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Operating Manual KOMAC00607-09EN Date: July 2009 Supercedes: None Control Panel Air-Cooled Screw Chillers AWS 50 Hertz R-134a

10 KOMAC00607-09EN System Architecture The overall controls architecture uses the following: • One Microtech III main controller • I/O extension mo

KOMAC00607-09EN 11 Sequence of Operation Figure 7, Unit Sequence of Operation (see Figure 9 for circuit sequence of operation) Is unit enabled?Is f

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KOMAC00607-09EN 13 Figure 8, Circuit Sequence of Operation Is circuit commanded to start?Is circuit commanded to shut down?Pumpdown circuitYesYesNoU

14 KOMAC00607-09EN Controller Operation MicroTech III Inputs/Outputs I/O for the unit control and for circuits one and two are found on CP1. The chil

KOMAC00607-09EN 15 Extension I/O Compressor #1 to #3 Analog Inputs # Description Signal Source Expected Range X1 Discharge Temperature NTC Ther

16 KOMAC00607-09EN Extension I/O Fan Module Circuit #1 & 2 Digital Inputs # Description Output Off Output On DI1 PVM/GFP Circuit #1 Fault

KOMAC00607-09EN 17 Setpoints The following parameters are remembered during power off, are factory set to the Default value, and can be adjusted to

18 KOMAC00607-09EN Description Default Range Unit Ft/Lb SI Clear Ice Timer No No,Yes SSS Communication No No, Yes PVM Multi Point Single P

KOMAC00607-09EN 19 Description Default Range Unit Ft/Lb SI Oil Press Differential 35 PSI 250 kPa 0-60 PSI / 0 to 415 kPa Low Oil Level Delay

2 KOMAC00607-09EN Table of Contents INTRODUCTION...3 OPERATING LIMITS:...4 CONT

20 KOMAC00607-09EN Auto Adjusted Ranges Some settings have different ranges of adjustment based on other settings. Cool LWT 1 and Cool LWT 2 Avail

KOMAC00607-09EN 21 Unit Functions Calculations LWT Slope LWT slope is calculated such that the slope represents the change in LWT over a time frame

22 KOMAC00607-09EN The Available Modes Set Point must only be changed when the unit switch is off. This is to avoid changing modes of operation inad

KOMAC00607-09EN 23 Unit Status The displayed unit status is determined by the conditions in the following table: Enum Status Conditions 0 Auto U

24 KOMAC00607-09EN • EWT is less than the Evap Freeze set point minus 0.6 °C and EWT sensor fault isn’t active The control state is Run when the fl

KOMAC00607-09EN 25 Leaving Water Temperature (LWT) Reset The base LWT target may be reset if the unit is in Cool mode and it is configured for a res

26 KOMAC00607-09EN Outside Air Temperature (OAT) Reset The Active Leaving Water variable is reset based on the outdoor ambient temperature. Paramete

KOMAC00607-09EN 27 Maximum Circuits Running If the number of compressors running is equal to the Max Circuits Running set point, no additional compr

28 KOMAC00607-09EN The compressor capacities are adjusted one at a time while maintaining a capacity imbalance that does not exceed 12.5%. Load/Unloa

KOMAC00607-09EN 29 As the signal varies from 4 mA up to 20 mA, the maximum unit capacity changes by steps of 1% from 100% to 0%. The unit capacity

KOMAC00607-09EN 3 Introduction This manual provides setup, operating, troubleshooting and maintenance information for the McQuay AWS chillers. HAZ

30 KOMAC00607-09EN Circuit Functions Calculations Refrigerant Saturated Temperature Refrigerant saturated temperature is calculated from the pressure

KOMAC00607-09EN 31 • Circuit switch is closed • No circuit alarms are active • Circuit Mode set point is set to Enable • BAS Circuit Mode set po

32 KOMAC00607-09EN Rapid Shutdown A rapid shutdown requires the compressor to stop and the circuit to go to the Off state immediately. The circuit

KOMAC00607-09EN 33 Capacity will not be increased above 25% until discharge superheat has been at least 22 degrees F for a time of at least 30 secon

34 KOMAC00607-09EN Condenser Fan Control The compressor must be running in order to stage fans on. All running fans will turn off when compressor go

KOMAC00607-09EN 35 When one fan is running, a fixed point is used in place of a deadband. When the Saturated Condenser temperature drops below 70°F

36 KOMAC00607-09EN The target value is adjusted as needed to maintain discharge superheat within a range from 27 degrees F to 45 degrees F. As the di

KOMAC00607-09EN 37 Alarms and Events Situations may arise that require some action from the chiller or that should be logged for future reference.

38 KOMAC00607-09EN 2: Evaporator Pump State = Start for time greater than Recirc Timeout Set Point and all pumps have been tried Action Taken: Rapid

KOMAC00607-09EN 39 Trigger: Sensor shorted or open Action Taken: Rapid stop all circuits Reset: This alarm can be cleared manually via the keypad,

4 KOMAC00607-09EN Operating Limits: • Maximum standby ambient temperature, 55°C • Maximum operating ambient temperature is 46°C, 52°C for Premium V

40 KOMAC00607-09EN Reset: Auto reset when sensor is back in range. Unit Power Restore Event description (as shown on screen): Unit Power Restore Tri

KOMAC00607-09EN 41 Reset: This alarm can be cleared manually if the evaporator pressure is above –10 psi. Low Pressure Start Fail Alarm description

42 KOMAC00607-09EN Oil Level Switch Alarm description (as shown on screen): Oil Level Low N Trigger: Oil level switch open for a time greater than Oi

KOMAC00607-09EN 43 Trigger: [Circuit 1 or Circuit 2 Number of Fans > 6 OR PVM Config = Multi Point] and communication with the I/O extension modu

44 KOMAC00607-09EN Reset: This alarm can be cleared manually via the keypad, but only if the sensor is back in range. Oil Pressure Sensor Fault Alar

KOMAC00607-09EN 45 Action Taken: Action Taken: Unload the compressor by decreasing the capacity by one step every 5 seconds until the evaporator pre

46 KOMAC00607-09EN Using the Controller The Unit Controller Operation Figure 9, Unit Controller The keypad/display consists of a 5-line by 22 c

KOMAC00607-09EN 47 Or a line in a menu may be a link to further menus. This is often referred to as a jump line, meaning pushing the navigation whe

48 KOMAC00607-09EN previous line (up) on the page. The faster the wheel is turned the faster the cursor moves. Pushing the wheel acts as an “Enter” b

KOMAC00607-09EN 49 Figure 13, Home Page, Main Menu Parameters and Links View/Set Unit Home Page Status/Settings >

KOMAC00607-09EN 5 General Description The control panel is located on the front of the unit at the compressor end. There are three doors. The contro

50 KOMAC00607-09EN Figure 14, Navigation, Part A View/Set Unit Status/Settings (view/set unit)Status/Settings > Unit Status R Set-Up >

KOMAC00607-09EN 51 Figure 15, Navigation, Part B View/Set Unit Power Conservation (view/set Status/Settings > Unit Capacity RSet-Up >

52 KOMAC00607-09EN Figure 16, Navigation, Part C View/Set Unit AWM Setup (view/set unit) Status/Settings > Apply Changes R/WSet-Up > DH

KOMAC00607-09EN 53 Optional Remote User Interface The optional remote user interface is a remote control panel that mimics operation of the controll

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KOMAC00607-09EN 55 Start-up and Shutdown NOTICE McQuay service personnel or factory authorized service agency must perform initial start-up in orde

56 KOMAC00607-09EN !CAUTION If all power to the unit is turned off, the compressor heaters will become inoperable. Once power is resumed to the uni

KOMAC00607-09EN 57 disconnect switches to "on." This will energize the crankcase heaters. Wait a minimum of 12 hours before starting up

58 KOMAC00607-09EN Field Wiring Diagram Figure 17, Typical Field Wiring Diagram, Sheet 1 NOTE: 1 Compressor Alarm No. 3 applies to future produc

KOMAC00607-09EN 59 Figure 17, Typical Field Wiring Diagram, Sheet 1 Note: The BAS interface modules and the remote display shown above are availa

6 KOMAC00607-09EN Power Panel Layout The power panel is at the front of the unit, behind the two doors to the right Figure 2, Power Panel, Left Side

60 KOMAC00607-09EN System Maintenance General On initial start-up and periodically during operation, it will be necessary to perform certain routine

KOMAC00607-09EN 61 1 Oil Filter - 250mm 2 Oil Filter Housing Cover 3 O-Ring – 89.5x3 4 O-Ring – 76.1x3.4 5 M8 Bolts • Un

62 KOMAC00607-09EN Remove filter and clean oil filter housing. Clean all other components. Replace the o-rings. Electrical Terminals !DANGER

KOMAC00607-09EN 63 An element inside the sight glass indicates the moisture condition corresponding to a given element color. If the sight glass do

64 KOMAC00607-09EN Appendix Definitions Active Setpoint The active setpoint is the setting in effect at any given moment. This variation occurs on s

KOMAC00607-09EN 65 High Saturated Condenser – Unload Value High Cond Unload Value = Max Saturated Condenser Value – 3 degrees F This function unload

66 KOMAC00607-09EN pLAN Peco Local Area Network is the proprietary name of the network connecting the control elements. Refrigerant Saturated Tempera

McQuay Italia S.p.A. • S.S. Nettunense, km 12+300 – 00040 Cecchina (Roma) Italia – Tel. (06) 937311 – Fax (06) 9374014 “The present publication is d

KOMAC00607-09EN 7 Economizer Components The chiller may or may not have economizers depending on design capacity requirements. An economizer is a we

8 KOMAC00607-09EN Figure 5, Piping Schematic with Economizer Circuit, One Circuit

KOMAC00607-09EN 9 Controller Description Hardware Structure The MicroTech III control system for AWS chillers consists of a main unit controller wi