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