McQuay M5ACV 030 CR Technical manual

M5ACV-2009
Air-Cooled Chiller
(R410A Inverter Series)
Models: M5ACV 030 CR
M5ACV 055 CR
M5ACV 075 CR
M5ACV 100 CR
M5ACV 135 CR
M5ACV 210 CR
Catalog

Table of Contents
Nomenclature ....................................................................................................................1
- Product Line up
Features ............................................................................................................................ 3
Application Information...................................................................................................... 4
- Refrigerant Circuit Diagram
- Chiller Panel Controller
- Precautions and Installation
Sound Data .....................................................................................................................49
Selection Process ........................................................................................................... 50
- Water Pressure drop vs Flow rate
- Glycol
Engineering and Physical Data ....................................................................................... 53
- Specifications
Performance Data ........................................................................................................... 62
Dimensional Data ............................................................................................................ 70
Electrical Data .................................................................................................................73
Wiring Diagrams.............................................................................................................. 76
Servicing and Maintenance ............................................................................................. 81
Troubleshooting ............................................................................................................... 82
Exploded View and Part List ........................................................................................... 91
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.
Caution: Sharp edges and coil surfaces are a potential injury hazard. Avoid contact with them.
Warning: Moving machinery and electrical power hazards. May cause severe personal injury
or death. Disconnect and lock off power before servicing equipment.
“McQuay” is a registered trademark of McQuay International. All rights reserved.
2009McQuay International. All rights reserved throughout the world.
Bulletin illustrations cover the general appearance of McQuay International products at the time of publication.
We reserve the right to make change in design and construction at any time without notice.
This manual supercedes M5ACV-2008

Nomenclature
MAC 100 C R -F X AA
Series
C : C series
Model Type
R : heatpump
Omitted if cooling
Capacity
100 : 100,000 Btu/h
Model Name
AC : Air cooled mini
chiller
Brand
McQuay
Electrical
A : 220-240V/1Ph/50Hz
F : 380-415V/3Ph/50Hz
Type of ref. connection
X : Not applicable
Production spec
variation
5 V
Type
Inverter
Refrigerant
5 : R410A
1

M5ACV Product Line-up
2
Wired handset WCCH
Gold Fin
Isolator Switch
Terminal block
Scroll compressor
Capillary tube (Normal circuit)
Capillary tube (Normal & Inverter circuit)
EXV (Inverter circuit)
EXV (Normal & Inverter circuit)
Pump only
Brass adaptor BSPT 1 1/4
Brass adaptor BSPT 1
Brass adaptor BSPT 1 1/2
030CR AXAA X X X X X X X
055CR FXAA X X X X X X X
075CR FXAA X X X X X X X
100CR FXAA X X X X X X X X
135CR FXAA X X X X X X X X
210CR FXAA X X XXXXX X
M5ACV
Classification
Heat pump model
Nomenclature
Product Line Up

Features
3
True Dual Circuits BPHE
The true dual BPHE puts the secondary circuit (water) in contact with 2 primary circuits (refrigerant). So even
if one primary circuit is shut off, each secondary channel is still in contact with a primary channel.
Inverter Compressor
Inverter compressor is programmed to run at the optimum speed, which is regulated by the input frequency
as it can varies according to the heat load requirement.
Inverter advantages are :
•Less start & stop – Frequency regulated compressor resulting in lesser in the sense of start and stop of
compressor, which greatly reduces the energy consumption.
•Fast cooling/heating – Inverter compressor has the ability to produce faster cooling/heating capacity at
the frequency higher than the dominant capacity frequency.
•Smart loading/unloading – with the integration of built in system algorithm; inverter compressor could
control the system’s loading and unloading sophisticatedly.
•Better compressor reliability – Reliability of inverter compressor is always better since there is lesser on/
off of the system especially during low load condition.
Elimination of Water Tank
Inverter system provides constant water temperature band, or much lesser water temperature fluctuation.
With this, water tank of the mini chiller system can be eliminated.
Built in Fan Speed
The built in algorithm now controls fan speed, resulting in cost saving since installation of external FSC (Fan
speed controller) can be exempted.
Safety Proctection
•High & low pressure switches
•Anti-freeze protection sensor
•Discharge temperature sensor
•Over pressure relief valve
•Water pressure differential switch
•Anti-freeze heater on BPHE
•Compressor, water pump overload protector
Anti Corrosion Heat Exchanger
Gold aluminum fin is offered as standard material of the condenser heat exchanger of this series of chiller.
Modular Installation
A network up to 50chillers in a system is possible. Control on the operation of the chillers will be done through
the microprocessor controller. The external water piping connection can be made either from the left or right
side of the unit.

Application Information
Refrigerant Circuit Diagram
Model : M5ACV 030CR
4
M5ACV030CR
Water / Refrigerant Circuit Diagram
P
EXV
FIL
TER
IL
TER
IL
DRIER
SUCTION
ACCUMULA
T
A
T
A
O
R
COMPRESSOR
CHARGE
COMPENSA
T
A
T
A
O
R
BPHE
W
A
TER
A
TER
A
OUT
W
A
W
A
W
TER
A
TER
A
IN
W
A
W
A
W
TER PUMP
A
TER PUMP
A
EXP
ANSION T
P
ANSION T
P
ANK
T
ANK
T
P
EXV
FIL
TER
IL
TER
IL
DRIER
SUCTION
ACCUMULA
T
A
T
A
O
R
COMPRESSOR
LIQUID RECEIVER
BPHE
W
A
TER
A
TER
A
OUT
W
A
W
A
W
TER
A
TER
A
IN
W
A
W
A
W
TER PUMP
A
TER PUMP
A
EXP
ANSION
P
ANSION
P
T
ANK
T
ANK
T
Model : M5ACV 055/075CR
M5ACV055CR
Water / Refrigerant Circuit Diagram

FIN TUBE
HEAT EXCHANGER
(SYSTEM 1)
FIN TUBE
HEAT EXCHANGER
(SYSTEM 2)
4-WAY VALVE
VARIABLE SPEED
COMPRESSOR
COMPRESSOR
SUCTION
ACCUMULATOR
SUCTION
ACCUMULATOR
WATER
OUT
WATER
IN
LIQUID
RECEIVER
LIQUID
RECEIVER
EXV
HEATING
CAP
TUBE
FILTER
DRIER
FILTER
DRIER
COOLING
CAP
TUBE
4-WAY VALVE
CHECK
VALVE
CHECK
VALVE
FIN TUBE
HEAT EXCHANGER
(SYSTEM 1)
FIN TUBE
HEAT EXCHANGER
(SYSTEM 2)
4-WAY VALVE
VARIABLE SPEED
COMPRESSOR
COMPRESSOR
SUCTION
ACCUMULATOR
SUCTION
ACCUMULATOR
WATER
OUT
LIQUID
RECEIVER
LIQUID
RECEIVER
EXV
HEATING
CAP
TUBE
FILTER
DRIER
FILTER
DRIER
COOLING
CAP
TUBE
4-WAY VALVE
CHECK
VALVE
CHECK
VALVE
P
EXPANSION
TANK
WATER PUMP
WATER
IN
P
EXPANSION
TANK
WATER PUMP
M5ACV 100CR
Refrigerant Circuit Diagram
M5ACV 135CR
Refrigerant Circuit Diagram
Model : M5ACV 100CR
Model : M5ACV 135CR
5

FIN TUBE
HEAT EXCHANGER
(SYSTEM 1)
VARIABLE SPEED
COMPRESSOR
COMPRESSOR
SUCTION
ACCUMULATOR
WATER
LIQUID
RECEIVER
EXV
FILTER
DRIER
CHECK
VALVE
EXV
CHECK
VALVE
COMPRESSOR
4-WAY VALVE
OIL
SEPARATOR
OIL
SEPARATOR
OIL
RETURN
TUBE
TWIN
TUBE JOINT
FILTER
DRIER
IN
LIQUID
RECEIVER
SUCTION
ACCUMULATOR
4-WAY VALVE
FIN TUBE
HEAT EXCHANGER
(SYSTEM 2)
TWIN
TUBE JOINT
FIN TUBE
HEAT EXCHANGER
(SYSTEM 1)
FIN TUBE
HEAT EXCHANGER
(SYSTEM 2)
4-WAY VALVE
VARIABLE SPEED
COMPRESSOR
COMPRESSOR
SUCTION
ACCUMULATOR
SUCTION
ACCUMULATOR
WATER
OUT
LIQUID
RECEIVER
LIQUID
RECEIVER
EXV
FILTER
DRIER
FILTER
DRIER
4-WAY VALVE
CHECK
VALVE
CHECK
VALVE
TWIN
TUBE JOINT
OIL
SEPARATOR
OIL
RETURN
TUBE
OIL
SEPARATOR
COMPRESSOR
TWIN
TUBE JOINT
EXV
WATER
IN
P
EXPANSION
TANK
WATER PUMP
Model : M5ACV 210CR
6
M5ACV 210CR
Refrigerant Circuit Diagram

Chiller Panel Controller
1. Safety Consideration
Only specially trained and technicians and installers are authorized to install and service this
equipment.
1.1 General Installation Recommendations
•Only supply DC voltage (9-17V, typically 12V, maximum current 200mA) as a power source
to the device.
•Input contact voltage supply should limit to 12VDC or 24VAC.
•Isolated all the low voltage wiring (communication bus, etc) from high voltage power supply
wiring.
2. General Description
2.1 General
The chiller panel controller is designed to control the chiller operation. This device allows the user
to have customized control for each connected unit.
2.2 Features
The requirements of user friendly and easy to use have been taken into account in designing this
chiller panel controller. It can do the task as follow:
•Whole system configuration
•Unique parameter settings
•Operation status display
•Tracing fault record (easy in hardware troubleshooting)
The display is shown in an 8-lines graphical LCD display. There are 8 dedicated keys available
in the panel,
•Menu selection
•Navigation on the screen
•Modification of the selected value
During first start-up, the panel will have a default configuration (timer schedule, set point,
miscellaneous settings, etc). User can do the changes on that particular configuration later.
2.3 Panel Position
The chiller panel controller can be installed anywhere, as long as it is easy to accessed by
authorized personnel.
The requirements of installation are:
•Avoid exposure to shocks
•Avoid any source of electromagnetic pollution
•Avoid installation on uneven vertical surface
2.4 Operation Environmetal Condition
• Temperature:
-10°C to 47°C operating temperature
-20°C to 85°C storage temperature
•Relative Humidity:
0 to 95% non-condensing
7

3. Hardware Description
Legend
3.1 Key Explanation
The 2 navigation keys permit item selection and modifying the selected value.
ENTER key is used to execute the navigation instruction
ESC key is used to cancel the navigation instruction
Shortcut key to switch the operation mode in the summary pages
Shortcut key to trigger ON/OFF in the summary pages
Shortcut key to show fault / alarm in the summary pages
1 & 2 Navigation key
3 Execute instruction key
4 Cancel instruction key
5 Switching to heat mode shortcut key
6 Switching to cool mode shortcut key
7 Toggle ON/OFF shortcut key
8 Show alarm key
9 Graphical LCD display
10 ON/OFF indicato
r
Legend
1 & 2 Chiller terminal unit connection
3Not available
4 CMOS reset jumper (JH2)
5 Chiller bus resistor or configuration (JH3)
6Not available
7Not available
8Not available
9Not available
10 Backup batter
y
8

4. Installation
4.1 Chiller Bus
Chiller Network
Chiller panel needs to be energized with +12Vdc. The 5 way wires that provided is once on the easiest
solution to establish a communication between the panel and chiller main board (CN8-JP13). If the 5-way
wires socket has been occupied in main board, just using 2 insulation wired are needed to establish a com-
munication between panel and chiller main board.
Chiller panel can support maximum up to 50 units of chiller. In the chiller network, duplication of main board
unit address is not allowed. Each chiller main board should have their unique unit address (0-50).
For first time running, user need to assign a unique unit address to each main board in the chiller network.
User should follow the procedure below:
•Only power ON one main board at once time. Make sure not others main boards are energized.
•By using the panel connected to the main board.
<ENTER> <ENTER>
Summary Pages Main Menu Setting Menu
<ENTER>
G7 Unit No 1. General Set Paraameter
<ENTER> <ENTER>
key in "0001" as pas sw ord
• Key in unique unit address and press ENTER to execute.
• De-energized the main board and repeat the procedures again all the main boards have been
assigned a unique unit address.
IMPORTANT : Do not assign a same unit address to more than one chiller main board.
RECOMMENDATION : Please select a coherant model (G1 Model) to all the chiller main boards in
the same network.
9
Supported up to 50 units of Chiller
Chiller Panel 0 Chiller Panel 1
(Master) (Slave)
5 way wire (CN8)
Chiller
Communication bus
Chiller 0 Chiller 1 Chiller 2

4.2 Others Configuration
•JH2 in chiller panel should let it open (put the jumper header on one pin only) all the time
unless user need to do CMOS reset to that particular panel.
•JH3 should let it open (put the jumper header on one pin only) all the time as well.
•Remember to put in the coin cell battery on the panel. Without the backup battery, the panel will
always reset the time to 12:00am, 1st Jan 2000.
4.3 Installation of Chiller Panel Controller
•Disconnect the unit and ensure no others unit energy source that supplies the panel.
•Open the rear panel of the Chiller Panel (insert a ‘flat-head’ screwdriver in the top joint of main
casing with rear panel to open the real panel).
•Pass the necessary wires of the panel across the large opening in the rear panel. Place the rear
panel flat support against the wall and make marks on the wall through the four installation holes
(inner and outer).
•Drill four appropriate holes in the marked places.
•Attach the rear panel to the wall and put on the screws on it. Ensure that all cables are passed
through the hole of the rear panel.
•Connect the wires to the corresponding terminal according to the wiring bus network. The
power supply and communication wires must be correctly connected to ensure that the
panel works.
•Close the chiller panel (ensure the bottom joint is aligned for the casing, then complete others joint
part. Ensure that the contacts at the back of the panel are aligned with each others).
10
Bus Wiring Diagram
JP13 JP13

5. Software Description
5.1 Introduction
The Chiller Panel Controller can be used to control / display the status of Chiller.
Status viewing:
• ON/OFF status
• Mode (Cooling / Heating/ Boiling)
• Mode set temperature
• Compressor status (ON/OFF/ DEFROST)
• Water in, Water Out, Outdoor air and Panel temperature
• Chiller model (Chiller, Heat Pump, Chiller/ Boiler, Chiller+Boiler, Heat Pump/Boiler, Heat Pump+
Boiler)
• Advance parameter settings
• Defrost sensor temperatures
• Compressor discharge sensor temperatures
• Compressor run times
• Incoming alarm/ fault/ error
Status settings:
• ON/OFF switching
• Mode setting (Cooling / Heating/ Boiling)
• Mode set temperature
• Manual entering defrost
• Advance parameter settings
• Password changing
• Panel option setting (Backlight, Alarm Buzzer, Screen saver, Contrast, Brightness, temperature
unit)
• Time and date settings
• Clearing compressor run time
11

5.2 Menu Structures
12
Status
Inverter Chiller
Summary Pages
Main Menu
Unit Selection
Menu
Operation Menu
Settings Menu
Timer Menu
Alarm Menu
Display Menu
Mode
Cool Set
Heat Set
Manual Defrost
Set Parameter [#]
Change
Password [#]
Panel Option
Set Panel ID
Clock Setting
Date Setting
Time Schedule
Timer
Show Alarms
Erase All Alarms
Defrost Sensor
Discharge Sensor
Comp Run Time
[#]
General
Regulator
Compressor
Defrost
Antifreeze
Inverter
Alarm and
Contact
[#] – Password required

5.3 Chiller Menu Structure
5.3.1 Summary Pages
There are 4 pages in [Summary Pages]. Press UP or DOWN for page scrolling. Press ENTER to go to
[Main Menu]. Time and date are shown on top of each page. Beside that, the bottom of each page shows
current control unit of the Chiller.
For example: [00] - Chiller Panel controls Chiller ID 0 currently
[03] - Chiller Panel controls Chiller ID 3 currently
[All] - Chiller Panel controls all Chiller currently
1st page: Display ON/OFF status, Mode settings and Temperature settings.
2nd page: Display Compressor status.
3rd page: Display Water In, Water Out, Outdoor air and Panel temperature
4th page: Display Chiller model, Compressor No. and Chiller ID.
13
01/01/2000 12:00am
Status : ON
Mode : Cooling
Cool Temp : 12.0°C
[00]
01/01/2000 12:00am
Compressor : ON
[00]
01/01/2000 12:00am
Water In :19.8°C
Water Out : 25.6°C
Outdoor Air : 32.2°C
Panel : 20.5°C
[00]
01/01/2000 12:00am
Model : Chiller
No. Comp : 1 Comp
Unit No : 0

5.3.2 Main Menu
Press ENTER in [Summary Pages] to go into this menu
There are 5 sub menus in [Main Menu]. Press UP or DOWN to select sub menus, ENTER to enter into
the sub menu or press ESC to exit to [Summary Pages]
5.3.2.1 OPERATION MENU
Select [Operation Menu] in [Main Menu] and press ENTER to go into this menu.
Some normal settings can be found here. Press UP or DOWN to select each settings, ENTER to start the
setting or press ESC here to exit to [Main Menu]
Settings : -ON/OFF unit
- Mode changing (Cooling/ Heating/ Boiling)
- Cooling temperature setting
- Manual Defrost Selection
5.3.2.1.1 Manual Defrost
Select [Manual Defrost] in [Operation Menu] and press ENTER to go into this menu.
This menu lets user select one compressor to enter into defrost cycle manually, as long as the
environment fulfill the defrost requirement.
14
MA IN MENU
Operating Menu
Setting Menu
Ti mer Menu
A lar m Menu
Display Menu
Def r os t Co mpr es s or
Co mp 1
OPERATION MENU
Status : ON
Mode : Cooling
Cool Temperature : 12.0°C
Heat Temperature : 40.0°C

5.3.2.2 Settings Menu
Select [Settings Menu] in [Main Menu] and press ENTER to go into this menu.
Some advance settings can be found here. Press UP or DOWN to select settings, ENTER to start the
setting or press ESC here to exit to [Main Menu].
Settings - Set Parameter
- Password Changing
- Panel Option
- Set Panel ID
5.3.2.2.1 Set Parameter
Select [Set Parameter] in [Settings Menu] and press ENTER to go into this menu.
There are 7 groups of advance parameters for user to set in this menu, Press UP or DOWN to
select the group, ENTER to go into the group or ESC to exit to [Setting Menu].
Settings: - General
- Regulator
- Compressor
- Defrost
- Antifreeze
- Inverter
- Alarm and Contact
5.3.2.2.2 Password Changing
Select [Password Changing] in [Setting Menu] and Press ENTER to go into this menu.
User can change the old password in this menu.
Press ESC to exit to [Settings Menu].
15
SETTINGS MENU
Set Parameter
Change Passw ord
Panel Option
Set Panel ID
Please enter the
Old passw ord ………..
0
- - - -
1. General
2. Regulator
3. Compressor
4. Defrost
5. Antifreeze
6. Inverter
7. Alarm and Contact

5.3.2.2.3 Panel Option
Select [Panel Option] in [Setting Menu] and Press ENTER to go into this menu.
User can do some miscellaneous for the panel. These settings would not affect whole system perfor-
mance.
Settings - Toggle Backlight
- Alarm Buzzer
- Enable / Disable Screen Saver
- Screen Saver timeout
- Contrast display
- Backlight brightness
- Temperature unit
Press ESC to exit to [Settings Menu]
5.3.2.2.4 Set Panel ID
Select [Set Panel ID] in [Settings Menu] and press ENTER to go into this menu.
User can assign the ID no, to the panel.
Example: If ID no. 0 has been assigned, the panel acts like Master Panel Unit. It can choose to control
each Chiller in the network.
If other ID no. (1-50) has been assigned, the panel acts like Slave Panel Unit. It is dedicated to
one particular Chiller. It can only control the Chiller with same ID in the network.
Press [ESC] to exit to [Settings Menu]
16
Ple ase enter the
Panel ID……
=> Unit 0
Backlight : Norm al :
Bu z zer : On
Scree n Saver : Dis able
Timeout : 5m
Contrast : 50%
Br ig htness : Me d ium
Temp Unit : ° C

17
5.3.2.3 Timer Menu
Select [Timer Menu] in [Main Menu] and press ENTER to go into this menu.
All the timer/ schedule settings are included in this menu. Press UP or DOWN to select each settings.
ENTER to start the setting or press ESC here to exit to [Main Menu].
Settings: - Set Clock
- Set Date
- Set Schedule ( 7 days Programmable Timer)
- Enable/ Disable Timer Schedule
5.3.2.3.1 Set Clock
Select [Clock Setting] in [Timer Menu] and press ENTER to go into this menu.
User can set the time in this menu. The time setting is in 24-hour format.
Pres [ESC] to exit to [Timer Menu].
TIMER MENU
Clock Se tting :
Dat e Se tting
Time Schedule
Timer : Disable
Set Time :
hh:mm
00: 00

5.3.2.3.2 Set Date
Select [Date Setting] in [Timer Menu] and press ENTER to go into this menu.
User can set the date in this menu. The date is set according to sequence below:
(year) / (month) / (day)
Press [ESC] to exit to [Timer Menu].
5.3.2.3.3 Set Schedule
Select [Schedule Timer] in [Timer Menu] and press ENTER to go into this menu.
This is the 7 days programmable timer schedule menu. There are 2 ON/OFF events in one day. User can
choose to set each day of week (Sunday - Saturday) ON/OFF timer. Before this schedule carry their
effect to the Chiller, user need to set the [Timer] in [Timer Menu] to enable.
Press [ESC] to exit to [Timer Menu].
5.3.2.4 Alarm Menu
Select [Alarm Menu] in [Main Menu] and press ENTER to go into this menu.
This place keeps records for all previous occurred fault/ alarms. User can view the alarm history and clear
that record (alarm history) as well. The panel can keep up to 20 fault/ alarm records.
Press ESC to exit to [Main Menu]
18
Set Date :
yyyy mm dd
2000 / 01 / 01
ALARM MENU
Show Alarms
Erase All Alarm
Timer 1 Timer 2
ON OFF ON OFF
Sun 0800 1600 _ _ _ _ _ _ _ _
Mon 0800 1600 _ _ _ _ _ _ _ _
Tue 0800 1600 _ _ _ _ _ _ _ _
Wed 0800 1600 _ _ _ _ _ _ _ _