Installation, Operation and Maintenance manual

402 C 06/10 B

Date: October 2006

Supersedes: 402 C 00/06 A



MHP

Air cooled water chillers















302 C 06/10 B pag. 2
Introduction

Purpose of the manual
The manual allows the installer and the operator to perform correctly all the operations referred to the installation
and maintenance of the chiller without provoking any damages to the unit or to the qualified personnel.
Therefore the manual is a great help for the qualified personnel that have to arrange the equipment to provide the
correct installation in accordance with local codes and regulation.

Inspection
When the equipment is received, all items on the bill of lading should be carefully checked to insure a complete
shipment. All units should be carefully checked and all shipping damage should be reported to the carrier. The unit
serial plate should be checked before unloading the unit to be sure that it agrees with the power supply available.
Physical damage to unit after acceptance is not McQuay responsibility.

Responsibilities
McQuay Italia declines all present and future responsibilities referred to injuries to people and damage to things
and unit, coming from operators negligence, the un-respected installation/maintenance data carrier in this manual,
the lacking of the current regulations respect referred to the safety of the equipment and the qualified personnel.

Servicing and maintenance
Servicing and maintenance of these unit must carried out by experienced personnel with specifying training in
refrigeration. Repeated check the safety devices and continuous cycling of control components must be analyzed
and corrected before being reset.
The simple design of the refrigeration circuit totally eliminates potential problems during normal unit operation. No
maintenance work is needed on the refrigeration circuit as long as the unit is operating normally.

Characteristics

General description
McQuay International introduces their newest air cooled heat pumps equipped with reciprocating compressors.
They are manufactured by McQuay to satisfy the requirements of the consultants and the end user. McQuay MHP
units are designed to minimize energy costs while maximizing the refrigeration capacities. Once again McQuay
has developed a line of heat pumps unsurpassed in performance and quality that will meet the most stringent
requirements of comfort cooling, ice storage and process applications.
McQuays chiller design experience, combined with outstanding features makes the MHP heat pumps unmatched
in the industry.

Safety measures
The unit must be suitably clamped to ground.
It is necessary to follow these cautions and warnings:
- The unit must be lifted only by using the proper tools able to support the weight of the unit.
- No admittance to unauthorized or unqualified personnel.
- No operation on electrical components is allowed without having switched off electricity supply.
- No operation on electrical components is allowed without using insulated platforms; no water or moisture should
be present.
- All the operation on refrigerant circuit and pressurised components are to be performed by qualified personnel
only.
- Compressor substitution or oil addition in this one must be performed by qualified personnel only.
- Sharp edges and coil surface are a potential injury hazard. Avoid contact with them.
- Disconnect all power to the unit while servicing condenser fan motors. Failure to do so may cause body injury.
- Avoid unrelated bodies into the water piping during the unit connection to the water system.
- It is necessary a mechanical filter for the piping connected to the exchangers entry.




302 C 06/10 B pag. 3
Installation
Before any operation please check the instruction for use.

Warning
Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and
regulations, and who are experienced with this type of equipment. Must be avoided the unit installation in places
that could be considered dangerous for all the maintenance operations.

Transport
It is necessary to be sure of the stability of the unit during transportation. Therefore the unit is supplied with a
transversal wooden beam placed on the unit base that must to be removed only after the final destination. In case
the unit has to be moved again, a similar solution is necessary.

Handling and lifting
Care should be taken to avoid rough handling or shock due to the unit drop. Do not push or pull the unit from
anything else than the base. When it is necessary to lift the unit suitable holes are provided in unit base to arrange
spreader bars and cables to prevent damage to the condenser coils or cabinet.

Location
The MHP units are produced for outside installation on roofs, floors or below ground level on condition that the
area is free from obstacles for the passage of the condenser air. The unit should be positioned on solid
foundations and perfectly level; in the case of installation on roofs or floors, it may be advisable to arrange the use
of suitable weight distribution beams. When the units are installed on the ground, a concrete base at least 250 mm
wider and longer than the units footprint should be laid. Furthermore, this base should withstand the unit weight
mentioned in the technical data table. When the units are positioned in areas which are easily accessible by
persons or animals, it is advisable to fit guards to protect the condenser coil guards and, when necessary, also
guards to protect the evaporator area.
Besides to obtain the best performance the location area it is necessary to follow the next precaution and advise:
Avoid air flow recirculation.
Take care that obstacle do not obstruct air flow.
Breezy ambient is required to ensure the right air suction and delivery.
To reduce noise and vibration a stiff floor is required.
To avoid that condenser coils get dirty avoid dusty ambient.
Chiller water must be quite clean and deprived of oil trace and rust particles. It is necessary a water filter on the
entering water pipes.

Space requirements
The MHP units are air-cooled, hence it is important to observe the minimum distances which guarantee the best
ventilation of the condenser coils. Limitations of space reducing the air flow could cause significant reductions in
cooling capacity, an increase in electricity consumption.
To determinate unit placement, careful consideration must be given to assure a sufficient air flow across the
condenser heat transfer surface. Must be avoided two conditions to achieve the best performance: warm air
recirculation and coil starvation.
Both these conditions cause an increase of condensing pressures that determinates reductions in unit efficiency
and capacity. The MHP heat pumps performance is little affected in many limited air flow situations because of its
special condensing coil geometry.
Moreover McQuays unique microprocessor has the ability to calculate the operating environment of the heat
pumps and the capacity to optimize its performance staying on-line during abnormal conditions.
Each side of the unit must be accessible after installation for periodic service. Fig.1 show you minimum
recommended clearance requirements.
Vertical condenser air discharge must be unobstructed because the unit would have its capacity and efficiency
significantly reduced.
If the units are positioned in places surrounded by walls or obstacles of the same height as the units, the units
should be at least 2500 mm from obstacles (fig.2). In the event the obstacles are higher than the units, the units
should be at least 3000 mm from the obstacle (fig.4). Unit installed closer than the minimum recommended
distance to a wall or other vertical riser may experience a combination of coil starvation and warm air recirculation,
thus causing reduction in unit capacity and efficiency reductions. Once again, the microprocessor will allow the
302 C 06/10 B pag. 4
chiller to stay on line, producing the maximum available capacity, even at less than recommended lateral
clearances.
When two or more units are positioned side by side it is recommended that the condenser coils are at least 3600
mm distance from one another (fig.3).
For other installation solutions, consult McQuay technicians.

Acoustic protection
The low noise levels of the MHP units means that they meet the most restrictive regulations, thanks to the
availability of two versions with different sound levels. When the noise level must meet special requirements it will
be necessary to pay the maximum attention to ensure the perfect insulation of the unit from the support base by
applying appropriate vibration-dampening devices, applying vibration-dampening mounts on the water pipes and
on the electrical connections.

Standard controls

MicroTech is installed as standard on all the units. Its touch sensitive keypad consists of twelve keys that can be
used to alter unit set points and control commands. A 32 character full English display on two lines illustrates the
machine's operating status & programmable parameters (set-points) e.g. temperatures & pressures of fluids
(water, refrigerant and air). MicroTech controls maximise the McQuay chillers energy efficiency and reliability
characteristics. It uses sophisticated software with predictive logic to select the most energy efficient combination
of compressor, EEV and condenser fan to maintain stable operating conditions and maximise energy efficiency.
The compressors are automatically rotated to ensure equal operating hours. MicroTech intervenes to protect
critical components in response to external signals from its system sensors measuring: motor temperatures,
refrigerant gas and oil pressures, electrical supply, evaporator and heat recovery condenser. A feature of
MicroTech includes a diagnostic memory of the latest fault conditions together with a record of when they
occurred; an internal clock checks continuously all the safety and running parameters taken all the actions to avoid
problems on the unit. In addition there are some mechanical devices that stop the unit in case of malfunctioning of
MicroTech. Some of the mainly alarm conditions are below listed: High pressure on condenser, low pressure on
condenser, lack of water flow, not possible to do the pump down, anti-freeze, low pressure on evaporator,
differential oil pressure, thermal protection compressor motors, check control of sensor, phase and voltage
monitoring, antifreeze monitoring. MicroTech provide the optimization of the compressors and fans running
operation, with automatic on/off function according to the loads system and the ambient temperature. Microtech's
internal clock can be used to program the operating schedule of the chiller in order to meet each specific building
load profile precisely. Microtech's parameters can be read & updated locally, or remotely via an MS Dos
compatible PC or remotely via Modem linking.

302 C 06/10 B pag. 5
High pressure control
The high pressure switch will shut-down the compressor when the discharge pressure excedes the setting point
value.

Checking control operation:
1. To check the control, either block off condenser surface or start the unit with condenser fan motor fuses in only
one fan fuse block and observe the cut out point of the control on a high pressure gauge.

2. Observe the discharge pressure gauge: when the pressure reaches the control cut-out point, this control should
stop the compressor.

Warning: during testing, stand by the emergency stop switch Q11 on control panel, to shut the unit down should
the safety control malfunction. Be sure that the installed gauge is accurately adjusted.

Phase/voltage monitor (optional)
The phase/voltage monitor is a device which provides protection against three-phase electrical motor loss due to
power failure conditions, phase loss, and phase reversal. Whenever any of these conditions occur, a contact
opens to the MicroTech controller (PVR Input) which then de-energizes all inputs. When proper power is restored,
contacts close and Micro-Tech enables compressors for operation. When three-phase power has been applied,
the output relay should close and the "run light" should come on. If the output relay does not close, perform the
following tests:

1. Check the voltages between L1-L2, L1-L3 and L2-L3 (L1, L2, L3 are the three phases). These voltages should
be approximately equal and within + 10% of the rated three-phase line-to-line voltage.

2. If these voltages are extremely low or widely unbalanced check the power system to determine the cause of the
problem.

3. If the voltages are good, using a phase tester, verify that phases are in A, B, C sequence for L1, L2 and L3.
Correct rotation is required for compressor operation. If required to do so by phase sequence, turn off the power
and interchange any two of the supply power leads at the disconnect. This may be necessary as the phase voltage
monitor is sensitive to phase reversal. Turn on the power. The output relay should now close after the appropriate
delay.

System Maintenance

General
To ensure proper operation at peak capacity and to avoid damage to package components, a program of periodic
inspections should be set up and followed. The following items are intended as a guide and are to be used during
inspection and must be combined with sound refrigeration and electrical practices to assure trouble-free
performance. The liquid line sight-glass indicator on all circuits must be checked to be sure the glass is full and
clear. If the indicator shows that a wet condition exists or if bubbles show in the glass, even with a full refrigerant
charge, the filter-drier element must be changed. Water supplies in some areas may tend to foul the water cooled
condenser to the point where cleaning is necessary. The fouled condenser will be indicated by an abnormally high
condensing pressure and may result in nuisance trip-outs. To clean the condenser, a chemical de-scaling solution
should be used according to the manufacturer's directions.

Compressor maintenance
Since the compressor is semi-hermetic with forced lubricating obtained through a reversible gear type pump, no
yearly maintenance is normally required. However, vibration is an excellent check for proper mechanical operation.
Compressor vibration is an indicator of the requirement for maintenance and contributes to a decrease in unit
performance and efficiency. It is recommended that the compressor be checked with a vibration analyzer at or
shortly after start-up and again on an annual basis. When performing the test the load should be maintained as
closely as possible to the load of the original test. The vibration analyzer test provides a fingerprint of the
compressor and when performed routinely can give a warning of impending problems. The compressor is supplied
with a lifetime oil filter. It is a good policy to replace this filter anytime the compressor is opened for servicing.

302 C 06/10 B pag. 6
Electrical control centre
Warning: Electric shock hazard. Turn off all power before continuing with following service.

Caution: It is necessary to de-energize the complete panel, including crankcase heater, before doing any
servicing inside.
Prior to attempting any service on the control centre it is advisable to study the wiring diagram so that you
understand the operation of the water chiller. Electrical components do not require particular maintenance other
than a monthly tightening of cables.

Warning: The warranty becomes void if the wiring is not in accordance with the specification. A blown fuse or
tripped protector indicates a short ground or overload.
Before replacing the fuse or restarting the compressor, the problem must be found and corrected. It is important to
have a qualified control panel electrician service this panel. Unqualified tampering with the controls can cause
serious damage to equipment and void the warranty.

Filter-driers
A replacement of the filter-drier is recommended during scheduled service maintenance of the unit, any time
excessive pressure drop is read across the filter-drier and/or when bubbles occur in the sight-glass with normal
sub-cooling. A partially clogged filter can also cause trips on the no liquid run sensor. The maximum
recommended pressure drop across the filter-drier at 75% to 100% circuit loading is 70 kPa. The maximum
recommended pressure drop across the filter-drier at 25% to 50% circuit loading is 35 kPa. The filter-drier should
also be changed if the moisture indicating liquid line sight-glass indicates excess moisture by the wet system
colour indicators. During the first few months of operation the filter-drier replacement may be necessary if the
pressure drop across the filter-drier exceeds the values listed in the paragraph above. Any residual particles from
the unit heat transfer tubing, compressor and miscellaneous components are swept by the refrigerant into the
liquid line and are caught by the filter-drier.
To change the filter drier, pump the unit down by opening the switches Q1, Q2 (ON/OFF switches compressors) in
off position.
Move the ON/OFF switch unit Q0 to the off position. Turn off all power to the unit and install jumpers across the
terminals F12, F22.
This jumps out the low pressure control. Close the manual liquid line shutoff valve.
Turn the power of the unit back on and restart the unit by moving the ON/OFF switch unit Q0. The unit will start
pumping down past the low pressure setting.
When the evaporator pressure reaches 0,3 bar, move switch Q0 to the off position. Remove the jump.
Close the suction line valve. Remove and replace the filter-drier. Evacuate the lines through the liquid line manual
shutoff valve to remove non condensable that may have entered during filter replacement.
Open the suction line valve. A leak check is recommended before returning the unit to operation.

Lead-Lag
A feature on all McQuay MHP air cooled heat pumps is a system for alternating the sequence in which the
compressors start to balance the number of starts and run hours. Lead-Lag of the refrigerant circuits is
accomplished automatically through the MicroTech Controller. When in the auto mode the circuit with the fewest
number of starts will be started first. If all circuits are operating and a stage down to one circuit is required, the
circuit with the most operating hours will cycle off first. The operator may override the MicroTech controller, and
manually select the lead circuit as circuit #1, #2, #3 or #4.

Refrigerant sight-glass
The refrigerant sight-glasses should be observed periodically (a weekly observation should be adequate). A clear
glass of liquid indicates that there is adequate refrigerant charge in the system to insure proper feed through the
expansion valve. Bubbling refrigerant in the sight-glass, during stable run conditions, indicates that the system
may be short of refrigerant charge. Refrigerant gas flashing in the sight-glass could also indicate an excessive
pressure drop in the liquid line, possibly due to a clogged filter-drier or a restriction elsewhere in the liquid line. If
sub-cooling is low add charge to clear the sight-glass. If sub-cooling is normal and flashing is visible in the sight-
glass check the pressure drop across the filter-drier. An element inside the sight-glass indicates the moisture
condition corresponding to a given element colour. If the sight-glass does not indicate a dry condition after about 3
hours of operation, the unit should be pumped down and the filter-driers changed.
The following table is a guide to determinate the dry or wet condition of the system:



302 C 06/10 B pag. 7
COLOUR MEANS
Green (Sky Blue) Dry
Yellow (Pink) West

Liquid line solenoid valve
The liquid line solenoid valves that shuts off refrigerant flow in the event of a power failure, do not normally require
any maintenance. (The expansion valve, on a sudden power failure, remains open to the position it was at when
the power failure occurred. During normal operation the EEV closes for automatic pump-down and the liquid line
solenoid valve closes only when the compressor stops.) They may, however, require replacement of the solenoid
coil or of the entire valve assembly. The solenoid coil can be checked to see that the stem is magnetized when
energized by touching a screwdriver to the top of the stem. If there is no magnetization either the coil is bad or
there is no power to the coil. The solenoid coil may be removed from the valve body without opening the
refrigerant piping after first moving pump-down switches Q1 and Q2 to the "manual pump-down" position and
opening the Q0 switch. For personal safety shut off and lock out the unit power. The coil can then be removed
from the valve body by simply removing a nut or snap-ring located at the top of the coil. The coil can then be
shipped off its mounting stud for replacement. Be sure to replace the coil on its mounting stud before returning
pump-down switches Q1 and Q2 to the "auto pump-down" position. To replace the entire solenoid valve follow the
steps involved when changing a filter-drier.

Thermostatic expansion valve
The expansion valve is responsible for allowing the proper amount of refrigerant to enter the evaporator regardless
of cooling load. It does this by maintaining a constant superheat. All MHP heat pumps are factory set for between
4C and 7C superheat.
If it is necessary to increase the superheat setting of the valve, remove the cap at the bottom of the valve to
expose the adjustment screw. Turn the screw clockwise (when viewed from the adjustment screw end) to increase
the superheat and counter clockwise to reduce superheat. Allow time for system rebalance after each superheat
adjustment.
The expansion valve, like the solenoid, should not normally require replacement, but if it does, the unit must be
pumped down by following the steps involved when charging a filter-drier. If the problem can be traced to the
power element only, it can be unscrewed from the valve body without removing the valve, but only after pumping
the unit down.

Warning: Adjustment of expansion valve should only be performed by a qualified refrigeration-service technician.

High condenser pressure control
MicroTech is also supplied with high pressure transducers on each refrigerant circuit. Although the main purpose
of the high pressure transducer is to maintain proper head pressure control, another is to convey a signal to the
MicroTech control to unload the compressor in the event of an excessive rise in discharge pressure. The
MicroTech control is set to not allow additional circuit loading approximately 207 kPa below the high pressure
switch trip setting. The high pressure alarm is in response to the signal sent by the pressure transducer. The high
pressure transducer can be checked by elevating discharge pressure (see Mechanical High Pressure Safety
Control) and observing the MicroTech display (or a pressure gage), and unit operation as the pressures pass the
rising high pressure values noted.

Evaporator
The evaporator is of the direct expansion, shell-and-tube type with refrigerant flowing through the tubes and water
flowing through the shell over the tubes. The tubes are internally finned to provide extended surface as well as
turbulent flow of refrigerant through the tubes. Normally no service work is required on the evaporator. There may
be instances where a tube will leak refrigerant into the water side of the system. In the cases where only one or
two tubes leak, the problem can best be solved by plugging the tube at both ends. When the tube must be
replaced, the old tube can be removed and replaced. To remove a tube, the unit should be temporarily pumped
down. Follow the steps involved when changing a filter-drier. These steps will insure a minimum amount of
refrigerant loss when the evaporator is opened up. The tubes are mechanically expanded into the tube sheets at
each end of the cooler. In order to remove the tubes, it is necessary to break this bond by collapsing the tube.
After doing this at both ends of the shell, the tube can be removed for replacement. The new tube can then be
inserted and re-expanded into the tube sheet.

302 C 06/10 B pag. 8
Note: The bond produced by expansion must be refrigerant tight. This bond must be produced by applying
Locktite (red) to the tube and rolling it into the tube sheet. After re-assembling the evaporator, a small amount of
refrigerant should be introduced by momentarily opening the manual liquid line valve. A leak check should then be
per-formed on the evaporator. Tube removal can only take place after the leaking tube is located. One method that
would be to subject each tube to air pressure by plugging each end and, with a pressure gauge attached to one of
the end plugs, observing if there is a loss of air pressure over a period of a minute or two. Another method is to
place a cork plug in each tube on both ends of the cooler and applying pressure to the shell of the cooler. After a
period of time the pressure will leak from the shell into the leaking tube or tubes and pop out the cork plug.

Air cooling condenser (Condensing coil)
Condensers are air cooled. Internally finned copper tubes bonded in a staggered pattern into slit aluminium fins.
No maintenance is ordinary required except the occasional removal of dirt and debris from the outside surface of
the fins. McQuay recommends the use of foaming coil cleaners available at air conditioning supply outlets. Use
caution when applying such cleaners as they may contain potentially harmful chemicals. Care should be taken not
to damage the fins during cleaning.

Compressor oil level
The oil level should be watched carefully upon initial start-up and for sometime thereafter. Lubrificating oil
approved by McQuay is mentioned on the compressor label. The oil level should be maintained at about one-third
of the sight-glass on the compressor body. Oil may be added to the compressor through the oil fill hole in the
crankcase. To add oil, isolate the crankcase and pour or pump in the necessary oil. If the system contains no
refrigerant, no special precautions are necessary other than keeping the oil clean and dry. If the system contains a
refrigerant charge, close the suction valve and reduce crankcase pressure to 0 bar. Stop the compressor and
close the discharge valve. Add the required amount of oil. During the period the compressor is exposed to the
atmosphere, the refrigerant will generate a vapour pressure, retarding the entrance of contaminants. Before
resealing the compressor, purge the crankcase by opening the suction valve slightly for 1 or 2 seconds. Close the
oil port, open the compressor valves and restore the system to operation.

Crankcase heater
The function of the heaters is to prevent oil dilution by refrigerant during compressor shutdown, which would cause
foaming and loss of pump pressure when unit starts up, with consequent reduction in lubricating oil flow to the
moving parts. Electric heaters are energized every time the compressor shuts-down.

Warning: Verify the heaters have operated for at least 12 hours prior to start-up.

Pump discharge side oil filter
Cleaning procedure:
1. Pump down the system.
2. Release residual pressure through a connection provided on the compressor.
3. Loosen the securing screws and remove the filter body.
4. During cleaning operation, plug the filter housing to prevent moisture from entering.
5. Remove the regulating valve from the filter body; remove the filter element, clean them carefully with a suitable
solvent, dry with compressed air, and reassemble in the same order.
6. Tighten the regulating valve and place the filter body in its housing on the compressor matching the oil inlet and
outlets holes.
7. Tighten the securing screws, open refrigerant inlet and outlet valves on the condenser, start the unit and check
for leaks.

Suction filter
Cleaning procedure:
1. Pump down the refrigerant into the condenser.
2. Release residual pressure through a connection provided on the compressor.
3. Remove suction piping.
4. Loosen the suction filter cover securing screws, remove the filter and clean it with a suitable solvent.
5. Reassemble all components in the same order.

302 C 06/10 B pag. 9
Caution: during filter cleaning operation, it is recommended to plug the filter housing to prevent moisture from
entering.

Refrigerant
MHP air cooled heat pumps are shipped factory charged with a full operating charge of refrigerant but there may
be times that a unit must be recharged at the jobsite. In case moisture is noticed in the system, through the
moisture indicator, the system must be evacuated to eliminate cause of trouble. After the evacuation, the system
must be dried reducing it to an almost perfect vacuum. For this purpose, a displacement vacuum pump should be
used.
When the system has been opened for extensive repairs, as for an overhaul, it is advisable to use the method of
the evacuation as follows:
1. Operate the vacuum pump up to a vacuum of 200 Pa (1,5 mm Hg).
2. Break the vacuum with refrigerant until the atmospheric pressure is reached.
3. Repeat operation 1 and 2.
4. Operate the pump until a final vacuum of 66,5 Pa is reached.
Any moisture and air left in the system will be absorbed by the dry refrigerant used to break the vacuum, and they
will be almost completely removed by the three evacuations.
If burnt oil or sludge are found in the refrigerant circuit (caused by the compressor motor burn-out), before the
vacuum operation it will be necessary to carefully clean the system using the filter dryer clean out method; which
basically involves the use of special filter dryers incorporating a suitable desiccant in both the liquid and suction
lines.

Adding refrigerant
Bubbles in the liquid line sight glass during full load compressor operation indicates refrigerant shortage: check
carefully for leaks, repair them and add refrigerant.
When the refrigerant circuit is empty, or after the system has been opened for extensive repair, check and repair
any possible leak and evacuate the system before charging operation, the compressor and liquid valves must be
opened and chilled water should be circulated in the evaporator.

Caution: Do not cut out any safety device while loading the refrigerator with refrigerant.

Charging the refrigerant
1. Connect the refrigerant bottle with a filling pipe to the filling valve on the evaporator head.
Before firmly tightening the refrigerant bottle valve, open it and force the air out from the filling pipe.
Tighten the charging valve connection.
2. When the refrigerant stops to enter the system, start the compressor and complete the refrigerant charge.
3. When the exact quantity of refrigerant has been predetermined, check the liquid sight glass.

If you do not know how much refrigerant has to be added, shut off the bottle valve every 5 minutes and continue to
charge the refrigerant until the sight glass is clear and free from bubbles.

Note: Do not discharge the refrigerant into the atmosphere. To recover it, use empty, clean and dry bottles. The
liquid refrigerant recovery can be made through the valve provided on the condenser coil sub-cooler outlet. To
facilitate the recovery of refrigerant, put the bottle inside a container full of ice; avoid excessive filling of the bottle
(7080% max).

In warranty return material procedure

Material may not be returned except by permission of McQuay Service department. A "Return Goods" tag will be
included with the returned material. This tag will all information required to expedite handling at our factory. Return
of the parts does not constitute an order for replacement. Therefore, a purchase order must be entered through
our nearest Sales Representative. The order should include part name, part number, model number and serial
number of the unit involved. Following our personal inspection of the returned part, if it is determined that the
failure is due to faulty material or workmanship, credit will be issued on the customer's purchase order. All parts
shall be returned to McQuay factory, transportation charges prepaid.
302 C 06/10 B pag. 10
Service & replacement parts

Always quote the model number, confirmation number and the machine's serial number stamped on the plaque
attached to the machine itself, whenever ordering maintenance service or replacement parts.
If replacement parts are being ordered, state the date the machine was installed and the date the breakdown
occurred. For an exact definition of the replacement part requested, make reference to the relative code number
or, failing that, attach a description of the part being requested.

Troubleshooting chart

PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS
Compressor will
not run

1. Main power switch open.
2. Unit Q0 system switch open.

3. Circuit switch in pump-down position.

4. Circuit breakers open.
5. Fuse blown or circuit breakers tripped.





6. Unit phase voltage monitor not satisfied.

7. Compressor overload tripped.


8. Defective compressor contactor or contactor
coil.
9. System shut down by safety devices.


10. No cooling required.

11. Motor electrical trouble.

12. Loose wiring.
1. Close switch.
2. Check unit status on MicroTech display.
Close switch.
3. Check circuit status on MicroTech display.
Close switch.
4. Close circuit breakers.
5. Check electrical circuits and motor
windings for shorts or grounds.
Investigate for possible overloading.
Check for loose or corroded connections.
Reset breakers or replace fuses after fault is
corrected.
6. Check unit power wiring to unit for correct
phasing. Check voltage.
7. Overloads are manual reset. Reset
overload at button on overload.
Clear alarm on MicroTech.
8. Check wiring. Repair or replace contactor.

9. Determine type and cause of shutdown
and correct problem before
attempting to restart.
10. Check control settings. Wait until unit
calls for cooling.
11. See 6, 7, 8 above.
12. Check circuits for voltage at required
points. Tighten all power wiring terminals.
Compressor will
stop and restart
repeately
1. Differential range at low pressure controls
too start.
2. Lack of refrigerant.
1. Erratic wire connections.

2. Low voltage.
Compressor
noisy or
vibrating
1. Flooding of refrigerant into crankcase
2. Worn compressor.
1. Check setting of expansion valve
2. Replace.
Compressor will
not load or
unload
1. Defective capacity control.
2. Un-loader mechanism defective.
1. Replace.
2. Replace.
High discharge
pressure
1. Discharge shutoff valve partially closed.
2. Non-condensable in the system.

3. Fans not running.
4. Fan control out of adjustment.



5. System overcharged with refrigerant.

6. Duty condenser coil.
7. Air recirculation from outlet into unit coils.
8. Air restriction into unit.
1. Open shutoff valve.
2. Purge the non-condensable from the
condenser coil after shutdown.
3. Check fan fuses and electrical circuits.
4. Check that unit setup in MicroTech
matches the unit model number.
Check MicroTech condenser pressure
sensor for proper operation.
5. Check for excessive sub-cooling.
Remove the excess charge.
6. Clean the condenser coil.
7. Remove the cause of recirculation.
8. Remove obstructions near unit.

302 C 06/10 B pag. 11

PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS
Low suction
pressure
1. Inadequate refrigerant charge quantity.

2. Evaporator dirty.
3. Clogged liquid line filter-drier.
4. Expansion valve malfunctioning.



5. Insufficient water flow to evaporator.

6. Water temperature leaving evaporator is too
low.
7. Evaporator head ring gasket slippage.
1. Check liquid line sight-glass. Check unit
for leaks.
2. Clean chemically.
3. Replace
4. Check expansion valve superheat and
valve opening position.
Replace valve only it certain valve is not
working.
5. Check water pressure drop across the
evaporator and Adjust gpm.
6. Adjust water temperature to higher value.

7. Low suction pressure and low superheat
both present may indicate an internal
problem. Consult factory.
High suction
pressure
1. Excessive load - high water temperature.
2. Compressor un-loaders open.

3. Superheat is too low.
1. Reduce load or add additional equipment.
2. See Corrective Steps below for failure of
compressor to load.
3. Check superheat on MicroTech display.
Check suction line sensor installation and
sensor.






We reserve the right to make changes in design and construction at any time without notice, thus the cover picture is not binding.


































































McQuay Italia S.P.A.
S.S. Nettunense, km 12+300 00040 Cecchina (Roma) Italia Tel. (06) 937311 Fax (06) 9374014 E-mail: mcquay.italiapcg.telpress.it.