McQuay ACR 065AS Installation Manual

Installation, Operation and Maintenance Manual IOMM ACR/AGR-1

Group: Chiller Part Number: 074644201 Effective: March 2000

Supersedes: IOMM ACR/AGR

AIR-COOLED, RECIPROCATING, SPLIT SYSTEMS

Chiller w/ Remote Evaporator, AGR 070AM-100AM Condensing Unit, ACR 060AS-120AS DX Evaporators, CDE

60 Hertz, R-22 Global Chiller Line

Table of Contents

Introduction.........................................3

Inspection...........................................................3

Installation...........................................4

Handling..............................................................4

Location...............................................................5

Service Access...................................................5

Vibration Isolators..............................................7

Water Piping.......................................................8

Flow Switch.........................................................9

Glycol Solutions...............................................10

Evaporator Flow and Pressure Drop.............11

Refrigerant Piping............................................13

Physical Data.....................................17

Electrical Data...................................22

Field Wiring.......................................................22

AGR-AM Data..................................................23

ACR Data..........................................................23

Electrical Notes.................................................26

Wiring Diagrams...............................................28

Dimensional Data..............................35

Startup...............................................38

System Adjustment..........................................42

Liquid Sightglass and Moisture Indicator...42

Refrigerant Charging.......................................42

Thermostatic Expansion Valve.......................42

Crankcase Heaters ...........................................42

DX Evaporator ..................................................43

Sequence of Operation....................................43

UNT Controller, AGR-AM...............45

General Description.........................................45

Optional Sensors..............................................45

Controller Inputs /Outputs.............................47

UNT Controller Features.................................51

Alarms................................................................53

ZONE TERMINAL (optional)........................53

Zone Terminal Glossary ..................................57

Global UNT Controller Troubleshooting

Chart...................................................................59

MicroTech Controller.......................61

General Description.........................................61

Optional Sensor Packages..............................61

Installation........................................................61

Sequence of Operation....................................70

Start-Up and Shutdown ..................................72

Keypad / Display.............................................73

Menu Descriptions..........................................76

MicroTech Controller Trouble Analysis.......87

Test Procedures................................................90

Pre Start-up.......................................................38

Start-Up .............................................................38

Shutdown..........................................................38

Water Piping Checkout...................................39

Refrigerant Piping Checkout..........................39

Electrical Check Out.........................................40

Operation...........................................41

Hot Gas Bypass (Optional).............................41

Filter Driers........................................................41

Unit Maintenance..............................97

Preventative Maintenance Schedule ............98

Service...............................................99

Liquid Line Solenoid Valve.............................99

Evaporator.......................................................100

Refrigerant Charging.....................................100

AGR Troubleshooting Chart........................102

Our facility is ISO 9002 Certified

"McQuay" is a registered trademark of McQuay International

"Illustrations and data cover the McQuay International products at the time of publication and we reserve the

right to make changes in design and construction at anytime without notice"

2 IOMM ACR/AGR-1



1997 McQuay International

Introduction

C=Cond. Unit

Design Vintage

M= Remote Evaporator

This Product Manual contains information on three different McQuay product lines.

• Model AGR-AM This is the AGR packaged chiller but with the shell and tube

• Model ACR-AS This is an air-cooled condensing unit for use with a remote

• Model CDE This is a DX evaporator that can be used in conjunction with the

IMPORTANT INFORMATION

evaporator shipped loose for remote mounting. Liquid line specialties are field supplied and mounted. Capacity control is included and is Johnson UNT as standard or optional McQuay MicroTech Control. This unit would be the normal choice when an indoor shell and tube water chiller and remote condensing unit with factory mounted capacity control is desired. NOTE: AGR-AM type units are not included in the ARI Certification Program.

evaporator, typically a water chiller or DX coil. Neither capacity control, liquid line specialties, nor evaporator are included. The ACR would be the choice when a DX coil (air handler) is used with a remote condensing unit or if some control other than the controls available on the AGR-AM are desired. NOTE: ACR type condensing units are not included in the ARI Certification Program.

Model ACR condensing unit. No controls or specialties are included.

Nomenclature

A G/C R - XXX A S/M

Application S= Standard Cooling

Air-Cooled

G=Chiller

Reciprocating Compressor

Model Size Nominal Tons

Inspection

Check all items carefully against the bill of lading. Inspect all units for damage upon arrival. Report shipping damage and file a claim with the carrier. Check the unit name plate before unloading, making certain it agrees with the power supply available. McQuay is not responsible for physical damage after unit leaves the factory.

Note: Unit shipping and operating weights are available in the Physical Data tables beginning on page 17.

IOMM ACR/AGR-1 3

Installation

Note: Installation is to be performed by qualified personnel who are familiar with local codes

and regulations.

WARNING

Sharp edges and coil surfaces are a potential hazard. Avoid contact with them.

Handling

Be careful to avoid rough handling of the unit. Do not push or pull the unit from anything other than the base. Block the pushing vehicle away from the unit to prevent damage to the sheet metal cabinet and end frame (see Figure 1).

To lift the unit, 2 1/2" (64mm) diameter lifting holes are provided in the base of the unit. Arrange spreader bars and cables to prevent damage to the condenser coils or cabinet (see Figure 2).

Figure 1, Suggested Pushing Arrangement

Blocking required across full width

Figure 2, Suggested Lifting Arrangement

Spreader Bars

recommended

(use caution)

4 IOMM ACR/AGR-1

Location

Unit Placement

AGR-AM and ACR units are for outdoor applications and can be mounted on a roof or ground level. Set units on a solid and level foundation. For roof mounted applications, install the unit on a steel channel or I-beam frame to support the unit above the roof. For ground level applications, install the unit on a substantial base that will not settle. A one piece concrete slab with footings extended below the frost line is recommended. Be sure the foundation is level (within 1/2” [13 mm] over its length and width). The foundation must support the operating weights listed in the Physical Data Tables.

On ground level applications protect fins against vandalism using the optional coil guards or by erecting a screen fence. The fence must allow free flow of air to the condenser coil for proper unit operation.

Clearances

The flow of air to and from the condenser coil must not be limited. Restricting air flow or allowing air recirculation will result in a decrease in unit performance and efficiency. There must be no obstruction above the unit that would deflect discharge air downward where it could be recirculated back to the inlet of the condenser coil. The condenser fans are propeller type and will not operate with ductwork on the fan outlet.

Do not allow debris to accumulate near the unit. Air movement may draw debris into the condenser coil causing air starvation. Give special consideration to low ambient operation where snow can accumulate. Keep condenser coils and fan discharge free of snow or other obstructions to permit adequate airflow.

Sound Isolation

The ultra-low sound levels of the AGR outdoor unit and the ACR condensing unit is suitable for most applications. When additional sound reduction is necessary, locate the unit away from sound sensitive areas. Avoid locations beneath windows or between structures where normal operating sounds may be objectionable. Reduce structurally transmitted sound by isolating water lines, electrical conduit and the unit itself. Use wall sleeves and rubber isolated piping hangers to reduce transmission of water or pump noise into occupied spaces. Use flexible electrical conduit to isolate sound transmission through electrical conduit. Spring isolators are effective in reducing the low amplitude sound generated by reciprocating compressors and for unit isolation in sound sensitive areas.

Service Access

Each end of the unit must be accessible after installation for periodic service. Compressors, filterdriers, and manual liquid line shutoff valves are accessible. The high pressure control is located in the control panel when using the Global UNT controller, and on the compressor when using the MicroTech controller. Low pressure, and motor protector controls are on the compressor. Most other operational, safety and starting controls are located in the unit control box.

The condenser fan and motors can be removed from the top of the unit.

IOMM ACR/AGR-1 5

Figure 3, Clearance Requirements

operation.

Do not block the flow of air to and from the condenser coil. Restricting airflow or allowing air recirculation will result in a decrease in unit performance and efficiency because discharge pressures are increased. There must be no obstruction above the unit that would deflect discharge air downward where it could be recirculated back to the inlet of the condenser coil. The condenser fans are propeller type and will not operate with ductwork on the fan outlet.

Install the unit with enough side clearance for air entrance to the coil and for servicing. Provide service access to the evaporator, compressors, electrical control panel and piping components. Do not allow debris to accumulate near the unit. Air movement may draw debris into the condenser coil causing coil starvation. Give special consideration to low ambient operation where snow can accumulate. Keep condenser coils and fan discharge free of snow or other obstructions to permit adequate airflow for proper unit

6 IOMM ACR/AGR-1

Vibration Isolators

Vibration isolators are recommended for all roof mounted installations or wherever vibration transmission is a consideration.

Table 1 through Table 4 list isolator point loads for all unit sizes, Figure 4 shows isolator locations. See Dimensional Data for detailed dimensions required to secure each isolator to the mounting surface.

The spring flex isolators are white type CP2-32, McQuay part number 047792932. A total of four per unit is required.

Figure 4, Isolator Locations Spring Isolator Dimensions

Table 1, AGR-AM Isolator Loads At Each Mounting Location With Aluminum Fins

Size

070 AM 973 442 1227 557 838 380 1051 477 4090 1855 075 AM 1205 547 1471 667 901 409 1093 496 4670 2118 080 AM 1265 574 1545 701 947 429 1148 521 4905 2225 085 AM 1313 596 1603 727 982 446 1191 540 5089 2308 090 AM 1348 611 1646 746 1008 457 1222 554 5224 2370 095 AM 1350 613 1649 748 1010 458 1225 556 5234 2374 100 AM 1351 613 1650 748 1011 459 1226 556 5238 2376

1 2 3 4 Total UnitAGR

lb kg lb kg lb kg lb kg lb kg

Table 2, ACR-A Isolator Loads At Each Mounting Location With Aluminum Fins

Size

060 A 867 393 1093 496 747 339 936 425 3642 1652 065 A 883 401 1114 505 761 345 954 433 3712 1684 070 A 891 404 1124 510 768 348 962 437 3745 1699 075 A 937 425 1181 535 807 366 1011 459 3935 1785 080 A 1205 547 1471 667 901 409 1093 496 4670 2118 090 A 1265 574 1545 701 947 429 1148 521 4905 2225 100 A 1348 611 1646 746 1008 457 1222 554 5224 2370 110 A 1350 613 1649 748 1010 458 1225 556 5234 2374 120 A 1351 613 1650 748 1011 459 1226 556 5238 2376

1 2 3 4 TOTAL UNITACR

lb kg lb kg lb kg lb kg lb kg

IOMM ACR/AGR-1 7

Table 3, AGR-AM Isolator Loads At Each Mounting Location With Copper Fins

Size

070 AM 1171 531 1476 670 1009 457 1264 574 4920 2232 075 AM 1526 692 1863 845 1142 518 1384 628 5915 2683 080 AM 1587 720 1937 879 1187 538 1439 653 6150 2790 085 AM 1634 741 1995 905 1222 554 1482 672 6334 2873 090 AM 1669 757 2038 924 1249 566 1514 687 6469 2934 095 AM 1672 758 2041 926 1250 567 1516 688 6479 2939 100 AM 1673 759 2042 926 1251 568 1517 688 6483 2941

1 2 3 4 TOTAL UNITAGR-AM

lb kg lb kg lb kg lb kg lb kg

Table 4, ACR-A Isolator Loads At Each Mounting Location With Copper Fins

Size

060 A 1025 465 1292 586 883 400 1107 502 4307 1954 065 A 1042 473 1313 596 897 407 1125 510 4377 1985 070 A 1089 494 1373 623 938 425 1176 533 4575 2075 075 A 1134 514 1430 648 977 443 1225 555 4765 2161 080 A 1526 692 1863 845 1142 518 1384 628 5915 2683 090 A 1587 720 1937 879 1187 538 1439 653 6150 2790 100 A 1669 757 2038 924 1249 566 1514 687 6469 2934 110 A 1672 758 2041 926 1250 567 1516 688 6479 2939 120 A 1673 759 2042 926 1251 568 1517 688 6483 2941

1 2 3 4 TOTAL UNITACR

lb kg lb kg lb kg lb kg lb kg

Water Piping

Local authorities can supply the installer with the proper building and safety codes required for safe and proper installation.

Install piping with minimum bends and changes in elevation to minimize pressure drop. Consider the following when installing water piping:

1. Vibration eliminators to reduce vibration and noise transmission to the building.

2. Shutoff valves to isolate the unit from the piping system during unit servicing.

3. Manual or automatic air vent valves at the high points of the system. Install drains at the lowest

points in the system.

4. A means of maintaining adequate system water pressure (expansion tank or regulating valve).

5. Temperature and pressure indicators located at the unit to aid in unit servicing.

6. A strainer or other means of removing foreign matter from the water before it enters the pump.

Place the strainer far enough upstream to prevent cavitation at the pump inlet (consult pump manufacturer for recommendations). The use of a strainer will prolong pump life and keep system performance up.

7. Place a strainer in the water line just before the inlet of the evaporator. This will help prevent

foreign material from entering and decreasing the performance of the evaporator.

CAUTION

If separate disconnect is used for the 115V supply to the evaporator heating cable,

mark the disconnect clearly to ensure disconnect is not accidentally shut off during

cold seasons.

8. The shell-and-tube evaporator has a thermostat and heating cable to prevent freeze-up down to

-20°F (-29°C) that should be used if located in a sub-freezing location. It is suggested that the heating cable be wired to a separate 110V supply circuit. All water piping to the unit must also be protected to prevent freezing.

8 IOMM ACR/AGR-1

9. If the unit is used as a replacement chiller on a previously existing piping system, flush the

system thoroughly before unit installation. Regular water analysis and chemical water treatment for the evaporator loop is recommended immediately at equipment start-up.

10. The total water volume in the system should be sufficient to prevent frequent “on-off” cycling.

Turnover rate should not be less than 15 minutes for normal variable cooling loads. Turnover rate for process cooling or a constant load, should not be less than 6 minutes.

11. When glycol is added to the water system for freeze protection, the refrigerant suction pressure

will be lower, cooling performance less, and water side pressure drop greater. If the percentage of glycol is high, or if propylene is used instead of ethylene glycol, the added pressure drop and loss of performance could be substantial. Reset the freezestat and low leaving water alarm temperatures. The freezestat is factory set as follows:

• UNT Control; Low Water Temp=38°F, Low Press=54psig

• MicroTech Control; Low Water Remp=36°F, Low Press=54psig

Reset the freezestat setting to approximately 4 to 5 degrees F (2.3 to 2.8 degrees C) below the leaving chilled water setpoint temperature. See the section titled “Glycol Solutions” for additional information concerning glycol.

12. Perform a preliminary leak check before insulating the piping and filling the system.

13. Piping insulation should include a vapor barrier to prevent condensation and possible damage to

the building structure.

Figure 5, Typical Field Evaporator Water Piping

Flow Switch

Mount a water flow switch in either the leaving water line to shut down the unit when water flow is interrupted. A flow switch is a safety control and should never be used to cycle a unit. The unit control circuit is provided with a remote start/stop feature.

A flow switch is available from McQuay (part number 017503300). It is a “paddle” type switch and adaptable to any pipe size from 3” (76mm) to 8” (203mm) nominal. Certain minimum flow rates are required to close the switch and are listed in Table 5. Installation should be as shown in Figure 6. Connect the normally open contacts of the flow switch in the unit control center at terminals 5 and 6. There is also a set of normally closed contacts on the switch that can be used for an indicator light or an alarm to indicate when a “no flow” condition exists. Freeze protect any flow switch that is installed outdoors. Differential pressure switches are not recommended for outdoor installation.

IOMM ACR/AGR-1 9

Note: The procedure does not specify the type of glycol. Use the derate factors found Table 6 for corrections when using ethylene glycol and those in Table 7 for propylene glycol.

Table 5, Flow Switch Minimum Flow Rates

NOMINAL PIPE SIZE

INCHES (mm)

1 (25.4) 6.00 (0.38) 1 1/4 (31.8) 9.80 (0.62) 1 1/2 (38.1) 12.70 (0.80)

2 (50.8) 18.80 (1.20)

2 1/2 (63.50 24.30 (1.50)

3 (76.20 30.00 (1.90) 4 (101.6) 39.70 (2.50) 5 (127.0) 58.70 (3.70) 6 (152.4) 79.20 (5.00)

MINIMUM REQUIRED FLOW TO

ACTIVATE SWITCH - gpm (L/s)

Figure 6, Flow Switch Installation

Flow direction marked

on switch

1" (25mm) NPT flow

switch connection

Tee

Glycol Solutions

The use of a glycol/water mixture in the CDE evaporator to prevent freezing will reduce system capacity and efficiency and increase pressure drop. The system capacity, required glycol solution flow rate, and pressure drop with glycol may be calculated using the following formulas and tables.

1. Capacity – Multiply the capacity based on water by the Capacity correction factor from Table 6

or Table 7.

2. Flow – Multiply the water evaporator flow by the Flow correction factor from Table 6 or Table 7 to

determine the increased evaporator flow due to glycol If the flow is unknown, it can be calculated from the following equation:

(gpm) Flow Glycol ×

For Metric Applications – Use the following equation for metric applications:

(l/s) Flow Glycol

CapacitykW

TDelta

−×=18.4

3. Pressure drop -- Multiply the water pressure drop from Figure 7 by Pressure Drop correction

factor from Table 6 or Table 7 to obtain corrected glycol pressure drop. High concentrations of propylene glycol at low temperatures may cause unacceptably high pressure drops.

glycolCapacityTons

)(24

TDelta

−

FactorCorrectionFlow

4. Power -- Multiply the water system power by Power correction factor from Table 6 or Table 7. Test coolant with a clean, accurate glycol solution hydrometer (similar to that found in service

stations) to determine the freezing point. Obtain percent glycol from the freezing point table below. It is recommended that a minimum of 25% solution by weight be used for protection against corrosion.

CAUTION

Do not use automotive grade antifreeze. Industrial grade glycols must be used.

Automotive antifreeze contains inhibitors that will cause plating on the copper tubes

within the chiller evaporator. The type and handling of glycol used must be

consistent with local codes.

10 IOMM ACR/AGR-1

Table 6, Ethylene Glycol Factors

Freeze Point%

E.G.

°F °C

10 26 -3 0.991 0.996 1.013 1.070 20 18 -8 0.982 0.992 1.040 1.129 30 7 -14 0.972 0.986 1.074 1.181 40 -7 -22 0.961 0.976 1.121 1.263 50 -28 -33 0.946 0.966 1.178 1.308

Capacity Power Flow Pressure Drop

Table 7, Propylene Glycol Factors

Freeze Point%

P.G.

°F °C

10 26 -3 0.987 0.992 1.010 1.068 20 19 -7 0.975 0.985 1.028 1.147 30 9 -13 0.962 0.978 1.050 1.248 40 -5 -21 0.946 0.971 1.078 1.366 50 -27 -33 0.929 0.965 1.116 1.481

Capacity Power Flow Pressure Drop

Table 8, Capacity and Power Derates

Fouling Factor

SEA

LEVEL

2000 feet

(610 m)

4000 feet

(1220 m)

6000 feet

(1830 m)

Chilled Water

Delta-T

°F °C Cap. Power Cap. Power Cap. Power Cap. Power

6 3.3 0.992 0.995 0.985 0.993 0.962 0.986 0.919 0.972

8 4.4 0.995 0.997 0.988 0.995 0.965 0.988 0.922 0.974 10 5.6 1.000 1.000 0.993 0.998 0.970 0.991 0.927 0.977 12 6.7 1.005 1.002 0.998 1.000 0.975 0.993 0.932 0.979 14 6.8 1.010 1.005 1.003 1.003 0.980 0.996 0.936 0.982 16 8.9 1.014 1.007 1.007 1.005 0.984 0.998 0.940 0.984

6 3.3 0.978 1.005 0.971 1.003 0.949 0.996 0.906 0.982

8 4.4 0.982 1.007 0.975 1.005 0.953 0.998 0.910 0.984 10 5.6 0.986 1.009 0.979 1.007 0.956 1.000 0.914 0.986 12 6.7 0.992 1.011 0.985 1.009 0.962 1.002 0.919 0.988 14 6.8 0.997 1.014 0.990 1.012 0.967 1.005 0.924 0.991 16 8.9 1.000 1.016 0.993 1.014 0.970 1.007 0.927 0.993

6 3.3 0.966 1.016 0.959 1.014 0.937 1.007 0.895 0.993

8 4.4 0.969 1.018 0.962 1.016 0.940 1.009 0.898 0.995 10 5.6 0.973 1.021 0.966 1.019 0.944 1.012 0.902 0.998 12 6.7 0.978 1.025 0.971 1.023 0.949 1.016 0.906 1.002 14 6.8 0.982 1.027 0.975 1.025 0.953 1.018 0.910 1.004 16 8.9 0.986 1.028 0.979 1.026 0.956 1.019 0.914 1.005

6 3.3 0.953 1.025 0.946 1.023 0.924 1.016 0.883 1.002

8 4.4 0.955 1.028 0.948 1.026 0.926 1.019 0.885 1.005 10 5.6 0.959 1.031 0.952 1.029 0.930 1.022 0.889 1.008 12 6.7 0.963 1.034 0.956 1.032 0.934 1.024 0.893 1.011 14 6.8 0.968 1.036 0.961 1.034 0.939 1.026 0.897 1.013 16 8.9 0.972 1.037 0.965 1.035 0.943 1.027 0.901 1.014

0.0001 (0.0176) 0.00025 (0.044) 0.00075 (0.132) 0.00175 (0.308)ALTITUDE

Evaporator Flow and Pressure Drop

Evaporator flow rate must fall between the minimum and maximum values shown in the evaporator pressure drop table on Figure 7.

Measure the chilled water pressure drop through the evaporator at factory installed pressure taps. It is important not to include the effect of valves or strainers in these readings.

Varying chilled water flow through the evaporator while the compressor(s) are operating is not recommended.

IOMM ACR/AGR-1 11

Figure 7, Pressure Drop Curve

CDE

Size

1204-1 070 AM 11.2 162 10.22 28.1 270 17.03 4.8 101 6.39 1255-1 075 AM 8.9 172 10.85 22.5 287 18.09 3.8 108 6.78

1455-1 090 AM 10.5 208 13.12 26.3 347 21.87 4.5 130 8.20

Minimum and maximum flows are to ensure the Delta-T for each unit size falls within the 6 - 16°F range for proper unit control.

AGR Unit Size

ft of Water gpm lps ft of Water gpm lps ft of Water gpm lps

- 080 AM 10.3 187 11.80 25.9 312 19.66 4.4 117 7.37

- 085 AM 11.8 202 12.74 29.7 337 21.24 5.0 126 7.97

- 095 AM 12.0 224 14.13 30.0 373 23.55 5.2 140 8.83

- 100 AM 13.4 238 15.02 33.6 397 25.02 5.7 149 9.38

NOMINAL MAXIMUM MINIMUM

PD Flow PD Flow PD Flow

12 IOMM ACR/AGR-1

Refrigerant Piping

Introduction

Proper refrigerant piping can represent the difference between a reliable, trouble free system and months or years of inefficient, problematic performance.

System concerns related to piping are:

1. Refrigerant pressure drop

2. Solid liquid feed to the expansion valve(s)

3. Continuous oil return The most important and least understood is number 3. “Continuous oil return”. The failure of oil to

return at or close to the rate of displacement from the compressor can result in oil trapping and ultimate compressor failure.

On the other hand, the instantaneous return of a large volume of compressor oil, as a slug, can be equally damaging to a compressor.

All compressors displace some oil during operation. Reciprocating compressors displace more than centrifugals, scroll and McQuay screw compressors since oil is carried into compressor cylinders with suction gas; and oil present on cylinder walls is entrained by that same gas as it is being compressed. The sum of the two is then pumped into the discharge piping.

Also more oil is displaced at start-up of a compressor than occurs during a normal running period. Thus, if a compressor experiences excessive starts because of recycling pumpdown control, the larger quantity of oil pumped out is trapped in the condenser with the refrigerant charge, and may not return regardless of the adequacy of the piping system.

A similar problem to a lesser extent occurs when the equipment is oversized for the available cooling load.

In short, extreme care should be exercised to assure that both piping and controls are suitable for the application such that displaced oil is returned to the compressor moderately. Note, too, that oil loss to the system can be due to a hang up in the evaporator, as well as in the piping.

Suction Lines

McQuay recommends the use of ASHRAE for guidelines in sizing and routing piping with one exception. See the 1998 ASHRAE Handbook Refrigeration Edition, Chapter 2, for tables and guidelines. The single exception is to the piping of direct expansion cooling coils located above the compressors. In all cases, regardless of whether the equipment has pumpdown control or not, a trap in the suction line equal to the height of the coil section is recommended. In its absence, upon a power failure, all of the liquid in the coil will fall by gravity to the compressor below.

Suction line gas velocities may range between 900 and 4000 feet per minute. Consideration should be given to the possibility of objectionable noise in or adjacent to occupied space. Where this is a concern, gas velocities on the low side are recommended.

Routing must also take into account the requirement established in the latest ANSI/ASHRAE 15. To size the suction line, determine:

a. The maximum tons for the circuit b. The actual length in feet c. The equivalent length contributed by elbows, fittings, valves or other refrigerant specialties.

ASHRAE Tables 2-10, 11 & 12 d. If a vertical riser exists including the trap at the coil, determine the minimum tons for the circuit.

IOMM ACR/AGR-1 13

Add b and c above to obtain the total equivalent feet. Use ASHRAE Table 3 (for R22) or Table 4 (for R134a). Suction line selections are based upon the pressure equivalent of a 2ºF loss per 100 equivalent feet.

Select a line size that displays an equal or slightly larger tons then that determined in 1a) above. To determine the actual line loss:

1. Modify the table tons by the value in Note 4 of Table 3 or 4 for the design condensing

temperature.

2. Use the formula in Note 3 to calculate the line loss in terms of the saturation temperature.

3. Convert the saturation temperature loss calculated to a pressure drop equivalent using the (Delta)

listed in the table for the comparable delta temperature.

Caution : Excessive pressure drop is undesirable because

• It reduces available compressor capacity.

• It increases power consumed from the net tons realized.

• It may affect the performance of the evaporator and expansion valve previously selected.

The line loss calculated, expressed in temperature, or PSID pressure drop will be used to establish the temperature required at the evaporator to produce the required cooling, as well as, the suction pressure that the compressor must operate at to deliver the required capacity.

Having selected the suction line size, based upon total equivalent length and maximum tons, verify the line size selected will maintain entrainment of the lubricating oil up any vertical risers at the minimum tons for the circuit. See d above, and ASHRAE Table 2-13.

If the line size selected will not maintain satisfactory oil return in a suction riser, the following options are available:

The vertical length can be sized smaller to accommodate the lower circuit tons at reduced load. Minimum compressor capacity can be increased by eliminating the lowest step of compressor

capacity. Hot gas bypass can be introduced at the distributor to the evaporator, increasing the volume of gas

available in the suction line to entrain the oil. An oil separator may be installed in the discharge line. With reciprocating compressor units only, and only as a last resort, double suction risers can be

utilized. A double suction riser works by providing an oil trap to assure the return of some oil, with refrigerant, up the smaller diameter line. The trap must be as small as possible, there must not be multiple traps, and whenever double risers are used in a suction line, a suction accumulator with a controlled oil return must be installed in the line ahead of the compressor.

Sizing A Double Riser

At maximum circuit tons, the line size should be selected from the table based upon the recommended maximum line loss.

With the minimum tons known, a smaller line size should be selected from ASHRAE Chapter 2, Table 13 or 14 capable of entraining oil at the reduced tons. The smaller sized line should be the one installed to be always active.

The net internal area of this smaller sized line (see Table 13 or 14) should be deducted from the area of the size selected in paragraph 1) immediately above. The remainder represents the area of the other riser. From Table 13 or 14, select a line size with an area equal, or close, to the calculated net area. The combination of these two risers will provide the required performance at full circuit tons. The line selected for the minimum load should always be active; and both lines should enter the overhead horizontal line in a manner to prevent spillage of oil back down the other riser.

14 IOMM ACR/AGR-1

Underground Refrigerant Lines

McQuay does not recommend the installation of suction lines underground. If job conditions require that they be located below ground, a suitable sized suction accumulator must be installed ahead of the compressor to interrupt liquid refrigerant slugs at start-up.

Long Vertical Riser Installation

Where job conditions require refrigerant gas lifts of more than 25 feet, McQuay recommends the installation of a short trap half-way up the riser or at not more than 20 feet intervals. These traps are required to capture and hold small quantities of oil during off cycles.

Liquid Lines

Liquid lines are generally sized for 1 to 2 degree F line losses or their equivalent in pressure drop. Actual selection can vary based upon the pressure drop expected from refrigerant specialties such as solenoids, refrigerant driers, valves, etc. piping lifts or risers and the amount of condenser sub-cooling expected.

The principal concern in sizing and routing liquid lines is assurance that liquid is present in the line at start-up of the compressor, and that liquid and not vapor is available at the inlet to the expansion valve during system operation.

Liquid may not be available in a liquid line at start-up if:

1. The solenoid valve is located adjacent to the condenser or condensing unit; remote from the

expansion valve.

2. An excessive length of liquid line is located in a heated ambient and the application permits

migration of the refrigerant to a cold air-cooled condenser.

3. Liquid refrigerant is permitted to gravitate from the liquid line to the condenser because of the

relative location of components.

4. Liquid line solenoid valves should be located adjacent to the expansion valve with possibly only

a sight glass interposing the two.

In the event 2 or 3 above are possible, the application should include a check valve at the condenser end of the liquid line. The check valve should be a low pressure drop valve. The line between the check valve and the solenoid valve can be comparable to a pressure vessel. As the line becomes heated the pressure will increase so the check valve should include a pressure relief device to relieve pressure to the condenser side of the circuit. The relief can be sized for a pressure differential from 80 to 180 psi, but not more than 180 psi, and should be auto-resetting as the pressure is relieved.

CAUTION

The liquid line should not include a check valve unless the line also includes an

automatic resetting pressure relief device.

CAUTION

If the relief device being used is relieving from the line to the condenser side of the

check valve, the maximum desirable pressure differential with R-22 refrigerant

is 180 psi, with 134a, 100 psi.

If liquid lines are short, they may be of smaller diameter than the size indicated in the ASHRAE Refrigerant Handbook, 1998 Edition, Chapter 2, Tables 3 or 4. As indicated above, the designer must size the liquid line to assure that pure liquid will reach the inlet of the expansion valve. If the condenser is sized to produce ten degrees F of subcooling. Each degree represents 3.05 psi with R-22 (or 2.2. psi with R-134a). The liquid line and its refrigerant specialties may have pressure losses

IOMM ACR/AGR-1 15

totaling 10 x 3.05 psi (or 10 x 2.2) and still satisfy the objective of delivering solid liquid to the expansion valve.

In calculating the pressure losses, or gains, note that each foot of rise in a liquid line results in approximately 0.5 psi loss. Thus a 10 foot rise represent 5 pounds per square inch loss in refrigerant pressure, or the equivalent of 1.6ºF subcooling with R-22. Total line losses will include values for line friction, equivalents for valves and elbows and pressure losses from manufacturers’ catalogs for driers, solenoids, sight glasses, etc.

In estimating condenser subcooling, note that saturated condensing pressure should be read, or estimated, at the same point in the system where the liquid refrigerant temperature is obtained. That condensing pressure is not the discharge pressure read at the compressor outlet. Because it is less, the net value of subcooling will be lower than might otherwise be assumed.

Where rises in liquid lines result in a 0.5 psi loss per foot of lift, a drop in the liquid line results in a rise in the refrigerant pressure. A substantial drop in the liquid line can assure the existence of pure liquid at the valve. If it is a substantial increase because of a large drop, the expansion valve selection must be re-checked to confirm that the valve to be used is not radically oversized.

Liquid Lines from Condensers to Receivers

Receivers in a refrigerant system have both liquid and gas contained within the same vessel. In aircooled condenser applications, the condensing temperature can change rapidly resulting in the requirement for more liquid at a lower temperature and pressure to be introduced into the receiver.

In order for this flow of lower temperature and pressure of liquid refrigerant to enter the receiver, 1) the receiver must be located below the condenser outlet with no restrictions in the line, and 2) the liquid line connecting the condenser and the receiver must be sized for a maximum velocity of 100 fpm. Piping sizes for this are shown in the ASHRAE tables.

Note: If the interconnecting piping described above contains a Seasontrol type head pressure control valve representing a restriction in the liquid line, a separate vent from the top of the receiver to the discharge line entering the condenser is required.

Liquid Line Components

To assist in laying out and specifying split systems, the following recommended (or equal) components can be used.

Table 9, Liquid Line Components

Unit

Model

ACR 070A Circuit #1 31.6 (379) C-967 E25S270 SA-17S OVE-30 7/8-1-3/8

ACR 075A Circuit #1 & #2 36.3 (436) ea. C-969 E25S290 SA-19S OVE-40 1 1/8-1-3/8

ACR 080 Circuit #1 & #2 40.0 (480) ea. C-969 E25S290 SA-19S OVE-40 1 1/8-1-3/8

ACR 090A Circuit #1 40.8 (490) C-969 E25S290 SA-19S OVE-40 1 1/8-1-3/8

ACR 100A Circuit #1 & #2 49.1 (589) ea. C-1449 E25S290 SA-19S OVE-55 1 1/8-1-3/8

ACR 110A Circuit #1 49.1 (589) C-1449 E25S290 SA-19S OVE-55 1 1/8-1-3/8

System

Circuit #2 36.3 (436) C-967 E25S270 SA-17S OVE-40 7/8-1-3/8

Circuit #2 49.1 (589) C-1449 E25S290 SA-19S OVE-55 1 1/8-1-3/8

Circuit #2 57.4 (689) C-1449 E25S290 SA-19S OVE-70 1 1/8-1-3/8

Nom.R-22

Tons

(mbh)

Sporlan Part Number Shown - (Equivalents Are Acceptable)

Filter

Drier

Solenoid

Valve

Sight Glass

Expansion

Valve

Unit Conn.

In/Out

ACR 120A Circuit #1 57.4 (689) ea. C-1449 E25S290 SA-19S OVE-70 1 1/8-1-3/8

16 IOMM ACR/AGR-1

Physical Data

AGR-AM

Table 10, AGR 070AM - 085AM

2540 x

3183

AGR MODEL NUMBERPHYSICAL DATA

2540 x

3183

2540 x

3183

2540 x

3183

2540 x

3183

STANDARD EFFICIENCY BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2

Unit Capacity @ ARI Conditions (1), Tons (kW) 67.5 (237.6) 70.1 (246.7) 77.9 (273.9) 84.7 (298.1) Number Of Refrigerant Circuits 2 2 2 2 Unit Operating Charge, R-22, lbs. (kg) 60 (27.2) 84 (38.1) 84 (38.1) 86 (39.9) 86 (39.9) 86 (39.9) 86 (39.9) 86 (39.9) Unit Operating Charge, R-134a, , lbs. (kg) 63 (28.6) 88 (40.0) 88 (40.0) 90 (41.9) 90 (41.9) 90 (41.9) 90 (41.9) 90 (41.9) Cabinet Dimensions, LxWxH, In. 94.0 x 88.2 x 96.2 136.4 x 88.2 x 96.2 136.4 x 88.2 x 96.2 136.4 x 88.2 x 96.2 Cabinet Dimensions, LxWxH, (mm) 2388 x 2241 x 2444 3463 x 2241 x 2444 3463 x 2241 x 2444 3463 x 2241 x 2444 Unit Operating Weight, Lbs. (kg) 4276 (5506) 5506 (2497) 5740 (2604) 5921 (2686) Unit Shipping Weight, Lbs. (kg) 4169 (5359) 5359 (2431) 5593 (2537) 5774 (2619) Add'l Weight If Copper Finned Coils, Lbs. (kg) 830 (375) 1245 (565) 1245 (565) 1245 (565)

COMPRESSORS

Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Semi-Hermetic Nominal Horsepower 35 40 40 40 40 50 50 50 Number Of Cylinders Per Compressor 6 6 6 6 6 8 8 8 Oil Charge Per Compressor, oz. 140 255 255 255 255 255 255 255 Oil Charge Per Compressor, (g) (3969) (7229) (7229) (7229) (7229) (7229) (7229) (7229)

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

Standard Staging - Circuit #1 in Lead 0-16-33-49-67 0-17-33-50-67 0-15-42-58-73 0-25-50-63-75

Standard Staging - Circuit #2 in Lead 0-17-33-51-67 0-17-33-50-67 0-27-42-56-71 0-25-50-63-75

CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING

Coil Face Area, sq. ft. 58 58 87 87 87 87 87 87 Coil Face Area, (m2) (5.4) (5.4) (8.1) (8.1) (8.1) (8.1) (8.1) (8.1) Finned Height x Finned Length, In. 100x 83.5 100x 83.5 100x125.3 100x125.3 100x125.3 100x125.3 100x125.3 100x125.3

Finned Height x Finned Length, (mm) Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3

Pumpdown capacity @ 90% lbs. (kg) 108 (49) 108 (49) 162 (73) 162 (73) 162 (73) 162 (73) 162 (73) 162 (73) Maximum Relief Valve Pressure Setting, psig (kPa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)

CONDENSER FANS – DIRECT DRIVE PROPELLER TYPE

Number Of Fans - Fan Diameter, In. (mm) 4 - 28 (712) 6 - 28 (712) 6 - 28 (712) 6 - 28 (712) Number Of Motors - HP (kW) 4 - 2.0 (1.5) 6 - 2.0 (1.5) 6 - 2.0 (1.5) 6 - 2.0 (1.5) Fan And Motor RPM, 60Hz 1140 1140 1140 1140 60 Hz Fan Tip Speed, fpm (m/Sec) 8357 (35.4) 8357 (35.4) 8357 (35.4) 8357 (35.4) 60 Hz Total Unit Airflow, cfm (m3/sec) 40800 (19.3) 61200 (28.9) 61200 (28.9) 61200 (28.9)

REMOTE DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE

Model Number 1204-1 1255-1 1255-1 1255-1 Diameter, in. - Length, ft. 12.75- 4 12.75 - 5.5 12.75 - 5.5 12.75 - 5.5 Diameter, (mm) – Length, (mm) 324 - 1220 324 - 1676 324 - 1676 324 - 1676 Water Volume, gallons, (l) 12.8 (48.5) 17.6 (66.6) 17.6 (66.6) 17.6 (66.6) Maximum Water Pressure, psig (kPa) 175 (1207) 175 (1207) 175 (1207) 175 (1207) Maximum Refrigerant Working Pressure, psig (kPa) 225 (1552) 225 (1552) 225 (1552) 225 (1552) Water Inlet / Outlet Victaulic Connections, In. (mm) 5 (141.3) 5 (141.3) 5 (141.3) 5 (141.3) Drain - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5) .375 (9.5) Vent - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5) .375 (9.5)

NOTES:

1. Includes evaporator. Does not include suction and liquid line charge. Outdoor unit and evaporator are shipped with R-22 holding charge.

2. Units with 1.0 Hp Fan Motors, Uses 1.5 Hp Fan Motors when unit is 380V / 60 Hz and 575V / 60Hz.

070AM 075AM 080AM 085AM

-83-100 -83-100 -86-100 -88-100

-84-100 -83-100 -85-100 -88-100

2032 x

2121

2032 x

2121

2540 x

3183

IOMM ACR/AGR-1 17

Table 11, AGR 090AM - 100AM

PHYSICAL DATA AGR MODEL NUMBER STANDARD EFFICIENCY 090AM 095AM 100AM BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2

Unit Capacity @ ARI Conditions (1), Tons (kW) 86.7 (305.2) 94.0 (330.1) 100.1 (352.0) Number Of Refrigerant Circuits 2 2 2 Unit Operating Charge, R-22, lbs.(kg) 90 (40.8) 90 (40.8) 90 (40.8) 90 (40.8) 92 (41.7) 92 (41.7) Unit Operating Charge, R-134a, lbs.(kg) 94 (42.8) 94 (42.8) 94 (42.8) 94 (42.8) 94 (42.8) 94 (42.8) Cabinet Dimensions, LxWxH, In. 136.4 x 88.2 x 96.2 136.4 x 88.2 x 96.2 136.4 x 88.2 x 96.2 Cabinet Dimensions, LxWxH, (mm) 3463 x 2241 x 2444 3463 x 2241 x 2444 3463 x 2241 x 2444 Unit Operating Weight, Lbs. (kg) 6184 (2805) 6194 (2810) 6194 (2810) Unit Shipping Weight, Lbs. (kg) 6008 (2725) 6018 (2730) 6018 (2730) Add'l Weight If Copper Finned Coils, Lbs. (kg) 1245 (565) 1245 (565) 1245 (565)

COMPRESSORS

Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Nominal Horsepower 50 50 50 60 60 60 Number Of Cylinders Per Compressor 8 8 8 8 8 8 Oil Charge Per Compressor, oz. 255 255 255 255 255 255 Oil Charge Per Compressor, (g) (7229) (7229) (7229) (7229) (7229) (7229)

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

Standard Staging - Circuit #1 in Lead 0-25-50-63-75 0-23-50-61-75 0-25-50-63-75

Standard Staging - Circuit #2 in Lead 0-25-50-63-75 0-27-50-64-75 0-25-50-63-75

CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING

Coil Face Area, sq. ft. 87 87 87 87 87 87 Coil Face Area, (m2) (8.1) (8.1) (8.1) (8.1) (8.1) (8.1) Finned Height x Finned Length, In. 100x125.3 100x125.3 100x125.3 100x125.3 100x125.3 100x125.3 Finned Height x Finned Length, (mm) 2540 x

Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 Pumpdown capacity @ 90% lbs. (kg) 162 (73) 162 (73) 162 (73) 162 (73) 162 (73) 162 (73) Maximum Relief Valve Pressure Setting, psig (kPa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)

CONDENSER FANS – DIRECT DRIVE PROPELLER TYPE

Number Of Fans - Fan Diameter, in. (mm) 6 - 28 (712) 6 - 28 (712) 6 - 28 (712) Number Of Motors - HP (kW) 6 - 2.0 (1.5) 6 - 2.0 (1.5) 6 - 2.0 (1.5) Fan And Motor RPM, 60Hz 1140 1140 1140 60 Hz Fan Tip Speed, fpm (m/sec) 8357 (35.4) 8357 (35.4) 8357 (35.4) 60 Hz Total Unit Airflow, cfm (m3/sec) 61200 (28.9) 61200 (28.9) 61200 (28.9)

DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE

Model Number 1455-1 1455-1 1455-1 Diameter, in. - Length, ft. 14 - 5.5 14 - 5.5 14 - 5.5 Diameter, (mm) – Length, (mm) 356 - 1676 356 - 1676 356 - 1676 Water Volume, gallons, (l) 21.2 (80.3) 21.2 (80.3) 21.2 (80.3) Maximum Water Pressure, psig (kPa) 175 (1207) 175 (1207) 175 (1207) Maximum Refrigerant Working Pressure, psig (kPa) 225 (1552) 225 (1552) 225 (1552) Water Inlet / Outlet Victaulic Connections, In. (mm) 5 (141.3) 5 (141.3) 5 (141.3) Drain - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5) Vent - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5)

NOTES:

1. Includes evaporator. Does not include suction and liquid line charge. Outdoor unit and evaporator are shipped with R-22 holding charge.

2. Units with 1.0 Hp Fan Motors, Uses 1.5 Hp Fan Motors when unit is 380V / 60 Hz and 575V / 60Hz.

-88-100 -86-100 -88-100

-88-100 -89-100 -88-100

3183

2540 x

3183

2540 x

3183

2540 x

3183

2540 x

3183

2540 x

3183

18 IOMM ACR/AGR-1

Table 12, ACR 060AS - 070AS

PHYSICAL DATA ACR MODEL NUMBER STANDARD EFFICIENCY 060AS 065AS 070AS

BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Unit Capacity @ ARI Conditions (1), mbh (kW) 703 (205.9) 738 (216.1) 762 (238.5) Number Of Refrigerant Circuits 2 2 2 Unit Operating Charge, R-22, Lbs. 46 46 46 46 55 55 Unit Operating Charge, R-22, (kg) (20.9) (20.9) (20.9) (20.9) (24.9) (24.9) Cabinet Dimensions, LxWxH, In. 94.0 x 88.2 x 86.2 94.0 x 88.2 x 86.2 94.0 x 88.2 x 96.2 Cabinet Dimensions, LxWxH, (mm) 2388 x 2241 x 2190 2388 x 2241 x 2190 2388 x 2241 x 2444 Unit Operating Weight, Lbs. (kg) 3642 (1652) 3712 (1684) 3745 (1699) Unit Shipping Weight, Lbs. (kg) 3550 (1610) 3620 (1642) 3635 (1649) Add'l Weight If Copper Finned Coils, Lbs. (kg) 665 (300) 665 (300) 830 (375)

COMPRESSORS

Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Nominal Horsepower 30 30 30 30 30 35 Number Of Cylinders Per Compressor 4 6 6 6 6 6 Oil Charge Per Compressor, Oz. 140 140 140 140 140 140 Oil Charge Per Compressor, (g) (3969) (3969) (3969) (3969) (3969) (3969)

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

Standard Staging - Circuit #1 in Lead 0-23-41-64-82-100 0-17-33-50-67 0-15-33-49-67 Standard 6 Stages (2) -83-100 -82-100 Standard Staging m3- Circuit #2 in Lead 0-18-41-59-82-100 0-17-33-50-67 0-18-33-51-67 Standard 6 Stages (2) -83-100

CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING

Coil Face Area,Sq. ft. 46.4 46.4 46.4 46.4 58 58 Coil Face Area, (m2) (4.3) (4.3) (4.3) (4.3) (5.4) (5.4) Finned Height x Finned Length, In. 80 x 83.5 80 x 83.5 80 x 83.5 80 x 83.5 100x 83.5 100x 83.5 Finned Height x Finned Length, (mm) 2032 x 2121 2032 x 2121 2032 x 2121 2032 x 2121 2032 x 2121 2032 x 2121 Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 Pumpdown Capacity @ 90% Full (lbs) 86 86 86 86 108 108 Pumpdown Capacity @ 90% Full (kgs) (39.) (39.) (39.) (39.) (49.) (49.) Maximum Relief Valve Pressure Setting, psig (kPa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)

CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE

Number Of Fans - Fan Diameter, in. (mm) 4 - 28 (712) 4 - 28 (712) 4 - 28 (712) Number Of Motors - HP (kW) 4 - 1.5 (1.1) 4 - 1.5 (1.1) 4 - 2.0 (1.5) Fan And Motor RPM, 60Hz 1140 1140 1140 60 Hz Fan Tip Speed, FPM (m/Sec) 8357 (35.4) 8357 (35.4) 8357 (35.4) 60 Hz Total Unit Airflow, CFM (m3/sec) 36800 (17.4) 36800 (17.4) 40800 (19.3)

NOTES:

1. Does not include evaporator, suction or liquid line charge. Unit shipped with R-22 holding charge.

2. Units with 1.0 Hp Fan Motors, Uses 1.5 Hp Fan Motors when unit is 380V / 60 Hz and 575V / 60Hz.

IOMM ACR/AGR-1 19

Table 13, ACR 075A - 090A

PHYSICAL DATA ACR MODEL NUMBER STANDARD EFFICIENCY 075AS 080AS 090AS BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2

Unit Capacity @ ARI Conditions (1), mbh (kW) 871 (255.0) 959 (280.7) 1078 (315.8) Number Of Refrigerant Circuits 2 2 2 Unit Operating Charge, R-22, Lbs. 55 55 80 80 80 80 Unit Operating Charge, R-22, (kg) (24.9) (24.9) (36.3) (36.3) (36.3) (36.3) Cabinet Dimensions, LxWxH, In. 94.0 x 88.2 x 96.2 136.4 x 88.2 x 96.2 136.4 x 88.2 x 96.2 Cabinet Dimensions, LxWxH, (mm) 2388 x 2241 x 2444 3463 x 2241 x 2444 3463 x 2241 x 2444 Unit Operating Weight, Lbs. (kg) 3935 (1785) 4670 (2118) 4905 (2225) Unit Shipping Weight, Lbs. (kg) 3825 (1735) 4510 (2046) 4745 (2152) Add'l Weight If Copper Finned Coils, Lbs. (kg) 830 (375) 1245 (565) 1245 (565)

COMPRESSORS

Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Nominal Horsepower 35 35 40 40 40 50 Number Of Cylinders Per Compressor 6 6 6 6 6 8 Oil Charge Per Compressor, Oz. 140 140 255 255 255 255 Oil Charge Per Compressor, (g) (3969) (3969) (7229) (7229) (7229) (7229)

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

Standard Staging - Circuit #1 in Lead 0-16-33-49-67 0-17-33-50-67 0-15-42-58-73 Standard 6 Stages -83-100 -83-100 -86-100 Standard Staging - Circuit #2 in Lead 0-17-33-51-67 0-17-33-50-67 0-27-42-56-71 Standard 6 Stages -84-100 -83-100 -85-100

CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING

Coil Face Area,Sq. Ft. 58 58 87 87 87 87 Coil Face Area, (M2) (5.4) (5.4) (8.1) (8.1) (8.1) (8.1) Finned Height x Finned Length, In. 100x 83.5 100x 83.5 100x125.9 100x125.9 100x125.9 100x125.9 Finned Height x Finned Length, (mm) 2032 x 2121 2032 x 2121 2540 x 3183 2540 x 3183 2540 x 3183 2540 x 3183 Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 Pumpdown Capacity @ 90% Full (lbs) 108 108 162 162 162 162 Pumpdown Capacity @ 90% Full (kgs) (49.) (49.) (73.5) (73.5) (73.5) (73.5) Maximum Relief Valve Pressure Setting, psig (kPa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)

CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE

Number Of Fans - Fan Diameter, In. (mm) 4 - 28 (712) 6 - 28 (712) 6 - 28 (712) Number Of Motors - HP (kW) 4 - 2.0 (1.5) 6 - 2.0 (1.5) 6 - 2.0 (1.5) Fan And Motor RPM, 60Hz 1140 1140 1140 60 Hz Fan Tip Speed, FPM (M/Sec) 8357 (35.4) 8357 (35.4) 8357 (35.4) 60 Hz Total Unit Airflow, CFM (M3/sec) 40800 (19.3) 61200 (28.9) 61200 (28.9)

NOTES:

1. Nominal capacity based on 95°F ambient air and 45 psig suction pressure, no refrigerant line loss.

2. Does not include evaporator, suction or liquid line charge. Unit shipped with R-22 holding charge.

3. Units with 1.0 Hp Fan Motors, Uses 1.5 Hp Fan Motors when unit is 380V / 60 Hz and 575V / 60Hz.

20 IOMM ACR/AGR-1

Table 14, ACR 100A - 120A

PHYSICAL DATA ACR MODEL NUMBER STANDARD EFFICIENCY 100AS 110AS 120AS BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2

Unit Capacity @ ARI Conditions (1), mbh (kW) 1178 (344.9) 1278 (374.1) 1376 (402.9) Number Of Refrigerant Circuits 2 2 2 Unit Operating Charge, R-22, Lbs. 82 82 82 82 84 84 Unit Operating Charge, R-22, (kg) (37.2) (37.2) (37.2) (37.2) (38.1) (38.1) Cabinet Dimensions, LxWxH, In. 136.4 x 88.2 x 96.2 136.4 x 88.2 x 96.2 136.4 x 88.2 x 96.2 Cabinet Dimensions, LxWxH, (mm) 3463 x 2241 x 2444 3463 x 2241 x 2444 3463 x 2241 x 2444 Unit Operating Weight, Lbs. (kg) 5224 (2370) 5234 (2374) 5056 (2293) Unit Shipping Weight, Lbs. (kg) 5060 (2295) 5070 (2300) 4888 (2217) Add'l Weight If Copper Finned Coils, Lbs. (kg) 1245 (565) 1245 (565) 1245 (565)

COMPRESSORS

Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Nominal Horsepower 50 50 50 60 60 60 Number Of Cylinders Per Compressor 8 8 8 8 8 8 Oil Charge Per Compressor, Oz. 255 255 255 255 255 255 Oil Charge Per Compressor, (g) (7229) (7229) (7229) (7229) (7229) (7229)

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

Standard Staging - Circuit #1 in Lead 0-25-50-63-75 0-23-50-61-75 0-25-50-63-75 Standard 6 Stages -88-100 -86-100 -88-100 Standard Staging - Circuit #2 in Lead 0-25-50-63-75 0-27-50-64-75 0-25-50-63-75 Standard 6 Stages -88-100 -89-100 -88-100

CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING

Coil Face Area,Sq. Ft. 87 87 87 87 87 87 Coil Face Area, (M2) (8.1) (8.1) (8.1) (8.1) (8.1) (8.1) Finned Height x Finned Length, In. 100x125.9 100x125.9 100x125.9 100x125.9 100x125.9 100x125.9 Finned Height x Finned Length, (mm) 2540 x 3183 2540 x 3183 2540 x 3183 2540 x 3183 2540 x 3183 2540 x 3183 Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 Pumpdown Capacity @ 90% Full (lbs) 162 162 162 162 162 162 Pumpdown Capacity @ 90% Full (kgs) (73.5) (73.5) (73.5) (73.5) (73.5) (73.5) Maximum Relief Valve Pressure Setting, psig (kPa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)

CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE

Number Of Fans - Fan Diameter, In. (mm) 6 - 28 (712) 6 - 28 (712) 6 - 28 (712) Number Of Motors - HP (kW) 6 - 2.0 (1.5) 6 - 2.0 (1.5) 6 - 2.0 (1.5) Fan And Motor RPM, 60Hz 1140 1140 1140 60 Hz Fan Tip Speed, FPM (M/Sec) 8357 (35.4) 8357 (35.4) 8357 (35.4) 60 Hz Total Unit Airflow, CFM (M3/sec) 61200 (28.9) 61200 (28.9) 61200 (28.9)

NOTES:

1. Nominal capacity based on 95°F ambient air and 45 psig suction pressure, no refrigerant line loss.

2. Does not include evaporator, suction or liquid line charge. Unit shipped with R-22 holding charge.

3. Units with 1.0 Hp Fan Motors, Uses 1.5 Hp Fan Motors when unit is 380V / 60 Hz and 575V / 60Hz.

IOMM ACR/AGR-1 21

Electrical Data

Field Wiring

Power Wiring

Internal power wiring to the compressors for single and multiple point option are

Wiring must comply with all applicable codes and ordinances. Warranty is void if wiring is not in accordance with specifications. Copper wire is required for all power lead terminations at the unit. Aluminum or copper can be used for all other wiring.

AGR-AM and ACR units have internal power wiring for single point power connection. A single large power terminal block is provided and wiring within the unit is sized in accordance with the National Electrical Code. A single field supplied fused disconnect is required. An optional factory mounted transformer may be installed.

AGR-AM remote water chillers and CDE chillers are equipped with a 420W electric heater to provide freeze protection if mounted in locations subject to below freezing temperatures. The heater comes with a receptacle plug that can be used or removed to hard wire to a power supply.

CAUTION

different. Field wiring must be installed according to unit wiring diagram.

Control Wiring

AGR-AM chillers are equipped with either a Johnson Controls UNT control or a McQuay MicroTech microprocessor control mounted in the outdoor unit. The control sensor for capacity control must be mounted in the leaving chilled water line in a thermowell provided in the water chiller nozzle. A sensor well is also located in the entering nozzle for use with some control options. The sensor is wired to the control with 30 ft. of cable. If a longer length is required, it is necessary to field splice the cable.

ACR condensing units are not equipped with a capacity control device and one must be field furnished and installed. Refer to Figure 12. Four or six steps of control are available.

AGR-AM and ACR units connected to water chillers must have a flow switch mounted in the chilled water line and wired to the control panel per the field wiring diagram. It is recommended that ACR units connected to DX air coils have an interlock to prevent compressor operation when there is no air flow.

22 IOMM ACR/AGR-1

AGR-AM Data ACR Data

Table 15, 60 Hz, Single Point Power Electrical Data

ACR-AS

Cond.

Unit

Model

060As

065AS

070AS

075AS

080AS 075AM

090AS 080A

100AS 085AM

110AS 095AM

120AS 100AM

All Electrical Data notes are on page 26

AGR-AM

Chiller

Unit Size

070AM

090AM

Volts

208 231 3 250 1 2.00 300 230 231 3 250 1 2.00 300 380 134 3 1/0 1 1.5 175 460 114 3 #2 1 1.25 150 575 90 3 #3 1 1.00 125

208 237 3 250 1 2.00 300 230 237 3 250 1 2.00 300 380 137 3 1/0 1 1.50 175 460 117 3 #1 1 1.00 150 575 90 3 #3 1 1.00 125

208 271 3 300 1 2.50 350 230 258 3 300 1 2.50 350 380 150 3 1/0 1 1.50 200 460 133 3 1/0 1 1.50 175 575 98 3 #3 1 1.00 125

208 298 3 350 1 2.50 400 230 275 3 300 1 2.50 350 380 160 3 2/0 1 1.50 225 460 146 3 1/0 1 1.50 200 575 104 3 #2 1 1.25 125

208 322 3 400 1 2.50 450 230 300 3 350 1 2.50 400 380 190 3 3/0 1 2.00 250 460 153 3 2/0 1 1.50 200 575 114 3 #2 1 1.25 150

208 351 3 500 1 3.00 450 230 329 3 400 1 2.50 450 380 220 3 4/0 1 2.00 300 460 163 3 2/0 1 1.50 225 575 126 3 #1 1 1.50 150

208 384 6 3/0 2 2.00 500 230 373 3 500 1 3.00 500 380 240 3 250 1 2.50 300 460 187 3 3/0 1 2.00 250 575 151 3 2/0 1 1.50 200

208 411 6 4/0 2 2.00 500 230 408 6 4/0 2 2.00 500 380 256 3 300 1 2.50 350 460 206 3 4/0 1 2.00 250 575 171 3 3/0 1 2.00 225

208 461 6 250 2 2.00 600 230 458 6 4/0 2 2.00 600 380 269 3 300 1 2.50 350 460 220 3 4/0 1 2.00 300 575 176 3 3/0 1 2.00 225

208 501 6 250 2 2.00 700 230 498 6 250 2 2.00 700 380 279 3 300 1 2.50 350 460 231 3 250 1 2.00 300 575 180 3 3/0 1 2.00 250

Minimum

Circuit

Ampacity

(MCA)

Field Wire Conduit Hub

Quantity

POWER SUPPLY

Wire

Gauge

Quantity

Nominal

Size

Max. Fuse

HACR Breaker

Size

IOMM ACR/AGR-1 23

Table 16, 60 Hz, Compressor & Condenser Fan Motor Amp Draw

ACR-A

Cond.

060AS

065AS

070AS

075AS

080AS 075AM

090AS 080AM

100AS 085AM

110AS 095AM

120AS 100AM

All Electrical Data notes are on page 26

Unit Size

AGR-AM

Chiller

Unit Size

070AM

090AM

Volts

208 89 95 5.8 4 23.7 470 565 292 340 230 89 95 5.8 4 21.4 470 565 292 340 380 52 55 3.4 4 14.4 285 342 N/A N/A 460 44 47 2.8 4 10.7 235 260 141 156 575 36 36 2.3 4 11.5 200 230 130 138

208 95 95 5.8 4 23.7 565 565 340 340 230 95 95 5.8 4 21.4 565 565 340 340 380 55 55 3.4 4 14.4 342 342 N/A N/A 460 47 47 2.8 4 10.7 260 260 156 156 575 36 36 2.3 4 11.5 230 230 138 138

208 95 122 5.8 4 23.7 565 650 340 400 230 95 112 5.8 4 21.4 565 594 340 340 380 55 65 3.4 4 14.4 342 365 N/A N/A 460 47 60 2.8 4 10.7 260 315 156 195 575 36 42 2.3 4 11.5 230 245 138 152

208 122 122 5.8 4 23.7 650 650 400 400 230 112 112 5.8 4 21.4 594 594 340 340 380 65 65 3.4 4 14.4 365 365 N/A N/A 460 60 60 2.8 4 10.7 315 315 195 195 575 42 42 2.3 4 11.5 245 245 152 152

208 122 135 7.8 4 30.5 650 754 400 463 230 112 127 7.2 4 27.6 594 594 340 340 380 65 87 4.1 4 20.0 365 365 N/A N/A 460 60 63 3.6 4 13.8 315 315 195 195 575 42 48 3.0 4 11.0 245 245 152 152

208 135 135 7.8 6 30.5 754 754 463 463 230 127 127 7.2 6 27.6 594 594 340 340 380 87 87 4.1 6 20.0 365 365 N/A N/A 460 63 63 3.6 6 13.8 315 315 195 195 575 48 48 3.0 6 11.0 245 245 152 152

208 135 162 7.8 6 30.5 754 1070 463 654 230 127 162 7.2 6 27.6 594 1070 340 654 380 87 103 4.1 6 20.0 365 740 N/A N/A 460 63 82 3.6 6 13.8 315 510 195 330 575 48 68 3.0 6 11.0 245 405 152 262

208 162 162 7.8 6 30.5 1070 1070 654 654 230 162 162 7.2 6 27.6 1070 1070 654 654 380 103 103 4.1 6 20.0 740 740 N/A N/A 460 82 82 3.6 6 13.8 510 510 330 330 575 68 68 3.0 6 11.0 405 405 262 262

208 162 202 7.8 6 30.5 1070 1070 654 654 230 162 202 7.2 6 27.6 1070 1070 654 654 380 103 113 4.1 6 20.0 740 740 N/A N/A 460 82 93 3.6 6 13.8 510 510 330 330 575 68 72 3.0 6 11.0 405 405 262 262

208 202 202 7.8 6 30.5 1070 1070 654 654 230 202 202 7.2 6 27.6 1070 1070 654 654 380 113 113 4.1 6 20.0 740 740 N/A N/A 460 93 93 3.6 6 13.8 510 510 330 330 575 72 72 3.0 6 11.0 405 405 262 262

Rated Load

Compressors Compressors

No.1No.

Amps

Fan

Motors

(Each)

No. Of

Fan

Motors

Fan

Motors

(Each)

Locked Rotor Amps

Across-The-Line Reduced Inrush

No. 1 No. 2 No. 1 No. 2

24 IOMM ACR/AGR-1

Table 17, 60 Hz Single Point Power, Field Wiring Data

ACR-AS

Cond.

Unit Size

060AS

065AS

070As

075AS

080AS 075AM

090AS 080AM

100AS 085AM

110AS 095AM

120AS 100AM

All Electrical Data notes are on page 26

AGR-AM

Chiller

Unit Size

070AM

090AM

Volts

208 335 # 4 - 400 MCM 250 250-500 MCM 230 335 # 4 - 400 MCM 250 250-500 MCM 380 335 # 4 - 400 MCM 150 #2 - 3/0 460 335 # 4 - 400 MCM 150 #2 - 3/0 575 335 # 4 - 400 MCM 100 #6 - 1/0

208 335 # 4 - 400 MCM 400 250 - 500 MCM 230 335 # 4 - 400 MCM 400 250 - 500 MCM 380 335 # 4 - 400 MCM 250 #4 - 350 MCM 460 335 # 4 - 400 MCM 150 #2 - 3/0 575 335 # 4 - 400 MCM 150 #2 - 3/0

208 335 # 4 - 400 MCM 400 250 - 500 MCM 230 335 # 4 - 400 MCM 400 250 - 500 MCM 380 335 # 4 - 400 MCM 250 #4 - 350 MCM 460 335 # 4 - 400 MCM 250 #4 - 350 MCM 575 335 # 4 - 400 MCM 150 #2 - 3/0

208 840 (2 qty.) 1/0 - 600 MCM 400 250 - 500 MCM 230 840 (2 qty.) 1/0 - 600 MCM 400 250 - 500 MCM 380 335 # 4 - 400 MCM 250 #4 - 350 MCM 460 335 # 4 - 400 MCM 250 #4 - 350 MCM 575 335 # 4 - 400 MCM 250 #4 - 350 MCM

208 840 (2 qty.) 1/0 - 600 MCM N/A N/A 230 840 (2 qty.) 1/0 - 600 MCM N/A N/A 380 335 # 4 - 400 MCM 400 250 - 500 MCM 460 335 # 4 - 400 MCM 250 #4 - 350 MCM 575 335 # 4 - 400 MCM 250 #4 - 350 MCM

Terminal

Wiring to Standard

Amps

Power Block

Connector Wire Range

(Copper Wire Only)

Wiring to Optional

Non-Fused Disconnect Switch

Terminal

Amps

Connector Wire Range

(Copper Wire Only)

IOMM ACR/AGR-1 25

Electrical Notes

Notes for “Electrical Data Single Point” Power:

1. Unit wire size ampacity (MCA) is equal to 125% of the largest compressor-motor RLA plus 100%

of RLA of all other loads in the circuit including the control transformer.

2. If the control transformer option is furnished, no separate 115V power is required.

3. If a separate 115V power supply is used for the control circuit, then the wire sizing amps is 10

amps for all unit sizes.

4. Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductor

ampacity in accordance with NEC. Voltage drop has not been included. Therefore, it is recommended that power leads be kept short. All terminal block connections must be made with copper (type THW) wire.

5. “Recommended Fuse Sizes” are selected at approximately 150% to 175% of the largest

compressor RLA, plus 100% of all other loads in the circuit.

6. “Maximum Fuse or HACR breaker size” is selected at approximately 225% of the largest

compressor RLA, plus 100% of all other loads in the circuit.

7. The recommended power lead wire sizes are based on an ambient temperature of 86°F (30°C).

Ampacity correction factors must be applied for other ambient temperatures. Refer to the National Electrical Code Handbook.

8. Must be electrically grounded according to national and local electrical codes.

9. MCA may vary slightly due to fan motor options such as SpeedTrol, TEFC.

Power Limitations:

Volts within ± 10 percent of nameplate rating. Maximum 3 percent phase unbalance.

Notes for “Compressor and Condenser Fan Amp Draw”:

1. Compressor RLA values are for wiring sizing purposes only but do not reflect normal operating

current draw at rated capacity. If unit is equipped with SpeedTrol condenser fan motors, the first motor on each refrigerant circuit is a single phase, 1hp motor, with a FLA of 2.8 amps at 460 volts,

5.6 amps at 208, 230, and 575 volts.

2. Compressor LRA for reduced inrush start is for the first winding only. If the unit is equipped with

SpeedTrol motors, the first motor is a single phase, 1 hp motor, with a LRA of 7.3 amps at 460 volts, 14.5 amps at 208, 230, and 575 volts.

Notes for “Field Wiring Data”

1. Requires a single disconnect to supply electrical power to the unit. This power supply must

either be fused or use an HACR type circuit breaker.

2. All field wiring to unit power block or optional non-fused disconnect switch must be copper.

3. All field wire size values given in table apply to 75°C rated wire per NEC.

26 IOMM ACR/AGR-1

Electrical Legend

Figure 8, Electrical Legend

IOMM ACR/AGR-1 27

Wiring Diagrams

Figure 9, AGR-AM, Typical Field Wiring with MicroTech Controller

28 IOMM ACR/AGR-1

Figure 10, AGR-AM, Typical Field Wiring Diagram with UNT Controller

IOMM ACR/AGR-1 29

Figure 11, ACR-A, Field Wiring Diagram (No Capacity Control)

30 IOMM ACR/AGR-1

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