McQuay MAC060D4 Instruction manual

Air Cooled Chiller
Models: MAC060/090/120D4
Contents
INSTALLATION, OPERATION & MAINTENANCE MANUAL

©2009McQuay
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MAC0906-V2
Part No.: M08019320011
1. Introduction
Introduction……………………………………………………………………………………………………3
Nomenclature ………………………………………………………………………………………………3
2. Features
General Specification………………………………………………………………………………………6
Parameter……………………………………………………………………………………………………7
Performance Chart……………………………………………………………………………………………8
Outlines And Dimensions …………………………………………………………………………………11
Operation Limit………………………………………………………………………………………………13
3. Installation
Unit Installation ………………………………………………………………………………………14
Water System Installation ……………………………………………………………………………16
Power Connection …………………………………………………………………………………………20
4. Servicing and Maintenance
Servicing and Maintenance ………………………………………………………………………………21
Troubleshooting and Solution ……………………………………………………………………………22
Schematic Diagram ………………………………………………………………………………………27
5. Notice
Notice ………………………………………………………………………………………………………28

©2009McQuay
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"McQuay" is a registered trademark of McQuay International.
All rights reserved throughout the world.
©2009 McQuay International
"Bulletin 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 any time without
notice."
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.
McQuay is not responsible for any unit damage, personal injury or death due to not complying with
these requirements.
Caution
!
Warnin
g
Sharp edges and coil surfaces are a potential injury hazard. Avoid contact with them.
!
It is not allowed to install the unit in public area.
Warnin
g
!
A fit Air-switch should be installed in the main electrical wire when the unit connects with electric
net system.
Moving machinery and electrical power is hazardous. It may cause severe personal injury o
r
death. Disconnect and lock off the Air-switch or power before servicing equipment.
Warnin
g
!

©2009McQuay
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1 Introduction
Introduction
For years, McQuay international has earned a reputation for providing the industry with various
highest quality and most technologically advanced air conditioning systems. Now Shenzhen McQuay is
proud to introduce the new generation air-cooled chiller-MAC D series. Inherited from the advantage of
the earlier product experiences and introduced the most up-to-date technology, the new MAC D series is
designed with the always-in-mind concept - to satisfy customers’ high efficiency, comfort, safety,
intelligence requirements to maximum extent. The unit can be flexibly coupled with multi fan coil units,
easily operated with artificial intelligence, additionally combined with indoor top level decoration, these
altogether bring you to enjoy the nobility coming from central air conditioning.
Nomenclature
MAC 060 D 4 - P AA M
Refrigerant type: 4:R407C Default for R22
Air Cooled Chiller
Cooling capacity
Design series
Market code
Description of the unit
Power supply feature: P for 208-230V/3～ /60Hz
Mcquay

©2009McQuay
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2 Features
Superior Performance
Extensive research work coupled with world leading manufacturing technology has resulted the new
design with superb performance and high efficiency.
Stringent quality control and component selection ensure performance and reliability. Major components
are rigorously tested and qualified prior to usage in the machine.
Every machine design has passed many hours of rigorous testing to ensure the machine reliability,
durability and quality.
Scroll compressor brings much higher energy efficiency. High efficiency heat exchanger ensures
strenuous exertion of equipment capacity. Water pump particularly designed for air conditioning
engineering is operating steadily with minimum vibration and noise.
These units are designed with double independent refrigerating system, greater energy saving is
achieved by only one compressor on duty under part load condition.
Robust Construction with Slim Outlook
Detailed engineering work coupled with extensive market research has resulted the new MAC model
come in new mono-block design to yield a compact and robust structure while maintaining the slim
outlook. The smaller capacity models MAC060D4 are having side discharge design, while the larger
capacity models MAC090/120D4 are having top discharge design.
Simple to Operate
The machine is complete with intelligent microprocessor controller and temperature sensor to
automatically control the operation to its optimum condition, making it very simple to operate. All
temperature settings are finished before shipment. The only thing for user to do is to start the unit by
pressing the ON/OFF button after ensuring unit proper function, then every operation can be
automatically performed by the unit itself.
Either wireless remote controller or wired remote controller is ready for choosing to meet satisfactory
indoor unit control, both compatible with the unit.
Friendly Installation
The machine has been designed with installation friendly in mind such that no refrigeration charging or
copper pipe brazing is required on site.
Threaded fitting is provided for easy water piping connection on site.
Taper threaded fittings target convenient disassembly or assembly.
Expansion chamber, water pump and water pressure differential switch is already equipped in this
compact packaged unit. In addition, McQuay provides accessory hydraulic kit with water storage tank,
auto water fill valve, auto air vent valve, auto pressure relief valve and strainer integrated in, aiming at
ensuring high efficiency and safe operation.

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Safety Control
Protection devices such as dual pressure protection and overload protection etc. is provided to ensure
unit operating within safety condition range. The microprocessor-based controller automatically directs
system on or off by processing the water temperature feedback. If the water temperature falls to
unacceptable low point, the controller automatically shut off the system to prevent hydraulic system
internal freeze for unit safety operation. Meanwhile, the microprocessor-based controller automatically
monitors every component operating status and malfunction, and feedback it to indoor controller to
greatly ease the work of status monitor and troubleshooting.
All Weather
The cabinet is made of electro galvanized mild steel sheet, coated with baked polyester power to ensure
the units extra durability in all climates against sun, rain, wind corrosion.
Space saving (small footprint) design of the machine eliminates large installation area requirement, no
need for equipment room.
The machine uses high quality parts to ensure durability in various climate conditions.
Simple to Maintain
The simple design of the machine allows for maximum serviceability. All components are with reach of
the maintenance personnel upon open up of the servicing panel. If emergency shutoff occurs, the
microprocessor-based controller will indicates the fault cause to quicken and ease troubleshooting.

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General Specification
Compressor
McQuay Mini Chillers are equipped with highly efficient, reliable and silence scroll compressors for
MAC060/090/120D4
Air-Cooler Condenser
The air-cooled condenser coil consists of staggered rows of 3/8’’ OD seamless copper tube,
mechanically expanded into die formed aluminum fins to ensure optimum heat exchange capability.
Condenser Fan Motor
To achieve the high air change requirement, the unit is equipped with high airflow propeller fan. The fan
is directly driven by weather proof motor to ensure reliable continuos operation.
Evaporator
The heat exchanger is made of stainless steel plates closely arranged and brazed together to ensure
high heat exchange efficiency. The complete heat exchanger is insulated with thermal closed cell nitric
rubber foam to give optimum thermal insulation.
Refrigerant Circuit
The refrigerant circuit is brazed and vacuumized in factory before accurately charged with R407C to
ensure optimum operating requirement, to ensure flawless continuous operation.
Additional Safety Protection
The units are equipped with intelligently designed safety control to ensure continuous safe operation.
Pressure switch and sensor is provided to prevent the compressor damage, resulting from both
abnormal high discharge pressure and low pressure due to insufficient gas.
The standard electronic controller provides accurate water temperature control in the circuit by closely
monitoring and reacting to the input from the water entering temperature, water leaving temperature and
ambient air temperature.
Pressure difference switch is provided in the unit to protect against lack of water flow.
During abnormal condition, the electronic controller will turn the unit off and the then display the faulty of
operation. (Refer to Troubleshooting sheet)

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Parameter
MODEL MAC060D4 MAC090D4 MAC120D4
NOMINAL COOLING CAPACITY W17500 30000 33500
POWER SUPPLY 208-230V/3～/60Hz
REFRIGERANT TYPE R407C
RATED COOLING POWER INPUT W6000 10100 10600
RATED COOLING CURRENT A18.8 34.7 35.7
TYPE/DRIVE Propeller/Direct
RATED POWER INPUT W360 1000 1000 FAN MOTOR
RATED CURRENT A1.6 3.7 3.7
TYPE Horizontal Multistage End-Suction
RATED POWER INPUT W1410 1410 1410
RATED CURRENT A3.4 3.4 3.4
PUMP
AVAILABLE HEAD m20.0 16.5 14.0
WATER FLOW RATE m3/h 2.71 4.65 5.19
UNIT WATER PRESSURE DROP kPa 95.5 100.5 110.0
HEIGHT(H) 1700 1840 1840
WIDTH (W) 1212 840 840
TOTAL UNIT
DIMENSION DEPTH (D)
mm
502 990 1290
INSTALLATION WATER PIPE CONNECTION Rc 1 Rc 1 1/2
CONDENSER TYPE Cross Aluminum Finned Seamless Copper Tubes
EVAPORATOR TYPE Stainless Steel Brazed Plate Heat Exchanger
SOUND LEVEL dB(A) 62 66 66
NET WEIGHT kg 215 270 312
Notes:
1) All specifications are subjected to change by manufacturer without prior notice.
2) Nominal cooling parameters are based on leaving water temperature 6.7℃, ambient temperature 35℃and 0.043 l/s per
kW water flow factor.
3) Rated cooling power input doesn’t include the pump consumption.
4) Actual performance can be determined by conducting correction after looking up the following charts.
Based on the ambient temperature and required return water temperature, we can locate the corresponding performance
factor in these charts, then the corresponding actual cooling (heating) capacity and power input can be determined by
using the performance chart.

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Performance Chart
Cooling Capacity Performance Chart
LWT : Leaving Water Temperature
MAC060D4
10.0
15.0
20.0
25.0
30.0
15℃20℃25℃30℃35℃40℃45℃48℃
Ambient Temperature(℃)
Cooling Capacity(kW)
LWT
(
℃
)
MAC090D4
20.0
25.0
30.0
35.0
40.0
45.0
15℃20℃25℃30℃35℃40℃45℃48℃
Ambient Temperature(℃)
Cooling Capacity(kW)
15℃
12℃
9℃
7℃
5℃
LWT
(
℃
)
15℃
12℃
9℃
7℃
5℃

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Cooling Power Input Char
LWT : Leaving Water Temperature
LWT
MAC120D4
20.0
25.0
30.0
35.0
40.0
45.0
50.0
55.0
60.0
15℃20℃25℃30℃35℃40℃45℃48℃
Ambient Temperature(℃)
Cooling Capacity(kW)
15℃
12℃
9℃
7℃
5℃
LWT
(
℃
)
MAC060D4
3.50
4.50
5.50
6.50
7.50
8.50
15℃20℃25℃30℃35℃40℃45℃48℃
Ambient Temperature(℃)
Cooling Power Input(kW)
LWT
(
℃
)
15℃
12℃
9℃
7℃
5℃
15℃
12℃
9℃
7℃
5℃

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LWT : Leaving Water Temperature
Notes:
The charts above show the unit performance characteristic in relationship with variable ambient temperature and
leaving water temperature. Please notice that there are some little differences between the performance of actual
manufactured unit and that obtained using these charts.
MAC090D4
7.00
8.00
9.00
10.00
11.00
12.00
13.00
14.00
15℃20℃25℃30℃35℃40℃45℃48℃
Ambient Temperature(℃)
Cooling Power Input(kW)
15℃
12℃
9℃
7℃
5℃
LWT
(
℃
)
MAC120D4
7.00
8.00
9.00
10.00
11.00
12.00
13.00
14.00
15.00
15℃20℃25℃30℃35℃40℃45℃48℃
Ambient Temperature(℃)
Cooling Power Input(kW)
15℃
12℃
9℃
7℃
5℃
LWT
(
℃
)

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Outlines and Dimensions
Model: MAC060D4
UNIT: mm
Model A B C D E F G H I J
MAC060D4 1212 502 1700 1135 1162 132 254 235 80 604.5
2-Rc1
4-10X20
E
A
D
G
F
C
B
J
HI

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Model: MAC090D4
UNIT: mm
Model A B C D E F G H
MAC090D4 900 990 180 215 285 271 Rc1-1/2 Rc1-1/2
MAC120D4 1200 1290 180 215 286 267 Rc1-1/2 Rc1-1/2
FE
C
Outlet G
D
Inlet H
4-14×20 Fixing Hole Zoom
265
1840
B 8
1575
B
A
840
45
845
877
Fixing Hole 4-14×20
16

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Accessory Hydraulic Kit
Accessory hydraulic kit consists of 40L capacity stainless steel water storage tank, 8L volume water
expansion chamber, safety valve, dirt drainage valve, and auto air vent valve etc.
Operation Limit
Water Drainage Port DN25
4-10x20
Chilled Water Inlet N
Chilled Water Outlet N
Dirt Drainage Port R1/2
448
680
500
816 400
30287
48 151 61
N
MAC-S1U/M R1
MAC-S4U/M R2
1515
leaving water temperature℃
5 7.5 10 12.5 15
4040
Ambient temperature℃
20
25
35
30 operating limit
20
25
35
30
Cooling mode
5
48 10
7.5 1512.5 48

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3 Installation
Unit Installation
The chiller must be installed by qualified company or personnel, which is authorized by McQuay, and the
installation must satisfy all the following requirements.
Location
In order to achieve maximum capacity, the location selection should fulfill the following requirements:
1) The location must be well ventilated, so that air can be drawn in and discharge out efficiently.
2) Install the unit in such a way that the hot air discharge cannot be drawn in again by itself or other
units.
3) Ensure that there is no obstruction to airflow into or out of the unit. Remove obstacles which blocking
intake or discharge the air if exist.
4) If good ventilation cannot be guaranteed when unit being installed indoors, it is advisable to induce
discharge air from air outlet to outdoors by installing duct which is as short as possible.
5) Support unit base up to create a space above foundation for ensuring free water drainage, and the
stable foundation with level surface must be sufficiently durable against the unit weight.
6) The location must not be susceptible to dust or oil to avoid condenser coil being choked by the
contaminant. As the general safety precaution, it is advised that no flammable danger gas should be
located near to the unit.
Air Intake
Air Intake
Air Discharge
Air Intake
Obstacles Block Air Discharge
Obstacles Block Air Intake

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7) It is advised to have sufficient clearance around the unit for proper condenser air flow and to facilitate
access for maintenance.( see clearance shown in figure below)
Delivery and Lifting
When transporting the unit, it is advisable to use forklift or crane to do this work. Only the wooden skid
base is allowed be served as the weight-supporter.
When hoisting, please keep the unit stable and without slope, meanwhile, be sure to avoid lifting ropes
contact with side heat exchanger, panel and unit’s top part.
After installation location is confirmed, remove the package base by unfastening the bolts.
Mounting
When mounting, please use foundation bolts or expansion bolts to fasten the
unit with foundation supporting legs.
It is advisable to pad the unit bottom against
vibration by using vibration absorption rubber.
350 350
900 900
Lifting Cable
<40°
Backing Angle Protection Cushion
>8m
1,838.4074
1,415.817
Front Side
>45°
Back Side
guiding device
>450mm
>450mm
>1000mm
>300mm
Front Side
Front Side
>450mm+h1 >450mm+h2
h2
h1
>450mm+h3 >100mm+
h
h4
h3
Front Side

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Water System Installation
Chilled water piping must be insulated and waterproof to avoid performance loss and moisture
condensing on it.
To guarantee the chilled water quality, the water strainer shipped with unit must be installed on the
chilled water inlet pipe.
When performing water pipe connection, use gripping pliers to fix the
unit connections to avoid the reserved connections on unit being
directly suffered from revolving torque when fastening.
Air vent valve should be installed at highest points on chilled water piping system, see detailed
information in “chilled water system installation schematic diagram”. After completing chilled water piping,
carry out leak detection and 0.4MPa pressure test to ensure having no mistake, then fully fill water in
system, open air vent valve, purge all the air trapped in the piping system, after that shut off the air vent
valve. Water drainage valve should be installed at lowest points on chilled water piping system.
In order to achieve the unit long-life operation, it is recommended to give first priority to new type plastic
water pipe such as PP-R, PVC, never use galvanized steel pipe when choosing the material of water
pipe.
The accessory strainer shipped with unit must be installed on water in pipe, otherwise failure of the unit
may be caused.
The unit should be connected with the water supply system through the automatic feeder that is the unit
accessory. The pressure of the water supply system must be more than 1.5 bar and less than 6 bar.
Caution
!
If the chiller is operated with very oily, salty or acidic water, these substances may lead to capacity drop.
Be sure to use clean water when filling in the water circuit to avoid heavy corrosion and choking of the
s
y
stem.
Caution
!
Don’t use the water pump equipped in unit to clean piping. If using the pump to clean is required, you can
fill clean water in system at water in side, meanwhile make the pump running, please conduct 30-minute
pump operation, then clean the strainer.
Caution
!
Side Panel Inlet/Outlet

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Limit to the water volume of the chiller
Vmin is referred to the below table：
Item Model Setting EWT(℃)Vmin(l)
14 151
13 188
12 251
11 376
1 MAC060D4
10 753
14 86
13 99
12 117
11 143
2 MAC090D4
10 184
14 96
13 111
12 131
11 160
3 MAC120D4
10 206
Notice：
1. The total water volume of the entire hydraulic system includes the water in main pipe, water tank
and terminal equipment, in which the 2-way valve is open.
2. If the water volume (V) while the unit is running is less than Vmin, it's recommended to install a
water tank of (Vmin-V)L, or it will cause the unit frequent ON/OFF
3. The Vmin in the table is calculated based on nominal cooling water flow and 5℃anti-freeze. If the
water flow and anti-freeze temperature change, related Vmin will change.
4. The table is applied for the water volume selection of normal chiller, not for the chiller under low
leaving water temperature with glycol.
If the system water volume is less than required water volume (Vmin) while the chiller is operating, it
will result in frequent ON/OFF
Caution
!

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Unit Water Pressure Drop
Water Pump Performance Chart
0
5
10
15
20
25
30
35
012345678910
Water Flowrate(m3/h)
H(m)
0
50
100
150
200
250
1.36 1.9 2.44 2.6 2.98 3.07 3.47 3.58 3.91 4.1 4.61 5.12 5.63 6.08 6.51 7.17
Water Flowrate(m3/h)
Unit Pressure Drop(kPa)
060 090
120

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Hydraulic System
When installing the MAC unit, using closed water system is strongly recommended by McQuay, and
please refer to the schematic diagram below.
In order to ensure energy saving and system safe operation, McQuay has provided hydraulic system
accessories, including insulated stainless steel water storage tank, safety valve, dirt drainage valve, auto
air vent valve, Y-shaped strainer and automatic water fill valve etc.
Auxiliary heater in the diagram below is available for option, please choose either type of auxiliary
electric heater or auxiliary gas heater. If you have the demand, please contact with local McQuay sales
representation, and install it according to below diagram, if you have no need of this option, the
components in dotted line box can be omitted.
The design, construction and acceptance check of the hydraulic system should respectively refer to
and comply with the corresponding manual, code and standard.
Notes
Thermometer
Flexible Joint
Shutoff Valve Shutoff Valve
Flexible Joint
Water Gauge
Check Valve
FCU
Flexible Joint
Heater
Water Supplement Valve
Globe Valve
Two Way Valve
FCU
FCU
FCU
Two Way Valve
Two Way Valve
Air Vent Valve Three Way Valve
Unit
Accessory Hydraulic Kit
Dirt Drainage Valve
Y Strainer