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Installation Operation Maintenance Manual Mac060 120D4 CP
Installation Operation Maintenance Manual Mac060 120D4 CP
Models: MAC060/090/120D4
Contents
1
MAC0906-V2
1. Introduction
Introduction……………………………………………………………………………………………………3
Nomenclature ………………………………………………………………………………………………3
2. Features
General Specification………………………………………………………………………………………6
Parameter……………………………………………………………………………………………………7
Performance Chart……………………………………………………………………………………………8
Operation Limit………………………………………………………………………………………………13
3. Installation
Unit Installation ………………………………………………………………………………………14
5. Notice
Notice ………………………………………………………………………………………………………28
©2009McQuay
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! Caution
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.
! Warning
Sharp edges and coil surfaces are a potential injury hazard. Avoid contact with them.
! Warning
It is not allowed to install the unit in public area.
! Warning
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 or
death. Disconnect and lock off the Air-switch or power before servicing equipment.
"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."
©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
Market code
Description of the unit
Power supply feature: P for 208-230V/3~/60Hz
Refrigerant type: 4:R407C Default for R22
Design series
Cooling capacity
Air Cooled Chiller
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.
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.
©2009McQuay
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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.
©2009McQuay
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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.
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.
©2009McQuay
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Parameter
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.
©2009McQuay
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Performance Chart
Cooling Capacity Performance Chart
MAC060D4
30.0
Cooling Capacity(kW)
25.0
20.0
15℃
LWT (℃)
12℃
15.0 9℃
7℃
5℃
10.0
15℃ 20℃ 25℃ 30℃ 35℃ 40℃ 45℃ 48℃
Ambient Temperature(℃)
MAC090D4
45.0
40.0
Cooling Capacity(kW)
35.0
30.0 15℃
LWT (℃)
12℃
9℃
25.0
7℃
5℃
20.0
15℃ 20℃ 25℃ 30℃ 35℃ 40℃ 45℃ 48℃
Ambient Temperature(℃)
©2009McQuay
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MAC120D4
60.0
55.0
50.0
Cooling Capacity(kW)
45.0
40.0
LWT
15℃
35.0
12℃
LWT (℃)
30.0 9℃
7℃
25.0
5℃
20.0
15℃ 20℃ 25℃ 30℃ 35℃ 40℃ 45℃ 48℃
Ambient Temperature(℃)
MAC060D4
8.50 15℃
LWT (℃)
12℃
Cooling Power Input(kW)
7.50 9℃
7℃
5℃
6.50
15℃
5.50 12℃
9℃
7℃
4.50
5℃
3.50
15℃ 20℃ 25℃ 30℃ 35℃ 40℃ 45℃ 48℃
Ambient Temperature(℃)
©2009McQuay
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MAC090D4
15℃
14.00
LWT (℃)
12℃
13.00 9℃
Cooling Power Input(kW)
7℃
12.00 5℃
11.00
10.00
9.00
8.00
7.00
15℃ 20℃ 25℃ 30℃ 35℃ 40℃ 45℃ 48℃
Ambient Temperature(℃)
MAC120D4
15℃
15.00
LWT (℃)
12℃
14.00 9℃
7℃
Cooling Power Input(kW)
13.00 5℃
12.00
11.00
10.00
9.00
8.00
7.00
15℃ 20℃ 25℃ 30℃ 35℃ 40℃ 45℃ 48℃
Ambient 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.
©2009McQuay
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Model: MAC060D4
G
4-10X20
F
E
A
D B
C
2-Rc1
I H
J
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
©2009McQuay
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Model: MAC090D4
16
840
877
845
4-14× 20 Fixing Hole Zoom
45
B
265
1840
1575
Outlet G Inlet H
D
C
E F B 8
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
©2009McQuay
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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.
N
MAC-S1U/M R1
MAC-S4U/M R2
448
680 4-10x20
816 400
302
Operation Limit
Cooling mode
5 7.5 10 12.5 15
48 48
Ambient temperature℃
40 40
35 35
30 operating limit 30
25 25
20 20
15 15
5 7.5 10 12.5 15
leaving water temperature℃
©2009McQuay
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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.
Air Discharge
Air Intake
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.
©2009McQuay
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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)
Back Side
900
>450mm
74
, 38 8 4. 0
1
350 350
>450mm
7
81
4 51 .
,
1
Front Side
900
guiding device
>1000mm
>450mm+h3
>300mm
>100mm+h
Front Side Front Side
Front Side
h3
h4
Lifting Cable
>8m
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.
©2009McQuay
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To guarantee the chilled water quality, the water strainer shipped with unit must be installed on the
chilled water inlet pipe.
Side Panel Inlet/Outlet
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.
! Caution
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
system.
! 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.
©2009McQuay
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! Caution
If the system water volume is less than required water volume (Vmin) while the chiller is operating, it
will result in frequent ON/OFF
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.
©2009McQuay
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250
120
060
200
090
Unit Pressure Drop(kPa)
150
100
50
0
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)
35
30
25
20
H(m)
15
10
0
0 1 2 3 4 5 6 7 8 9 10
Water Flowrate(m3/h)
©2009McQuay
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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.
FCU
FCU
FCU
FCU
Flexible Joint
Heater
Flexible Joint
Thermometer
Check Valve
Flexible Joint
Y Strainer
Unit
Notes
The design, construction and acceptance check of the hydraulic system should respectively refer to
and comply with the corresponding manual, code and standard.
©2009McQuay
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Power Connection
Laws and regulations concerning electrical wiring work vary by country. Therefore, work should basically
be performed according to the regulations of each country.
Before power connection, make sure that your local power supply type accords with the unit nameplate.
Please use suitable size dedicated wire to power this unit. The connections must be made secured
without tension the terminals.
All electric work must be performed by licensed technician be according to local regulations and the
instructions given in this catalogue.
The unit must be properly earth connected. Do not connect the earth wire to gas pipe, city water pipe or
telephone wire, improper earth connection may cause electrical shock.
Every wire should be firmly connected without tension to the cables and terminals.
All cables should not contact with refrigerating piping and moveable components such as compressor
and fan motor etc.
! Caution
At emergency (if you smell something burning), stop operation and turn the power source switch off,
ask for your dealer’s instruction. Continuing the operation without eliminating the emergency state
may cause a machine trouble, fire, or electrical shock.
Don’t extend your fingers or other foreign pieces such as stick into unit air outlet, otherwise the unit
could be damaged or you could be injured.
Electrical Data
Model MAC060D4 MAC090D4 MAC120D4
Power Supply 208-230V/3~/60Hz
Max. Input (W) 8500 14200 14750
Max. Current (A) 24.9 45.0 45.5
Cross Section Area (mm²) 6 10 10
Power Cable
Q.T.Y 4
©2009McQuay
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The optimum design of the refrigerating system eliminates the possibility of problems being occurred
during normal operation. There is no need to conduct any maintenance to refrigerant piping if the unit is
under normal running.
McQuay designers have given full consideration to make servicing convenient during unit development.
After opening service panel, both servicing and maintenance can be easily carried out.
Under normal environment, the only work needed is checking the return air way and cleaning the heat
exchange surface regularly at month or season interval decided on operating condition.
If the surrounding is very dirty or oily, for maintaining superior performance and sufficient capacity,
please ask specialized personnel to do regular cleaning of heat exchanger.
Maintenance
For keeping consistent performance and durability with safe, effective and long-life operation, always
conduct proper and regular maintenance to the unit.
For long period of operation time, the heat exchanger will become dirty impairing its effectiveness and
reducing the performance of the air conditioner. Consult your local dealer on the cleaning of the heat
exchanger.
No main maintenance or servicing needed for the internal water circuit unless the water pump is failure.
It is advised that regular check on the strainer should be conducted and replaced the water strainer if the
strainer is dirty or clogged.
Always check the water level in the system, for the target of protecting the moving components in the
hydraulic kit from overheating, excessive wearing and water freeze.
All the chilled water in the hydraulic system must be drained out completely during unit shutdown in
winter, to avoid water piping damage due to freeze.
©2009McQuay
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©2009McQuay
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Error code and Description
high pressure
ER20 ER35 Reserved ER50 ————
malfunction
low pressure
ER21 ER36 Reserved ER51 TH12 malfunction
malfunction
ER22 ------- ER37 Reserved ER52 ————
low pressure sensor
ER23 ------- ER38 Reserved ER53
malfunction
ER24 ------- ER39 Reserved ER54 Reserved
ER25 EWT/LWT too low ER40 TH1 malfunction ER55 Reserved
ER26 ------- ER41 TH2 malfunction EC78 ————
ambient temperature
ER27 ER42 TH3 malfunction
too high/low
ER28 ------- ER43 TH4 malfunction
super heat too low
ER29 ER44 ————
protection
©2009McQuay
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Reasons for Malfunction Generating and Solutions
©2009McQuay
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©2009McQuay
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Item Error Code Description Reasons Solutions
1. motor failure(cooling) Change fan motor;
discharge 2. return air short circuit (cooling) Improve terminal equipment air circulation;
ER33 3. condenser is dirty (cooling) Clean condenser
11 temperature
(LED) 4. EWT is too high re-set EWT by service personal
too high
5. lack of refrigerant or leakage charge refrigerant
ER40 1. Comp.1 discharge temperature sensor disconnect check TH1 resistance/ change
12 TH1 failure
(LED) 2. PCB failure change PCB
ER41 1. Comp 2 discharge temperature sensor disconnect check TH2 resistance/ change
13 TH2 failure
(LED) 2. PCB failure change PCB
ER42 1. mid- coil temperature sensor disconnect check TH3 resistance/ change
14 TH3 failure
(LED) 2. PCB failure change PCB
1. condenser inlet temperature sensor disconnect check TH4 resistance/ change
ER43
15 TH4 failure 2. condenser inlet temperature beyond 120℃ Refer to item 11
(LED)
3. PCB failure change PCB
ER47 1. ambient temperature sensor disconnect/short circuit check TH8 resistance/ change
18 TH8 failure
(LED) 2. PCB failure change PCB
ER49 1. condenser outlet temperature disconnect/short circuit check TH10 resistance/ change
19 TH10 failure
(LED) 2. PCB failure change PCB
ER51 1. suction temperature sensor disconnect/short circuit check TH12 resistance/ change
20 TH12 failure
(LED) 2. PCB failure change PCB
1. low pressure sensor phase wrong re-do the wiring
ER53 low pressure
21 2. low pressure sensor is broken/disconnect/short circuit change low pressure sensor cable
(LED) sensor failure
3. PCB failure change PCB
Note: For trouble elimination, we recommend service personnel to bring a 10K resistance (25℃)。 If there is sensor failure, connect the resistance
with PCB temperature port to find out the solution.
©2009McQuay
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Schematic Diagram
1 5
Chilled Water In
6 4
Chilled Water Out
LEGEND
Refrigerant Fow Direction
7.Accumulator
©2009McQuay
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5 Notice
Inspection
As soon as the unit is received, it should be inspected for any damage that may have occurred in transit.
If damage is evident, it should be noted on the carrier’s freight bill. A separate request for inspection by
the carrier’s agent should be made in writing at once.
Concealed damage must be reported within 15 days of receipt of shipment. Check shipment against the
bill of lading to verify that all items were delivered. Any shortages should be noted on the delivery receipt,
and a claim filed immediately.
©2009McQuay
While utmost care is taken in ensuring that all details in the publication are correct at the time of
going to press, we are constantly striving for improvement and therefore reserve the right to alter
model specifications and equipment without notice. Details of specifications and equipment are also
subject to change to suit local conditions and requirements and not all models are available in every
market.