are not recommended. The maximum water temperature that can be circulated through the evaporator in a non-operating mode is 100 F (37.8 C). Table 1, Ethylene glycol % Freeze Point E.G. F C Capacity Power GPM PD Table 2, Propylene glycol % Freeze Point P.G. F C Capacity Power GPM PD NOTE: Ethylene and propylene glycol ratings are outside the scope of ARI Standard 590 certification program Product Manual 970 AGR 055AS through 100AS 9

10 Fouling factor Performance tables are based on water with a fouling factor of ft hr F / BTU,( m C / kw) per ARI 590. As fouling is increased, performance decreases. For performance at other than (0.044) fouling factor refer to Table 3. Foreign matter in the chilled water system will adversely affect the heat transfer capability of the evaporator, and could increase the pressure drop and reduce the water flow. To ensure optimum unit operation, maintain proper water treatment. Table 3, Capacity and Power Derates ALTITUD E Chilled Water Fouling Factor Delta-T (0.044) (0.132) (0.308) F C Capacity Power Capacity Power Capacity Power SEA LEVEL feet feet feet AGR 055AS through 100AS Product Manual 970

11 Performance Data Table 4, 60 Hz, R-22 English Units AMBIENT AIR TEMPERATURE AGR LWT 75 F 85 F 95 F 105 F 115 F UNIT SIZE ( F) CAPAC. PWR CAPAC. PWR CAPAC. PWR CAPAC. PWR CAPAC. PWR TONS kwi EER TONS kwi EER TONS kwi EER TONS kwi EER TONS kwi EER AS AS AS AS AS AS AS AS AS AS Notes: 1. Boxed ratings certified in accordance with ARI Standard Ratings based on HCFC-22, evaporator fouling factor of , evaporator temperature drop of 10 F, and at sea level. 3. Ratings based on circuit #1 in lead position and #2 in the lag position. 4. kwi input is for compressors only, EER is for the entire unit, including compressors, fan motors and control power. 5. For LWT below 40 F please refer to Application Data section. 6. For 208V units, multiply capacity and EER by For units with SpeedTrol option, multiply capacity and EER by For units with 6-stage capacity option, multiply capacity and EER by 0.98 Product Manual 970 AGR 055AS through 100AS 11

12 Table 5, 60 Hz, R-22 Metric Units AMBIENT AIR TEMPERATURE AGR LWT 25 C 30 C 35 C 40 C 45 C UNIT SIZE ( C) CAPAC. PWR CAPAC. PWR CAPAC. PWR CAPAC. PWR CAPAC. PWR kw kwi COP kw kwi COP kw kwi COP kw kwi COP kw kwi COP AS AS AS AS AS AS AS AS AS AS NOTES: 1. Boxed ratings certified in accordance with ARI Standard Ratings based on HCFC-22, evaporator fouling of , evaporator temperature drop of 10 F and sea level altitude. 3. Ratings are based on circuit #1 in lead position and circuit #2 in lag position. 4. Interpolation is allowed; extrapolation is not permitted. Consult McQuay for performance outside the cataloged ratings. 5. KWi input is for compressors only. EER is for the entire unit, including compressors, fan motors and control power. 6. For LWT below 40 F and below please refer to Application Data. 7. For 208V units, multiply capacity and EER by For units with SpeedTrol option, multiply capacity and EER by For units with 6-stage capacity option, multiply capacity and EER by AGR 055AS through 100AS Product Manual 970

13 Part Load Data Table 6, 60 Hz, R-22 English Units 60 HZ AGR % Load Capacity Power Tons Unit kw EER IPLV AS AS AS AS AS AS AS AS AS AS Notes: Certified in accordance with ARI Standard 590 Product Manual 970 AGR 055AS through 100AS 13

14 Pressure Drop Curves Figure 3, Pressure Drops NOMINAL MINIMUM MAXIMUM Flow Pressure Drop Flow Pressure Drop Flow Pressure Drop Unit (GPM) (L / s) (ft) of water KPa (GPM) (L / s) (ft) of Water KPa (GPM) (L/s) (ft) of water KPa 055A A A A A A A A A A Minimum and maximum flows are established to ensure the Delta-T for each unit size falls within the 6-16 F range for proper unit control. Contact factory for unit operation outside of minimum and maximum flows shown. 14 AGR 055AS through 100AS Product Manual 970

15 Electrical Data Table 7, 60 Hz, Single Point Power Electrical Data Minimum POWER SUPPLY Max. Fuse AGR Circuit Field Wire Conduit Hub or Unit Volts Ampacity Wire Nominal HACR Breaker Size (MCA) Quantity Gauge Quantity Size Size A / # # A / / # A / / # A / / # A / / # / A / / / / A / / / / A / / / A / / A / All Electrical Data notes are on page 20 Product Manual 970 AGR 055AS through 100AS 15

16 Table 8, 60 Hz, Multiple Point Power Electrical Data Electrical Circuit #1 Electrical Circuit #2 AGR Min. Power Supply Max. Fuse Min. Power Supply Max. Fuse Unit Volts Circuit Field Wire Conduit Hub or Circuit Field Wire Conduit Hub or Size Amps Wire Hub HACR Breaker Amps Wire Hub HACR Breaker (MCA) Qty. Gauge Qty. Size Size (MCA) Qty. Gauge Qty. Size Size # # # # A # # # # # # # / # / A # # # # # # / / / / A # # # # # # / / / / A # # # # # # / / / / A # # # # # # / / / / A # / # # # # / / / / A / / # # # # / / / / A / / # # # # / / A / / # # # # A / / # # # # All Electrical Data notes are on page AGR 055AS through 100AS Product Manual 970

17 Table 9, 60 Hz, Compressor And Condenser Fan Motor Amp Draw Rated Load Amps Locked Rotor Amps AGR Compressors Fan No. Of Fan Compressors Unit Volts No. No. Motors Fan Motors Across-The-Line Reduced Inrush Size 1 2 (Each) Motors (Each) No. 1 No. 2 No. 1 No A N/A N/A A N/A N/A A N/A N/A A N/A N/A A N/A N/A A N/A N/A A N/A N/A A N/A N/A A N/A N/A A N/A N/A All Electrical Data notes are on page 20 Product Manual 970 AGR 055AS through 100AS 17

18 Table 10, 60 Hz Single Point Power, Field Wiring Data Wiring to Standard Wiring to Optional AGR Power Block Non-Fused Disconnect Switch Unit Volts Terminal Connector Wire Range Terminal Connector Wire Range Size Amps (Copper Wire Only) Amps (Copper Wire Only) # MCM MCM # MCM MCM 055A # MCM 150 #2-3/ # MCM 150 #2-3/ # MCM 100 #6-1/ # MCM MCM # MCM MCM 060A # MCM 250 #4-350 MCM # MCM 150 #2-3/ # MCM 150 #2-3/ # MCM MCM # MCM MCM 065A # MCM 250 #4-350 MCM # MCM 250 #4-350 MCM # MCM 150 #2-3/ # MCM MCM # MCM MCM 070A # MCM 250 #4-350 MCM # MCM 250 #4-350 MCM # MCM 150 #2-3/ # MCM MCM # MCM MCM 075A # MCM 250 #4-350 MCM # MCM 250 #4-350 MCM # MCM 150 #2-3/ (2 qty.) 1/0-600 MCM MCM (2 qty.) 1/0-600 MCM MCM 080A # MCM 250 #4-350 MCM # MCM 250 #4-350 MCM # MCM 250 #4-350 MCM (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM 085A # MCM MCM # MCM 250 #4-350 MCM # MCM 250 #4-350 MCM (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM 090A # MCM MCM # MCM 250 #4-350 MCM # MCM 250 #4-350 MCM (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM 095A # MCM MCM # MCM 250 #4-350 MCM # MCM 250 #4-350 MCM (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM 100A # MCM MCM # MCM 250 #4-350 MCM # MCM 250 #4-350 MCM All Electrical Data notes are on page AGR 055AS through 100AS Product Manual 970

19 Table 11, 60 Hz Multiple Point Power, Field Wiring Data Wiring to Standard AGR Power Blocks Unit Volts Terminal Amps Connector Wire Range (Copper Wire Only) Size Circuit 1 Circuit 2 Circuit 1 Circuit #12-2/0 #12-2/ #12-2/0 #12-2/0 055A #12-2/0 #12-2/ #12-2/0 #12-2/ #12-2/0 #12-2/ #4-400 # #4-400 # A #12-2/0 #12-2/ #12-2/0 #12-2/ #12-2/0 #12-2/ #4-400 # #4-400 # A #12-2/0 #12-2/ #12-2/0 #12-2/ #12-2/0 #12-2/ #4-400 # #4-400 # A #12-2/0 #12-2/ #12-2/0 #12-2/ #12-2/0 #12-2/ #4-400 # #4-400 # A #12-2/0 #12-2/ #12-2/0 #12-2/ #12-2/0 #12-2/ #4-400 # #4-400 # A #12-2/0 #12-2/ #12-2/0 #12-2/ #12-2/0 #12-2/ #4-400 # #4-400 # A #12-2/0 #12-2/ #12-2/0 #12-2/ #12-2/0 #12-2/ #4-400 # #4-400 # A #4-400 # #12-2/0 #12-2/ #12-2/0 #12-2/ #4-400 # #4-400 # A #4-400 # #12-2/0 #12-2/ #12-2/0 #12-2/ #4-400 # #4-400 # A #4-400 # #12-2/0 #12-2/ #12-2/0 #12-2/0 All Electrical Data notes are on page 20 Product Manual 970 AGR 055AS through 100AS 19

20 Notes for Electrical Data Single Point Power: 1. Unit wire size ampacity (MCA) is equal to 125% of the largest compressor-motor RLA plus 100% of RLA of all other loads in the circuit including the control transformer. 2. If the control transformer option is furnished, a separate 115v power is not required. 3. If a separate 115V power supply is used for the control circuit, then the wire sizing amps is 10 amps for all unit sizes. 4. Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductor ampacity in accordance with NEC. Nominal voltage drop has been included. It is recommended that power leads be kept short. All terminal block connections must be made with copper (type THW) wire. 5. Recommended Fuse Sizes or HACR breaker size is selected at approximately 150% to 175% of the largest compressor RLA, plus 100% of all other loads in the circuit. 6. Maximum Fuse or HCAR breaker size is selected based on 225% of the largest compressor RLA, plus 100% of all other loads in the circuit. 7. The recommended power lead wire sizes are based on an ambient temperature of 86 F (30 C). Ampacity correction factors must be applied for other ambient temperatures. Refer to the National Electrical Code Handbook. 8. Must be electrically grounded according to national and local electrical codes. Voltage Limitations: Within ± 10 percent of unit nameplate rating Notes for Compressor and Condenser Fan Amp Draw : 1. Compressor RLA values are for wiring sizing purposes only and may be higher than nominal operating current draw at rated capacity. 2. If unit is equipped with SpeedTrol condenser fan motors, the first motor on each refrigerant circuit is a single phase, 1hp motor, with a FLA of 2.8 amps at 460 volts, 5.6 amps at 208, 230, and 575 volts. 3. Compressor LRA for reduced inrush start are for the first winding of part-winding start only. 4. If the unit is equipped with SpeedTrol motors, the first motor is a single phase, 1 hp motor, with a LRA of 7.3 amps at 460 volts, 14.5 amps at 208, 230, and 575 volts. Notes for Field Wiring Data 1. The standard unit requires a single disconnect to supply electrical power to the unit. Power supply must either be fused or use an HACR type circuit breaker. 2. Multiple point power connection for field wiring is available as an option. Two power terminal blocks are supplied in the unit, one for each system in the unit. Each power terminal block supplies both compressor and fan motor power for each system. If the control transformer option is furnished, it is connected to the system #1 power terminal block. 3. All field wiring to unit power block or optional non-fused disconnect switch must be copper. 4. All field wire size values given in table apply to 75 C rated wire per NEC. 20 AGR 055AS through 100AS Product Manual 970

21 Figure 4, Typical Field Wiring with MicroTech Controller DISCONNECT (BY OTHERS) UNIT MAIN TERMINAL BLOCK GND LUG 3 PHASE POWER SUPPLY TO COMPRESSOR(S) AND FAN MOTORS FUSED CONTROL CIRCUIT TRANSFORMER OPTION N 120VAC CONTROL POWER DISCONNECT (BY OTHERS) 10A FUSE (BY OTHERS) SEPARATE EVAPORATOR DISCONNECT HEATER POWER (BY OTHERS) 10A OPTION FUSE 120VAC (BY OTHERS) (BY OTHERS) N 120 VAC TB NB CONTROL CIRCUIT FUSE IF SEPARATE EVAPORATOR HEATER POWER OPTION IS USED - REMOVE WIRES 540 AND 545. ALARM BELL OPTION 24V OR 120VAC (BY OTHERS) N FACTORY SUPPLIED ALARM FIELD WIRED ALARM BELL CHW PUMP RELAY (BY OTHERS) 9 10 TB3 19 5A SOLID STATE RELAY 24V OR 120VAC 1.5 AMPS MAX. 24VAC TIME AMBIENT CLOCK THERMOSTAT AUTO OFF REMOTE STOP ON (BY OTHERS) CHW FLOW SWITCH (BY OTHERS) 4-20 MA FOR CHW RESET (BY OTHERS) 4-20 MA FOR DEMAND LIMIT (BY OTHERS) MANUAL 28 TB GND MJ GND IF REMOTE STOP CONTROL IS USED, REMOVE JUMPER FROM TERM 140 TO 141. *(CONNECTION TO RMS (REMOTE MONITORING SEQUENCE) OR TO NMP (NETWORK MASTER PANEL) *MICROTECH ONLY GND * COMMUNICATION PORT "B" See Note 3 for Electrical Data Single Point Power on page 20 Product Manual 970 AGR 055AS through 100AS 21

22 Figure 5, Typical Field Wiring Diagram with UNT Controller DISCONNECT (BY OTHERS) UNIT MAIN TERMINAL BLOCK GND LUG 3 PHASE POWER SUPPLY TO COMPRESSOR(S) AND FAN MOTORS FUSED CONTROL CIRCUIT TRANSFORMER OPTION SEPARATE EVAPORATOR DISCONNECT HEATER POWER (BY OTHERS) OPTION 120VAC (BY OTHERS) N N 120VAC CONTROL POWER DISCONNECT (BY OTHERS) 10A FUSE (BY OTHERS) 10A FUSE (BY OTHERS) 120 VAC TB NB CONTROL CIRCUIT FUSE IF SEPARATE EVAPORATOR HEATER POWER OPTION IS USED - REMOVE WIRES 540 AND 545. FACTORY SUPPLIED ALARM TIME DELAY FIELD WIRED ALARM BELL OPTION ALARM BELL TB VAC REMOTE STOP (BY OTHERS) AMBIENT THERMOSTAT CHW FLOW SWITCH (BY OTHERS) TIME CLOCK AUTO OFF ON MANUAL 28 TB GND MJ IF REMOTE STOP CONTROL OR TIME CLOCK IS USED, REMOVE JUMPER FROM TERM 140 TO SEE OPTIONS BELOW (ONLY ONE SELECTION AVAIL. AT A TIME.) 0-10V-DEMAND LIMIT TEMP.-ZONE TEMP. 2-10V-REMOTE RESET TEMP.-RETURN EVAP. WATER TEMP.-*OUTSIDE AIR *STANDARD SELECTION See note 3 for Electrical Data Single Point Power on page AGR 055AS through 100AS Product Manual 970

23 Physical Data Table 12, AGR 0550A Through 070A PHYSICAL DATA AGR MODEL NUMBER STANDARD EFFICIENCY 055AS 060AS 065AS 070AS BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Unit ARI Conditions (1), Tons (kw) 54.3 (190.9) 59.3 (208.5) 63.5 (223.3) 67.3 (236.6) Number Of Refrigerant Circuits Unit Operating Charge, R-22, Lbs Unit Operating Charge, R-22, (kg) (24.5) (24.5) (25.4) (25.4) (28.1) (28.1) (29.5) (29.5) Cabinet Dimensions, LxWxH, In x 88.2 x x 88.2 x x 88.2 x x 88.2 x 96.2 Cabinet Dimensions, LxWxH, (mm) 2388 x 2241 x x 2241 x x 2241 x x 2241 x 2444 Unit Operating Weight, Lbs. (kg) 4000 (1814) 4008 (1818) 4230 (1919) 4276 (1940) Unit Shipping Weight, Lbs. (kg) 3892 (1765) 3900 (1769) 4123 (1870) 4169 (1891) Add'l Weight If Copper Finned Coils, Lbs. (kg) 665 (300) 665 (300) 830 (375) 830 (375) COMPRESSORS Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Semi-Hermetic Nominal Horsepower Number Of Cylinders Per Compressor Oil Charge Per Compressor, Oz Oil Charge Per Compressor, (g) (3969) (3969) (3969) (3969) (3969) (3969) (3969) (7229) CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT Standard Staging - Circuit #1 in Lead Standard 4 Stages Standard Staging - Circuit #2 in Lead Standard 4 Stages Optional Staging - Circuit #1 in Lead Optional 6 Stages Optional Staging - Circuit #2 in Lead Optional 6 Stages CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING Coil Face Area,Sq. Ft Coil Face Area, (M 2 ) (4.3) (4.3) (4.3) (4.3) (5.4) (5.4) (5.4) (5.4) Finned Height x Finned Length, In. 80 x x x x x x x x 83.5 Finned Height x Finned Length, (mm) 2032 x x x x x x x x 2121 Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 Maximum Relief Valve Pressure Setting, psig (kpa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE Number Of Fans - Fan Diameter, In. (mm) 4-28 (712) 4-28 (712) 4-28 (712) 4-28 (712) Number Of Motors - HP (kw) (1.1) (1.1) (1.1) (1.5) Fan And Motor RPM, 60Hz Hz Fan Tip Speed, FPM (M/Sec) 8357 (35.4) 8357 (35.4) 8357 (35.4) 8357 (35.4) 60 Hz Total Unit Airflow, CFM (M3/sec) (17.4) (17.4) (18.1) (19.3) DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE Diameter, in. - Length, Ft Diameter, (mm) - Length, (mm) Water Volume, Gallons, (L) 12.8 (48.5) 12.8 (48.5) 12.8 (48.5) 12.8 (48.5) Maximum Water Pressure, psig (kpa) 175 (1207) 175 (1207) 175 (1207) 175 (1207) Maximum Refrigerant Working Pressure, psig (kpa) 225 (1552) 225 (1552) 225 (1552) 225 (1552) Water Inlet / Outlet Victaulic Connections, In. (mm) 4 (101.6) 4 (101.6) 4 (101.6) 5 (141.3) Drain - NPT int, In. (mm).375 (9.5).375 (9.5).375 (9.5).375 (9.5) Vent - NPT int, In. (mm).375 (9.5).375 (9.5).375 (9.5).375 (9.5) NOTE: 1. Nominal capacity based on 95F ambient air and 54F/44F water range. Product Manual 970 AGR 055AS through 100AS 23

24 Table 13, AGR 075A Through 085A PHYSICAL DATA AGR MODEL NUMBER STANDARD EFFICIENCY 075AS 080AS 085AS BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Unit ARI Conditions (1), Tons (kw) 71.7 (252.1) 77.9 (273.9) 84.1 (295.7) Number Of Refrigerant Circuits Unit Operating Charge, R-22, Lbs Unit Operating Charge, R-22, (kg) (39.9) (39.9) (40.8) (41.7) (41.7) (41.7) Cabinet Dimensions, LxWxH, In x 88.2 x x 88.2 x x 88.2 x 96.2 Cabinet Dimensions, LxWxH, (mm) 3463 x 2241 x x 2241 x x 2241 x 2444 Unit Operating Weight, Lbs. (kg) 5506 (2497) 5740 (2604) 5921 (2686) Unit Shipping Weight, Lbs. (kg) 5359 (2431) 5593 (2537) 5774 (2619) Add'l Weight If Copper Finned Coils, Lbs. (kg) 1245 (565) 1245 (565) 1245 (565) COMPRESSORS Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Nominal Horsepower Number Of Cylinders Per Compressor Oil Charge Per Compressor, Oz Oil Charge Per Compressor, (g) (7229) (7229) (7229) (7229) (7229) (7229) CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT Standard Staging - Circuit #1 in Lead Standard 4 Stages Standard Staging - Circuit #2 in Lead Standard 4 Stages Optional Staging - Circuit #1 in Lead Optional 6 Stages Optional Staging - Circuit #2 in Lead Optional 6 Stages CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING Coil Face Area,Sq. Ft Coil Face Area, (M 2 ) (8.1) (8.1) (8.1) (8.1) (8.1) (8.1) Finned Height x Finned Length, In. 100x x x x x x125.3 Finned Height x Finned Length, (mm) 2540 x x x x x x 3183 Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 Maximum Relief Valve Pressure Setting, psig (kpa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE Number Of Fans - Fan Diameter, In. (mm) 6-28 (712) 6-28 (712) 6-28 (712) Number Of Motors - HP (kw) (1.5) (1.5) (1.5) Fan And Motor RPM, 60Hz Hz Fan Tip Speed, FPM (M/Sec) 8357 (35.4) 8357 (35.4) 8357 (35.4) 60 Hz Total Unit Airflow, CFM (M3/sec) (28.9) (28.9) (28.9) DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE Diameter, in. - Length, Ft Diameter, (mm) - Length, (mm) Water Volume, Gallons, (L) 17.6 (66.6) 17.6 (66.6) 17.6 (66.6) Maximum Water Pressure, psig (kpa) 175 (1207) 175 (1207) 175 (1207) Maximum Refrigerant Working Pressure, psig (kpa) 225 (1552) 225 (1552) 225 (1552) Water Inlet / Outlet Victaulic Connections, In. (mm) 5 (141.3) 5 (141.3) 5 (141.3) Drain - NPT int, In. (mm).375 (9.5).375 (9.5).375 (9.5) Vent - NPT int, In. (mm).375 (9.5).375 (9.5).375 (9.5) NOTE: 1. Nominal capacity based on 95F ambient air and 54F/44F water range. 24 AGR 055AS through 100AS Product Manual 970

25 Table 14, AGR 090A Through 100A PHYSICAL DATA AGR MODEL NUMBER STANDARD EFFICIENCY 090AS 095AS 100AS BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Unit ARI Conditions (1), Tons (kw) 86.5 (304.1) 93.4 (328.4) 99.3 (349.1) Number Of Refrigerant Circuits Unit Operating Charge, R-22, Lbs Unit Operating Charge, R-22, (kg) (42.6) (42.6) (42.6) (42.6) (42.6) (43.5) Cabinet Dimensions, LxWxH, In x 88.2 x x 88.2 x x 88.2 x 96.2 Cabinet Dimensions, LxWxH, (mm) 3463 x 2241 x x 2241 x x 2241 x 2444 Unit Operating Weight, Lbs. (kg) 6184 (2805) 6194 (2810) 6194 (2810) Unit Shipping Weight, Lbs. (kg) 6008 (2725) 6018 (2730) 6018 (2730) Add'l Weight If Copper Finned Coils, Lbs. (kg) 1245 (565) 1245 (565) 1245 (565) COMPRESSORS Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Nominal Horsepower Number Of Cylinders Per Compressor Oil Charge Per Compressor, Oz Oil Charge Per Compressor, (g) (7229) (7229) (7229) (7229) (7229) (7229) CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT Standard Staging - Circuit #1 in Lead Standard 4 Stages Standard Staging - Circuit #2 in Lead Standard 4 Stages Optional Staging - Circuit #1 in Lead Optional 6 Stages Optional Staging - Circuit #2 in Lead Optional 6 Stages CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING Coil Face Area,Sq. Ft Coil Face Area, (M 2 ) (8.1) (8.1) (8.1) (8.1) (8.1) (8.1) Finned Height x Finned Length, In. 100x x x x x x125.3 Finned Height x Finned Length, (mm) 2540 x x x x x x 3183 Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 Maximum Relief Valve Pressure Setting, psig (kpa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE Number Of Fans - Fan Diameter, In. (mm) 6-28 (712) 6-28 (712) 6-28 (712) Number Of Motors - HP (kw) (1.5) (1.5) (1.5) Fan And Motor RPM, 60Hz Hz Fan Tip Speed, FPM (M/Sec) 8357 (35.4) 8357 (35.4) 8357 (35.4) 60 Hz Total Unit Airflow, CFM (M3/sec) (28.9) (28.9) (28.9) DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE Diameter, in. - Length, Ft Diameter, (mm) - Length, (mm) Water Volume, Gallons, (L) 21.2 (80.3) 21.2 (80.3) 21.2 (80.3) Maximum Water Pressure, psig (kpa) 175 (1207) 175 (1207) 175 (1207) Maximum Refrigerant Working Pressure, psig (kpa) 225 (1552) 225 (1552) 225 (1552) Water Inlet / Outlet Victaulic Connections, In. (mm) 5 (141.3) 5 (141.3) 5 (141.3) Drain - NPT int, In. (mm).375 (9.5).375 (9.5).375 (9.5) Vent - NPT int, In. (mm).375 (9.5).375 (9.5).375 (9.5) NOTE: 1. Nominal capacity based on 95F ambient air and 54F/44F water range. Product Manual 970 AGR 055AS through 100AS 25

26 Dimensional Data Figure 6, Dimensions AGR 055AS through 070AS AGR Center of Gravity Additional Weight MODEL inch / mm for Units with Copper Number A B C D E F X Y Z Operating Shipping Fin Coils lb / kg 055AS 86.2 (2190) 81.7 (2075) 61.6 (1565) 22.3 (566) 4.3 (108) 16.0 (406) 44.6 (1133) 41.2 (1046) 36.4 (925) 4055 (1840) 3950 ( (300) 060AS 86.2 (2190) 81.7 (2075) 61.6 (1565) 22.3 (566) 4.3 (108) 16.0 (406) 44.6 (1133) 41.2 (1046) 36.4 (925) 4115 (1865) 4010 (1820) 665 (300) 065AS 96.2 (2444) 91.7 (2329) 61.6 (1565) 22.3 (566) 4.3 (108) 16.0 (406) 45.0 (1143) 41.8 (1062) 38.8 (986) 4295 (1950) 4190 (1900) 830 (375) 070AS 96.2 (2444) 91.7 (2329) 60.0 (1525) 23.9 (607) 4.3 (108) 16.0 (406) 45.0 (1143) 41.8 (1062) 38.8 (986) 4275 (1940) 4170 (1890) 830 (375) 26 AGR 055AS through 100AS Product Manual 970

27 Figure 7, Dimensions AGR 075AS through 100AS AGR Center of Gravity Additional Weight MODEL inch / mm for Units with Copper Number A B C D E F X Y Z Operating Shipping Fin Coils lb / kg 075AS 96.2 (2444) 91.7 (2329) 99.2 (2520) 45.2 (1148) 4.4 (112) 17.5 (444) 60.4 (1534) 42.2 (1072) 37.3 (947) 5510 (2500) 5630 (2430) 1245 (565) 080AS 96.2 (2444) 91.7 (2329) 99.2 (2520) 45.2 (1148) 4.4 (112) 17.5 (444) 60.4 (1534) 41.5 (1054) 36.9 (937) 5740 (2605) 5595 (2540) 1245 (565) 085AS 96.2 (2444) 91.7 (2329) 99.2 (2520) 45.2 (1148) 4.4 (112) 17.5 (444) 60.4 (1534) 40.8 (1036) 36.2 (919) 5920 (2685) 5775 (2620) 1245 (565) 090AS 96.2 (2444) 91.7 (2329) 99.2 (2520) 45.2 (1148) 3.8 (96) 17.5 (444) 60.4 (1534) 42.0 (1067) 36.8 (935) 6185 (2805) 6010 (2725) 1245 (565) 095AS 96.2 (2444) 91.7 (2329) 99.2 (2520) 45.2 (1148) 3.8 (96) 17.5 (444) 60.4 (1534) 42.0 (1067) 35.4 (899) 6195 (2810) 6020 (2730) 1245 (565) 100AS 96.2 (2444) 91.7 (2329) 99.2 (2520) 45.2 (1148) 3.8 (96) 17.5 (444) 60.4 (1534) 42.0 (1067) 35.4 (899) 6195 (2810) 6020 (2730) 1245 (565) Product Manual 970 AGR 055AS through 100AS 27

28 Application Data Unit Placement AGR units are for outdoor applications and can be mounted either on a roof or at ground level. For roof mounted applications, install the unit on a steel channel or I-beam frame to support the unit above the roof. For ground level applications, install the unit on a substantial base that will not settle. A one piece concrete slab with footings extended below the frost line is recommended. Be sure the foundation is level (within 1/2"(13mm) over its length and width). The foundation must be strong enough to support the operating weights listed in Table 12 through Table 14. On ground level applications protect fins against vandalism using the optional coil guards or by erecting a screen fence. The fence must allow free flow of air to the condenser coil for proper unit operation. Clearances Do not block the flow of air to and from the condenser coil. Restricting airflow or allowing air recirculation will result in a decrease in unit performance and efficiency because discharge pressures Figure 8, Clearances (4 and 6 fan units) are increased. There must be no obstruction above the unit that would deflect discharge air downward where it could be recirculated back to the inlet of the condenser coil. The condenser fans are propeller type and will not operate with ductwork on the fan outlet. Install the unit with enough side clearance for air entrance to the coil and for servicing. Provide service access to the evaporator, compressors, electrical control panel and piping components. Do not allow debris to accumulate near the unit. Air movement may draw debris into the condenser coil causing coil starvation. Give special consideration to low ambient operation where snow can accumulate. Keep condenser coils and fan discharge free of snow or other obstructions to permit adequate airflow for proper unit operation. 28 AGR 055AS through 100AS Product Manual 970

29 Sound Isolation The ultra-low sound levels for the AGR chiller is sufficient for most applications. However, there will be applications where sound levels are an issue. Avoid locations beneath windows or between structures where normal operating sounds may be objectionable. Reduce structurally transmitted sound by isolating water lines, electrical conduit and the unit itself. Use wall sleeves and rubber isolated piping hangers to reduce transmission of water or pump noise into occupied spaces. Use flexible electrical conduit to isolate sound through electrical conduit. Spring isolators are effective in reducing the low amplitude sound generated by reciprocating compressors and for unit isolation in sound sensitive areas. Typical Chilled Water Piping Flush the system water piping thoroughly before making connections to the unit evaporator. Install a strainer of 40 mesh in the return water line before the inlet to the chiller. Design the water piping so the chilled water circulating pump discharges into the evaporator inlet. Connect the return water line to the evaporator inlet connection (the connection closest to the compressors). Connect the supply water line to the evaporator outlet connection. Install a flow switch in the horizontal piping of the supply (evaporator outlet) water line. Provide drain connections at low points in the system to permit complete drainage of the system. Locate air vents at the high points in the system to purge air out of the system. A vent connection on top of the evaporator vessel allows air to be purged out of the evaporator. Purge air from the water system before unit start-up to ensure adequate flow through the evaporator. Install pressure gauges in the inlet and outlet water lines to the evaporator. Measure pressure drop through the evaporator and compare to flow as shown in Figure 9. Vibration eliminators are recommended in both the supply and return water lines. Insulate chilled water piping to reduce heat loss and prevent condensation. Chillers not running in the winter should have their water systems thoroughly drained to protect against freezing. If the chiller operates year round, or if the system is not drained for the winter, protect the chilled water piping exposed to outdoor temperature against freezing. Wrap the lines with a heater cable and add proper amount of glycol to the system to further protect the system. The total water volume in the system should be sufficient to prevent on-off cycling. Turnover rate should not be less than 15 minutes for normal varible loads. Turnover rate for process cooling or a constant load, should not be less than 6 minutes. Chilled Water Piping The thermostat sensor is factory mounted in the leaving water well. If an optional high return water sensor is provided, install sensor bulb in a field supplied tee or strap to the outside of the water line. Figure 9, Typical chilled water piping Product Manual 970 AGR 055AS through 100AS 29

30 Series Compared to Parallel Operation Consider system pressure drop when designing the water piping. Parallel piped systems have half of the total system flow going through the evaporator of each chiller, reducing the individual unit and total system pressure drop. Series piped evaporators require that the total system water flows through both evaporators. Not only is the pressure drop through each evaporator increased but the pressure drops must be added together to obtain the total evaporator pressure drop. Series piped evaporators normally require larger circulating pumps for the chilled water system. Temperature and Water Flow Limitations AGR units are designed to operate in temperatures from 40 F (-4.5 C) to 115 F (46 C). A low ambient option with SpeedTrol condenser fan control allows operation down to 0 F (-18 C). The minimum ambient temperature is based on still conditions where the wind is not greater than five mph. Greater wind velocities directly into the unit condenser coil will result in reduced discharge pressure, decreasing the minimum operating ambient temperature. When possible, position the unit on the down wind side of the building or where the unit will be least affected by wind. Field installed wind baffles are available. The baffles allow the chiller to operate effectively down to the ambient temperature for which the unit was designed. Evaporator flow rates below the minimum values may result in laminar flow causing freeze-up problems, scaling and poor control. Flow rates above the maximum values will result in unacceptable pressure drops and may cause excessive nozzle and tube erosion, potentially leading to failure. Evaporator Freeze Protection Evaporator freeze-up can be a concern in the application of air-cooled water chillers. To protect against freeze-up, insulation and an electric heater cable are furnished with the unit. This protects the evaporator down to -20 F (-29 C) ambient. Although the evaporator is equipped with freeze protection, it does not protect water piping external to the unit or the evaporator if there is a power failure or heater cable burnout. Consider the following recommendations for additional protection. 1. If the unit will not be operated during the winter, drain evaporator and chilled water piping. Drain and vent connections are provided on the evaporator to ease draining. 2. Add a glycol solution to the chilled water system to provide freeze protection. The freeze point should be approximately ten degrees below minimum design ambient temperature. The evaporator heater cable is wired to the 115 volt circuit in the control box. This power should be supplied from a separate source, but it may be supplied from the control circuit. Operation of the heater cable is automatic through the ambient sensing thermostat which energizes the evaporator heater cable for protection against freeze-up. Unless the evaporator is drained in the winter, the disconnect to the evaporator heater must not be open. Extended Shutdown This unit is equipped with a recycling pumpdown control system. This permits the compressors to run and re-pumpdown following a 2 hour off cycle if the refrigerant evaporator pressure is high enough to close the low pressure switch (57 to 60 psig). If the unit is expected to be off for an extended period of time, completely de-energize the unit except for piping and chiller vessel heat tape or modify the control scheme at the site to operate on a one-time NON-recycling pumpdown. 30 AGR 055AS through 100AS Product Manual 970

31 Optional Features Control Circuit Transformer For applications where a separate 115 volt power source is not available, the transformer is factory installed and wired between the line voltage power terminal block and the 115 volt control circuit. Hot Gas Bypass Hot gas bypass permits unit operation down to 10% of full load capacity. This option includes a hot gas bypass valve, solenoid valve, and manual shutoff valve for each circuit. Gauges Optional factory mounted gauges include high side and low side refrigerant gauges and oil pressure gauge for each refrigerant circuit for units with the standard UNT controller. (The data is included on the optional MicroTech control keypad display.) High Return Water Staging Thermostat Optional factor installed high return temperature unloader thermostat senses high return water temperatures at startup and unloads the refrigerant circuit to avoid unit shutdown due to compressor motor overload. Field location of the thermostat bulb is required. (Included on the MicroTech.) High Ambient Staging Pressurestat Optional factory installed high ambient unloading pressurestat senses head pressure exceeding 375 psig (2586 kpa) and unloads the compressor to keep head pressure below maximum limits under extremely high temperature operating conditions. This feature allows unit to run part loaded instead of shutting unit down due to high head pressure. (Included as part of the MicroTech control option.) SpeedTrol Head Pressure Control Optional SpeedTrol head pressure control allows unit operation down to 0 F (-18 C). (Not available on 380 volt - 60 Hertz units.) SpeedTrol includes a single-phase variable speed motor in the first fan position for each system. Protective Coil Guards Optional factory installed vinyl-coated welded wire coil guards provide all-around fin protection on ground level installations. Optional factory installed vinyl-coated base frame wire guards are available around the compressor and base frame areas for complete protection. Copper Fin Condenser Coils Copper fin condenser coils and coated coils are available as an option on all models. Disconnect Switch A factory installed service use, non-fused disconnect switch (mounted inside the power section of control box) is available with single point power supply only. Product Manual 970 AGR 055AS through 100AS 31

32 Circuit Breakers Factory installed circuit breakers are available on unit with single or multiple point power supply. This option provides unit installed compressor short circuit protection and makes servicing easier. Phase Loss/Voltage Protection Two levels of phase failure protection are available as a factory installed option to guard against compressor motor burnout: Phase loss with under/over voltage protection Phase loss with under/over voltage protection and multiple LED indication of fault type Water Flow Switch A water flow switch is available for field installation in the chilled water piping to prevent evaporator freeze-up under low or no flow conditions. Terminals are provided in the unit control center for field hook-up of the water flow safety switch. If this option is not ordered with the unit, then a field supplied water flow switch is required. Time Clock A 24 hour time clock for remote field installation for night shutdown is available. The time clock is field connected to the remote shutdown terminals provided in the unit control center. A time clock is also available with a spring carry-over. During normal operation, the spring is wound to operate the clock for up to 10 hours should power be lost to the unit. (Standard on MicroTech.) Vibration Isolators Spring vibration isolators are available for field installation to reduce vibration transmission through the unit base. Chilled Water Reset In applications when outside temperature effect load of the building, outdoor air reset can be provided to increase the system efficiency. The amount of reset is adjustable between 5 F and 20 F (3 C and 11 C). Zone Terminal Display Standard global UNT controller. (Not available on MicroTech option.) 32 AGR 055AS through 100AS Product Manual 970

33 MicroTech The control panel contains a Model microprocessor based controller. The operator can review and change operating parameters from the interface keypad. The interface keypad has twelve input keys and a two line by sixteen character display. The system is protected by a simple password scheme allowing access to authorized personnel. A valid password must be entered before any setpoints can be changed. MicroTech continuously performs self-diagnostic checks and will automatically shutdown a compressor, a refrigerant circuit, or the entire unit should a fault occur. The cause of the shutdown will be retained in memory and can easily be displayed for operator review. The MicroTech controller will also retain and display the time the fault occurred and the operating conditions that were present at the time of the fault. In addition to alarm diagnostics, the controller also provides the operator with a warning of pre-alarm conditions. Personal Computer Monitoring MicroTech Monitor software may be used on the customers personal computer to communicate with the MicroTech controller. The controller connects directly or remotely over phone lines with an optional modem. Dual Setpoint Control Ice storage applications; factory supplied with microprocessor based dual setpoint control. A field supplied time clock will determine whether the chiller operates in normal or ice mode. Cycle Counter and Run Hour Meter Factory installed keypad selectable cycle counters and hour meters are available for each compressor. Figure 10, Optional MicroTech Control Panel Product Manual 970 AGR 055AS through 100AS 33

34 Product Specification SECTION 15XXX AIR-COOLED RECIPROCATING COMPRESSOR CHILLERS AGR 055A - AGR 100A PART 1 - GENERAL 1.01 SUMMARY Section includes design, performance criteria, refrigerants, controls, and installation requirements for air-cooled reciprocating compressor chillers REFERENCES Comply with applicable Standards/Codes of ARI 590, ANSI/ASHRAE 15, ETL, cetl, ASME Section VIII, NEC, ASHRAE Standard 90.1, and OSHA as adopted by the State SUBMITTALS A. Submit shop drawings and product data in accordance with the specifications. B. Submittals shall include the following: 1. Dimensioned plan and elevation view drawings, required clearances, and location of all field connections. 2. Summary of all auxiliary utility requirements such as: electricity, water, compressed air, etc. Summary shall indicate quality and quantity of each required utility. 3. Single line schematic drawing of the power field hookup requirements, indicating all items which are furnished. 4. Schematic diagram of control system indicating points for field interface/connection. 5. Diagram shall fully delineate field and factory wiring. 6. Installation manuals QUALITY ASSURANCE A. Qualifications: Equipment manufacturer must specialize in the manufacture of the products specified and have five years experience with the equipment and refrigerant offered. B. Regulatory Requirements: Comply with the codes and standards specified. C Chiller manufacturer plant must be ISO9002 Registered. 34 AGR 055AS through 100AS Product Manual 970

35 1.05 DELIVERY AND HANDLING A. Chillers shall be delivered to the job site completely assembled and charged with refrigerant and oil by the manufacturer. B. Comply with the manufacturers instructions for rigging and handling equipment WARRANTY The refrigeration equipment manufacturer s warranty shall be for a period of one year from date of equipment start-up but not more than 18 months from shipment. The warranty shall cover material and workmanship that prove defective within the above period, excluding refrigerant MAINTENANCE Maintenance of the chillers shall be the responsibility of the owner and performed in accordance with the manufacturer s instructions. PART 2--PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS A. McQuay International B. (Approved Equal) 2.02 UNIT DESCRIPTION Provide and install as shown on the plans factory assembled, factory charged, and factory run tested air-cooled reciprocating compressor packaged chillers in the quantity specified. Each chiller shall consist of reciprocating semi-hermetic compressors, multi-circuit direct expansion evaporator, air-cooled condenser section, control system and all components necessary for safe and controlled unit operation DESIGN REQUIREMENTS A. General: Provide a complete reciprocating compressor packaged chiller as specified herein and as shown on the drawings. The unit shall be in accordance with the standards referenced in section 1.02 and any local codes in effect. B. Performance: Refer to the schedule of performance on the drawings. The chiller shall be capable of stable operation to a minimum of 30 percent of full load without hot gas bypass. Performance shall be in accordance with ARI Standard 590. C. Acoustics: Sound pressure levels for the unit shall not exceed the following specified levels. The manufacturer shall provide the necessary sound treatment to meet these levels if required. Sound data shall be provided with the quotation and be measured at 30 feet from the unit and one meter above the unit base line Octave Band dba Product Manual 970 AGR 055AS through 100AS 35

36 2.04 CHILLER COMPONENTS A. Structure: The chiller shall have a heavy duty fully painted formed steel, full length and width base. The base, condenser support legs and all other sheet metal components shall be galvanized, phosphorized, and painted. Coils shall be protected with wire grilles or louvers. Adequate space shall be provided to service or remove all components. B. Compressors: The compressors shall be accessible hermetic reciprocating type with suction and discharge service valves, crankcase oil heater and suction strainer. Compressors shall have a forced feed lubrication system with a reversible oil pump and initial oil charge. The compressor motor shall be refrigerant gas cooled, high torque, hermetic induction type, four-pole, with inherent thermal protection on all three phases and shall be mounted on RIS vibration isolator pads. C. Evaporator: The evaporator shall be direct expansion, shell and tube with carbon steel shell and high efficiency copper tubes rolled into steel tube sheets. Internal baffles shall be polypropylene. The refrigerant heads shall have multi-pass baffles to insure oil return and be removable to permit access to the tubes from either end. The shall be insulated with 3/4 inch (19mm) closed cell polymer insulation with a minimum K factor of 0.28 at 75 F (23 C) and be heated with an electric heater to provide freeze protection to -20 F (-29 C) ambient temperature. The refrigerant side working pressure shall be at least 225 psig (1552 kpa). The water side working pressure shall be at least 175 psig (1207 kpa) The evaporator must be designed, constructed, inspected, and stamped according to the ASME Code. D. Condenser: The condenser coils shall consist of 3/8 inch (10mm) seamless copper tubes mechanically bonded into rippled plate type fins. The fins shall have full drawn collars to completely cover the tubes. A subcooling coil shall be an integral part of the main condenser coil. Condenser fans shall be propeller type arranged for vertical air discharge and individually driven by direct drive fan motors. Each fan shall be in its own compartment to eliminate cross flow of condenser air during fan cycling and shall be equipped with a heavy-gauge vinyl coated fan guard. Fan motors shall be weather protected, three-phase, direct-drive, 1140 rpm, open dripproof type. Speed controlled fan motors shall be single-phase. E. Refrigerant Circuit: The refrigerant circuit shall include a liquid line shutoff valve, refrigerant filter-drier, sight glass with moisture indicator, liquid line solenoid valve (no exceptions), thermal expansion valve, and insulated suction line. 36 AGR 055AS through 100AS Product Manual 970

37 F. Control System: A centrally located weatherproof control panel shall contain the field power connection points, control interlock terminals, and control system. Power and starting components shall include factory fusing of fan motors and control circuit; individual contactors for each fan motor, solid-state start timer, solid-state three-phase motor overload protection, inherent fan motor overload protection and unit power terminal blocks for connection to remote disconnect switch. Terminals shall also be provided for power supply to the evaporator heater circuit. Hinged access doors shall be lockable. Barrier panels are required to protect against accidental contact with line voltage when accessing the control system. The operating and safety controls shall be: Global UNT microprocessor based control that accomplishes unit capacity control by 4-stage cross-circuit compressor cycling based on leaving chilled water temperature. Set point and control band shall easily field adjusted and anti-cycling and stage delay relays are to be included. Safety controls shall include low and high refrigerant pressure safeties, low evaporator flow, sensor failures, and evaporator freeze protection. Motor protection shall include phase voltage, volts ratio, and solid state compressor motor protection. The controller shall be equipped with a Zone Terminal option that provides an onboard LCD display of unit operating parameters and adjustment of any optional controls. - OR - MicroTech microprocessor control with a 12 key keypad and 4-line, 40 character backlit liquid crystal display operator interface. The controller shall continuously perform self diagnostic checks on all system temperatures, pressures, and safeties, and automatically shut down a circuit or the entire unit at fault conditions. The cause, time, and date of the occurrence shall be recorded and displayed along with availability to view the seven previous incidents. The controller shall take proactive measures to stay on-line for non critical abnormalities; staging down capacity, activating a pre-alarm signal and automatically switching to the alarm menu on the display. These pre-alarms shall be self clearing when the off-condition is corrected. Critical shutdown alarms such as high condenser pressure, freeze protection, and low evaporator pressure shall be manual reset and cleared at the keypad to resume operation. The refrigerant discharge pressure shall be controlled by a FanTrol system that cycles condenser fans based on discharge pressure and shall be operational 40 F (4.4 C). - OR - The refrigerant discharge pressure shall be controlled by a SpeedTrol control employing both fan cycling and fan speed control and allow operation to 0 F (-18 C). Product Manual 970 AGR 055AS through 100AS 37

38 2.05 OPTIONS AND ACCESSORIES The following options are to be included: Hot gas bypass on all circuits Low ambient, variable speed, head pressure control to 0 F (-17.8 C) Copper fin condenser coils Wire mesh coil guards to provide fin protection Chilled water flow switch to be field mounted in the chilled water line and field wired to terminals in the control panel Spring vibration isolators for field installation Control circuit transformer Factory mounted refrigerant pressure gauges for each circuit High return water staging thermostat to prevent compressor overload due to warm water starts High ambient staging thermostat to prevent compressor overload due to unusually high ambient temperatures Dual setpoint control switched by a remote signal from the building control system. Factory installed nonfused disconnect switch mounted in the unit control panel Factory installed circuit breaker to provide unit short circuit protection Phase loss with under/over voltage protection and with LED indication of the fault type. PART 3 - EXECUTION 3.01 INSTALLATION A. Install in strict accordance with manufacturer s requirements, shop drawings, and contract documents. B. Adjust and level chiller in alignment on supports. C. Coordinate electrical installation with electrical contractor. D Coordinate controls with control contractor. E. Provide all appurtenances required to ensure a fully operational and functional chiller START-UP A. Ensure proper charge of refrigerant and oil. B. Provide testing, and starting of machine, and instruct the Owner in its proper operation and maintenance. END OF SECTION 38 AGR 055AS through 100AS Product Manual 970

39 Product Manual 970 AGR 055AS through 100AS 39

40 13600 Industrial Park Boulevard, P.O. Box 1551, Minneapolis, MN USA (612)

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