McQuay R410A SINGLE COMPRESSOR SERIES User manual

AIR COOLED CHILLER
(R410A SINGLE COMPRESSOR SERIES)
INSTALLATION MANUAL
Group: Mini Chiller
Part Number: A08019024588
Date: February 2005
IM-5ACC-0205SC
© 2005 McQuay International

English
i
5AC 020/025 CR
1181,610,0 10,0
460,0
85,0 128,5
128,5
789,5
475,0
55,2
80,0 300,0 80,0
OUTLINEAND DIMENSIONS

ii
!Caution Sharp edges and coil surfaces are potential locations which may cause
injury hazards.Avoid from being in contact with these places.
!Avertissement Lesbordscoupantsetlessurfacesdurefroidisseurtuulaireprésentent
unrisquedeblessure.Mieuxvautéviterlecontactaveccesendroits.
!Vorsicht ScharfeKantenundWärmetauscherflächenstelleneineGefahrenquelledar.
Jeglicher Kontakt mit diesen Stellen ist zu vermeiden.
!Cautela Per preservarsi da eventuali ferite, evitare di toccare gli spigoli affilali e la
superficie della serpentina.
!Cuidado LosBordesafiladosylasuperficiedelserpentínpuedenproducirlesiones.
Evite tocarlos.
!Осторожно Острые края и поверхности змеевиков являются
потенциальными местами нанесения травм. Остерегайтесь
контакта с этими местами.
This product is subjected to Waste of Electrical and Electronic Equipment Regulations (WEE
E
Regulations). The waste product shall be separately collected by specific collection and treatment centre
.
P
lease refer to local authorithy for these centres. This is only applicable to European Union countries
.
Ce produit est soumis
à
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r
r
é
é
é
lectriques e
t
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é
é
ê
é
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é
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tre ces centres. Ceci
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est uniquement applicable aux pays de l'Union Euro
p
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enne
.
Questo prodotto
è
soggetto alle disposizioni RAEE (Rifiuti di apparecchiature elettriche ed elettroniche)
.
à
à
locali. Questa disposizione
à
è
valida solamente i paes
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ctrico y Electr
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solamente aplicable a los p
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Europea
.
Dieses Produkt unterliegt den Bestimmungen zur Entsorgung von elektrischen und elektronische
n
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ü
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NOTICE

English
iii
MODEL : 5AC 020/025 CR
LIVE
COM2
COM1
BOILER
W_PUMP
OUT_FAN2
4WV2
A_FREEZE
ALM_OUT
ALM_IN
4WV1
OUT_FAN1
AUX-H
12V
F02
F01
LP2
LP1
HP2
HP1
C02
C01
FLOW
PO
ALM
DE2
DE1
C/H
ON/OFF
N
CN6 WI WOOA
CD1 CD2 DF1DF2
COMP DISCHARGE SENSOR (1)
OUTDOOR AIR TEMP SENSOR
LEAVING WATER SENSOR
ENTERING WATER SENSOR
N/L2
220-240/1pH/50Hz
L/L1TB1 12V 12V 12V N1 N1 N1 1 2 O/F PUMPC/H
HEATOFF
COOLON
4WV
HTR AL
IN
AL
OUT
LP HP FL
H
T
R
OF
OUT
OF
IN
TB3
LNC
OF
CSRE
COMP.
LNE
PUMP
FUSE
10A
5B
4B 1A
2A
SWITCH
A
B
COMP
COMP
CAP
98
95
96
C O/L
1
3
2
4
DEFROST SENSOR (1)
TB2
4WV
OF
CAP
R
R
5
7
6
8
R
E
L
A
Y
1
3
2
4
5
7
6
8
R
E
L
A
Y
R1 R2
C
S
PART NO : 50 13 4 066985
ELECTRICALWIRING DIAGRAM

iv
ISOLATOR DIAGRAM
TB1 L/L1 N/L2
N
L1
Power supply 230V / 1Ph-N / 50Hz
5AC/AC020/025 CR
AC TERMINAL BOX
ISOLATOR
E
FUSE

English
This manual provides the procedures of installation to ensure a safe and good standard of operation for the
chiller.
Special adjustments may be necessary to suit local requirements.
Before using the chiller, please read this instruction manual carefully and keep it for future reference.
INSTALLATION MANUAL
AIR COOLED CHILLER
MODEL
Part No.:A08019024588
HEAT PUMP
R410A
5AC 020 CR / M5AC 020 CR
5AC 025 CR / M5AC 025 CR
IM-5ACC-0205SC
!!
!!
!WARNING
• Installation and maintenance should be performed by qualified person who are familiar with local code and
regulation, and experienced with this type of appliance.

1-1
!!
!!
!CAUTION
Please take note of the following important points when installing.
• Do not install the unit where leakage of flammable gas may occur.
If gas leaks and accumulates around the unit, it may cause fire ignition.
• Do not overcharge the unit.
This unit is factory pre-charged. Overcharge will cause over-current or damage to the compressor.
• Sharp edges and aluminium fin coil surface are potential which may cause injury hazards.
Avoid from being in contact with these locations.
INDEX
- OutlineAnd Dimensions page i-ii
- Electrical Wiring Diagram page iii
- Isolator Diagram page iv
- Transportation page 1
- Installation Location page 2
- Unit Installation page 3
- Physical Data page 4
- Water Piping and Fitting page 5
- Electrical And Wiring page 5
- Electrical Data page 5
TRANSPORTATION
• Usespreaderbars orforkliftto lifttheunit toavoiddamage tothepanels. Figure 1providesthe dimensionsofthe cratefor
lifting. Avoid violent movements. Do not remove crate until it is at its final location.
640.0
- Recommended FuseAnd Cable Sizes page 6
- Water Piping System Setup page 7
- Refrigerant Circuit page 7
- Special PrecautionsWhen Dealing With
R410AUnit page 7
- Control Operation Guide page 8
- ServicingAnd Maintenance page 9
- Troubleshooting page 10
- Fan Speed Controller (Optional) page 11
- Isolator Switch Field Installation page 11
Figure 1

1-2
English
500 1000 1000 500
1500
500 500
1500
500
INSTALLATION LOCATION
• Installation work should be done by the authorized dealer or qualified contractor. Never install the unit yourself.
• Make sure there is sufficient space for airflow around the unit. The discharged air should be directed outside using a duct
should the unit be installed in a plant room.
• Vibration isolator should be provided to prevent vibration and noise from the unit.
• When installing the unit on the ground, make sure the selected site is not subject to flooding.
• There should be sufficient space allocated for ventilation, servicing and maintenance when installing the unit. Refer to the
following figures for proper location.
Figure 2: For single unit installation
AIR FLOW
AIR FLOW
MIN 500
Figure 3: For multiple unit installation
AIR FLOW
AIR FLOW
AIR FLOW
AIR FLOW AIR FLOW
MIN 500

1-3
5AC 020/025 CR
UNIT INSTALLATION
!!
!!
!CAUTION
• Improper handling of unit during installation could result in leaks, electrical shock or unit malfunction.
• Contact your dealer for reinstallation or dismantling of unit.
• Do not introduce foreign objects such as fingers, sticks etc. into the air inlet and air outlet.
• Do not climb or place objects on top of mini chiller.
50 50
100
Figure 4: For floor installation
Note: All units are in mm unless specified.
• Unit subjects to floor installation must be placed on a concrete slab. The slab must have thickness of 100mm and 50mm
wider and longer than the footprint of the unit (Figure 4). Place the concrete slab a distant from building to prevent
vibration and noise.
• Inthe caseofheatpump operationwithan outdoortemperaturebelow 0°C, theunitmust beinstalledat least300mmabove
ground level. This is necessary to prevent ice from accumulating on the frame and to permit proper operation in the event
of heavy snowfalls.
• The unit must be leveled on both axes. (Tolerance is less than 2mm per meter.)

1-4
English
PHYSICALDATA
Table A-1 : R410A - Heatpump
Model 5AC020CR 5AC025CR
Nominal cooling capacity kW 4.98 6.15
Nominal heating capacity kW 6.30 7.320
Operating Weight kg 115.50 122.50
Refrigerant charge R410A kg 1.20 1.725
Compressor 1 Rotary comp
Control system LCD Electronic Control
Refrigerant - water heat exchanger Brazed Plate Heat Exchanger
Water connections (BSP) inches 1 1
Maximum water pressure kPa 1000 1000
Hydronic circuit
Pump High Head Circulator
Available pressure (Cooling / Heating) kPa 87/68 163/93
Water inlet connection (BSPT) inches 1 1
Water outlet connection (BSPT) inches 1 1
Drain tap coupling (BSPT) inches 1/2 1/2
Closed expansion tank water volume litre 2 2
Refrigerant - air heat exchanger
Tube diameter mm 9.52 9.52
No. of rows 1 2
Tubes/row 30 30
Fin spacing mm 1.27 1.59
O/D Fan
Diameter inches 18 18
No. of blades 5 5
Air flow (high speed) m3/min 62.3 62.3
Fan speed (high speed) r/min 910 920
Note: For cooling nominal values are based on 12°C / 7°C entering / leaving evaporator water temperature, 35°C air ambient temperature.
For heating nominal values are based on 40°C / 45°C entering / leaving evaporator water temperature, 7°C/6°C (DB/WB) air ambient temperature.

1-5
P
WATER PIPINGAND FITTING
• All water pipe must be adequately insulated to prevent capacity losses and condensation.
• Install a 40 to 60-mesh strainer to ensure good water quality.
• Water pipes recommended are black steel pipe and copper pipe.
• During installation, the piping of the unit should be clamped before rotating the installation pipe to reduce the moment
induce on the piping.
• Users are recommended to install the pipes and accessories as shown in Figure 5.
• An air vent must be installed at the highest position, whileadrainage plug at the lowest position of the water circuit. After
the leak test (0.6MPa), open the air vent to release any air trapped in the water circuit.
• Run the clean water through the water inlet and operate the pump to drain out the dirty water. Clean the strainer after
running the pump for 30 minutes.
• Fill up the water circuit after connecting the pipes and equipment. Check water leakage at all connections and joints. Do
not start the unit when the system is leaking.
• To optimize the capacity of the system, ensure that the system is free of air bubbles. The air trapped in the system would
make the system unbalanced.
!!
!!
!CAUTION
• Do not allow water to remain in the water pipes if the unit is not operating for a long period.
Water must be drained out if the unit is not running during winter. Failing to do so would cause the pipe to crack.
• Do not drink the chilled water in the unit.
5AC 020/025 CR
PRESSURE GAUGE
GATE
VALVE
GATE
VALVE BALANCING VALVE
THERMOMETER
FLEXIBLE GATE VALVE (LOWER
POSITION FOR DRAINAGE)
AIRVENT (INSTALL
HIGHEST POSITION)
FAN COIL UNIT/AIR HANDLING UNIT
GATE
VALVE
Figure 5
THERMO-
METER
GATE VALVE GATE VALVE
BALANCING
VALVE
STRAINER
CHECK
VALVE
BYPASS VALVE
(DIFFER ENT PRESSURE TYPE)
ELECTRICALAND WIRING
• Refer to the wiring diagram provided on the unit when making electrical wiring.
• Do not ground any electrical equipment to the water piping.
• Install an external isolator switch (if it is not provided) to prevent electrical shock.
ELECTRICALDATA
Table B-1 : ( R410A - Heatpump )
Model 5AC020CR 5AC025CR
Power supply V-ph-Hz 230 / 1 / 50
Voltage range V 220 - 240
Nominal Power Input (Cooling/Heating) kW 2.55/2.59 2.76/2.79
Nominal Current Input (Cooling/Heating) A 11.9/12.1 12.7/12.9
Maximum Starting Current A67 68
Pump Power Input (Cooling/Heating) W 185/193 195/209
Full Load Current (FLA) A14 15
MAKE UP
VALVE

1-6
English
Model 5AC020CR 5AC025CR
Voltage Range ** 220 ~ 240V /1Ph /50Hz + N + !
Recommended Fuse * A 27 38
Power Supply Cable Size * mm210 10
Number of Conductor 3 3
Interconnection Cable Size * mm21.5 1.5
Cooling / Heat Pump RECOMMENDED FUSEAND CABLE SIZES
IMPORTANT : * The figures shown in the table are for information purpose only. They should be checked and selected to
comply with the local/national codes of regulations. This is also subjected to the type of installation and
conductors used.
** The appropriate voltage range should be checked with label data on the unit.
!!
!!
!CAUTION
• All field wiring must be installed in accordance with the national wiring regulation.
• All the terminals and connections must be tightened. Improper connection and fastenings could cause electric shock,
short circuit and fire.
• Ensure that the rated voltage of the unit corresponds to that of the name plate before commencing wiring work
according to the wiring diagram.
• The unit must be GROUNDED to prevent possible hazards due to insulation failure.
• All electrical wiring must not touch the refrigerant piping, compressor, pump, fan motor or any moving parts of
the fan motors.
• Do not operate the chiller with wet hands. It would result in electric shock.
• Donot use fuseofdifferentamperagethan stated. Usingwireetc. toreplacea fuse couldcauseequipment damage
or fire.
P
5AC 020/025 CR
Water / Refrigerant Circuit Diagram
CHECK
VALVE
BPHE
COMPRESSOR
CHARGE
COMPENSATOR
AUTO AIR VENT
WATER
OUT
WATER
IN
EXPANSION
TANK
WATER STORAGE
TANK
CHECK
VALVE
FILTER
DRIER
HEATING
CAP
TUBE
COOLING
CAP
TUBE
SUCTION
ACCUMULATOR
Figure 6 PART NO : 70-03-4-080547
WATER PUMP

1-7
WATER PIPING SYSTEM SETUP
• Fill up the water circuit after connecting all the pipes and equipment. Perform leak checks for all connections and joints.
Do not start the unit when the system is leaking.
• To optimize the capacity of the system, ensure that the system is free of air bubbles. The air trapped in the system would
make the system unbalanced.
• Ensure that the water tank is not full. This is to ensure optimal performance of the mini chiller. If the pressure is too high,
release the pressure from the auto pressure relief valve on the tank.
REFRIGERANT CIRCUIT
• All chiller units are pre-charged with R410Arefrigerant.
SPECIALPRECAUTIONS WHEN DEALING WITH R410A UNIT
• R410A is a near azeotrope refrigerant blend of hydro fluorocarbon (HFC) which is environmental friendly. It has Zero
Ozone Depletion Potential (ODP=0) and this conforms to Montreal Protocol regulations. It has no flame propagation and
a low toxic refrigerant (rated asA1 by ARI). R410Ais a mixture of R32 (50%) and R125 (50%).
• POE oil is used as lubricant for R410A compressor, which is different from the mineral oil used for R22 compressor.
During installation or servicing, extra precaution must be taken not to expose the R410A system too long to moist air.
Residual POE oil in the piping and components can absorb moisture from the air.
• Refrigerant R410A is more easily affected by dust of moisture compared with R22, make sure to temporarily cover the
ends of the tubing prior to installation.
• No additional charge of compressor oil only is permitted.
• No refrigerant other than R410A is permitted.
• Tools designed specifically for R410Aonly.
i) Manifold gauge and charging hose
ii) Gas leak detector
iii) Refrigerant cylinder/charging cylinder
iv) Vacuum pump c/w adaptor
v) Flare tools
vi) Refrigerant recovery machine
!!
!!
!CAUTION
• R410Amust be charged as liquid. Usually R410Acylinder is equipped with a dip-pipe for liquid withdrawal.
If there is no dip-pipe, the cylinder should be inverted so as to withdraw liquid R410A from the valve.
• Do not top-up when servicing leak, as this will reduce the unit performance. Vacuum the unit thoroughly and then
charge the unit with fresh R410Aaccording to the amount recommended in the specification.
• Do not touch the compressor or refrigerant piping when the chiller is running. If necessary wear protective gloves.

1-8
English
1. Handset location
The handset is located in the terminal box behind the service panel.
2. LED Display (microprocessor board)
The keypad LED will light up when the unit is powered up.
The LCD will light up when the unit is turned on.
3. LCD display (controller handset)
During normal operations, the LCD can display the entering water temperature, the leaving water temperature, the enter-
ing water setpoint temperature, compressor on or off status and outdoor air temperature.When malfunctioning occurred,
the LCD would blink. The display would show the faulty parameter and the date and time of the occurrence.
4. Controller functioning specification
There is a 3 minute delay for the compressor and fan motor to restart (default setting).
CONTROL OPERATION GUIDE
The unit is equipped with a microprocessor controller board. The microprocessor controller is provided to give temperature
control for the system by accurately measuring and controlling the water entering and water leaving temperature. The tem-
perature setting in the unit is preset in the factory. It is not recommended to change the setting unless necessary. A wired
controller handset is connected to the microprocessor board. Every parameter setting and reading can be observed from the
LCD of the handset.
!!
!!
!CAUTION
• Use the controller handset to switch on / off the unit. Do not plug off the main power supply directly, it would cause
the unit to breakdown.
• Do not change the settings of the safety devices.

1-9
• Servicing
Servicing or maintenance of these units must be carried out by experienced personnel with specific training in refrigeration.
Repeatedly check the safety devices and continuous cycling of control components. These items must be analyzed and
corrected before being reset.
The simple design of the refrigeration circuit totally eliminates potential problems during normal unit operation. No mainte-
nance work is needed on the refrigeration circuit as long as the unit is operating normally.
Ease of maintenance has been taken into consideration during the design stage such that the unit is easily accessible from the
service panels. The electrical components are especially easy to access since it is located in the terminal box in the front
service panel (Figure 7).
Under normal circumstances, these chillers required only a check and cleaning of air intake through the coil surface. These
can be done monthly or quarterly depending on the surrounding where the units are installed.
When the surrounding is very oily or dusty, then the coils must be regularly cleaned by a qualified air condition service
technician to ensure sufficient cooling capacity and efficient unit operation. The normal life span might be shortened if no
proper service is provided.
• Maintenance
For consistent performance and durability, always conduct proper and regular maintenance to the unit.
For prolong period of operation time, the heat exchanger will become dirty impairing its effectiveness and reducing the
performance of the units. Consult your local dealer about the cleaning of the heat exchanger.
No major maintenance or servicing is needed for the internal water circuit in the unit except the water pump failure. It is
advisable to conduct regular check on the filter and change the water filter if it is dirty or choked.
Always check the water level in the system in order to protect the moving components in the hydraulic kit from over heating
and excessive wear.
SERVICING AND MAINTENANCE
Figure 7
!!
!!
!CAUTION
• Do not attempt to do any service or maintenance when the unit is operating.
• Do not spray any chemical agents or flammable agents to the unit. It could cause fire or explosion.

1-10
English
1. Compressor does
not start.
2. Fan does not work.
3. Unit does work,
but insufficient
cooling.
4. Flow Switch Error
TROUBLESHOOTING
When any malfunction is occurred, immediately switch off the power supply to the unit, and contact the local dealer, if
necessary. Some simple troubleshooting tips are given below :
SYMPTOMS POSSIBLE CAUSES REMEDIALACTION
• No power supply.
• Fuses blown or automatic circuit break-
down open.
• Defective contactor or coil.
• Unit is stopped because safety device has
tripped.
• Loose wires.
• Compressor faulty.
• No power supply.
• Fan motor faulty.
• Thermostat setting too high.
• Condenser coil dirty.
• Obstacleblockingairinletoroutletof the
unit.
• Insufficient refrigerant in the system.
• Improper water flow rate.
• Water in the system is contaminated.
• No water in the system.
• Low water level in the system.
• Check power supply.
• Look for short circuit or grounded wires in
motor windings. Replace fuses and reset
circuit breakers when the fault has been
corrected. Check tightness and soundness of
all electrical connections.
• Repair or replace.
• Determine the type of safety shut down and
correctthe default beforetheunit isrestarted.
• Check wire connections and tighten terminal
screws.
• Contact local dealer.
• Check power supply.
• Contact local dealer.
• Reset thermostat.
• Contact local dealer.
• Remove the obstacle.
• Contact local dealer.
• Contact local dealer.
• Contact local dealer.
• Check water supply.
• Check water supply.
!!
!!
!CAUTION
• Troubleshooting must be performed by qualified personnel.

1-11
Operation of the mini chillers without any fan speed control is limited to an ambient
temperature of 17°C. With the fan speed control, the units are able to operate down to -5°C.
Thefan speedcontrollerdoes not comeasastandard itemin theminichillerunits.It isfield-
installed.
Allminichillers will have a 1/4" access valve provided foralongtheliquidlineof the refrig-
erant circuit. This valve is for direct pressure connection to the fan speed controller.
To install the fan speed controller, screw in the female adaptor to the 1/4" access valve. Use
a pair of spanners to tighten properly (max. torque 15 Nm). See Fig. 8. Ensure there is no
leakage at the joint.
Wire the fan speed controller to the terminal blocks. See Fig. 9.
FAN SPEED CONTROLLER (OPTIONAL)
TB3
Power supply 230V / 1Ph-N / 50Hz
Remove this wire
when doing wiring
for fan speed
controller
Figure 8
OF IN OF OUT
OF IN OF OUT
Wiring for fan
speed controller
(FSC) FSC
TB3
TO (PCB)
OUT_FAN1 TO (A) OF
CAPACITOR
L1 N
TB1 L/L1 N/L2
5AC 020/025 CR
Figure 9
15 Nm
ISOLATOR SWITCH FIELD INSTALLATION
The isolator switch does not come as standard item with the units. It is advisable to have it field installed. The isolator switch
mustbecapable ofmaking,carryingandbreaking currentsundernormalcircuitcondition. It mustbeofAC23Adutyand fully
compliant to IEC: 947-3.
For isolator switch selection, check the starting and running consumption specified in Table B. Be sure to connect a ground
wire from incoming power supply, either direct to the terminal box panel or use an auxiliary ground terminal in the isolator
switch. To install an isolator switch, wire it to the terminal block as shown in the two figures in page iv.

• In the event that there is any conflict in the interpretation of this manual and any translation of the same in any language,
the English version of this manual shall prevail.
• The manufacturer reserves the right to revise any of the specification and design contain herein at any time without prior
notification.
• En cas de désaccord sur l’interprétation de ce manuel ou une de ses traductions, la version anglaise fera autorité.
• Le fabriquant se réserve le droit de modifier à tout moment et sans préavis la conception et les caractéristiques techniques
des appareils présentés dans ce manuel.
• Im Falle einer widersprüchlichenAuslegung der vorliegendenAnleitungbzw. einerihrer Übersetzungen gilt dieAusführung
in Englisch.
• Änderungen von Design und technischen Merkmalen der in dieserAnleitung beschriebenen Geräte bleiben dem Hersteller
jederzeit vorbehalten.
• Nel caso ci fossero conflitti nell’interpretazione di questo manuale o delle sue stesse traduzioni in altre lingue, la versione
in lingua inglese prevale.
• Il fabbricante mantiene il diritto di cambiare qualsiasi specificazione e disegno contenuti qui senza precedente notifica.
• En caso de conflicto en la interpretación de este manual, y en su traducción a cualquier idioma, prevalecerá la versión
inglesa.
• El fabricante se reserva el derecho a modificar cualquiera de las especificaciones y diseños contenidos en el presente
manual en cualquier momento y sin notificación previa.
•В случае противоречия перевода данного руководства с другими переводами одного и того же текста,
английский вариант рассматривается как приоритетный.
•Завод-изготовитель оставляет за собой право изменять характеристики и конструкцию в любое время
без предварительного уведомления.