McQuay ACU 150 Installation Manual

Installation and Maintenance Manual IM-799
Air-Cooled Split Systems
Models ACU 075 to 300 75 to 300 MBH
60 Hz, R-22 Refrigerant
ACU 075 to 150
Group: Unitary
Part Number: IM-799
Date: August 2005
Supersedes: July 2004
ACU 200 to 300
© 2004 McQuay International
IM-799 Page 1
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unit Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 7
Location For Installation of Condensing Units . . . . . . . . 7
Field Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sound Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Vacuuming and Charging . . . . . . . . . . . . . . . . . . . . . . . . 8
Vacuuming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Field Charging Precautions . . . . . . . . . . . . . . . . . . . . . . . 8
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Charging Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Service Valves on ACU Units . . . . . . . . . . . . . 9
How Much Refrigerant? . . . . . . . . . . . . . . . . . . . . . . . . . 9
Charging Procedures - Single Phase Compressor . . . . 10
Piping Works and Flaring Technique . . . . . . . . . . . . . 11
Special Precautions When Mounting TXV Bulb . . . . . 11
Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Suction Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Underground Refrigerant Lines . . . . . . . . . . . . . . . . . . 12
Long Vertical Riser Installation . . . . . . . . . . . . . . . . . . 12
Liquid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Start-up and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 18
Pre Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Refrigerant Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
..................................................................................................................................................................................................................
Manufactured in an ISO certified facility.
"McQuay" is a registered trademark of McQuay International.
© 2004 McQuay International
"Illustrations and information cover the McQuay International products at the time of publication and we reserve the right to make changes in
Page 2 IM-799
design and construction at any time without notice."
INTRODUCTION
General Description
McQuay air-cooled condensing units are complete, self-con­tained automatic refrigerating units. Every unit is completely assembled, factory wired, and tested. Each unit consists of air-
cooled condensers, Copeland Compliant Scroll compressor, and internal refrigerant piping, ready to be piped to a field-supplied evaporator and liquid line accessories.
The electrical control center includes all equipment protection and operating controls necessary for automatic operation except for the staging control for the steps of capacity in the unit. Condenser fan motors are three-phase and started by their own contactors with inherent overload protection. The com­pressor has internal line breakage motor protection for inherent thermal overload protection, except Model ACU 300 which has solid-state motor protection.
®
hermetic
Receiving Inspection
McQuay products are carefully inspected prior to shipment and the carrier has assumed responsibility for loss or damage upon acceptance of the shipment.
Upon receiving your shipment, check all items carefully against the Bill of Lading. Inspect the unit and/or accessories for shipping damage as soon as they are received. Immedi­ately file claims for loss or damage, either shipping or con­cealed, with the shipping company.
Check the unit nameplate to verify the model number and elec­trical characteristics are correct. In the event an incorrect unit is shipped, it must be returned to the supplier and must NOT be installed. The manufacturer disclaims all responsibility for the installation of incorrectly shipped units.
Important Message to the Installer
This equipment is to be installed by an experienced installation company and fully trained personnel. Carefully read all instructions and take into account any special considerations prior to installing the unit. Give this manual to the owner and explain its provisions.
Important Message to the Owner
Read these instructions carefully and keep them near the prod­uct for future reference. Although these instructions are addressed primarily to the installer, useful maintenance infor­mation is included. Have the installer acquaint you with the operation of the product and periodic maintenance require­ments.
Recognize Safety Symbols, Words, and Labels
The following symbols and labels are used throughout this manual to indicate immediate or potential hazards. It is the owner's and installer's responsibility to read and comply with all safety information and instructions accompanying these symbols. Failure to heed safety information increases the risk of property damage and/or product damage, serious personal injury or death. Improper installation, operation or mainte­nance can void the warranty.
DANGER
Immediate hazards which WILL result in property damage, product damage, severe personal injury and/ or death.
Codes and Regulations
This product is designed and manufactured to permit installa­tion in accordance with National Codes. System design should, where applicable, follow information presented in accepted industry guides such as the ASHRAE Handbooks. It is the installer' s responsibility to install the product in accor­dance with National Codes and/or prevailing local codes and regulations. The manufacturer disclaims all responsibility for
equipment installed in violation of any code or regulations.
IMPORTANT
The United States Environmental Protection Agency (EPA) regulations cover introduction and disposal of refrigerants in this unit. Failure to follow those regulations can harm the environment and lead to substantial fines. Because regulations can change, a certified technician should perform any work done on this unit. If you have any questions, please contact the local office of the EPA.
WARNING
Hazards or unsafe practice CAN result in property damage, product damage, sever personal injury and/or death.
CAUTION
Hazards or unsafe practices which CAN result in property damage, product damage, and/or personal injury.
Replacement Parts
Replacement parts can be obtained by contacting McQuay at 1
-800-37-PARTS. When contacting McQuay for service or replacement parts, refer to the model number and serial num­ber of the unit as stamped on the nameplate attached to the unit.
General Warning
WARNING
Sharp edges and coil surfaces can cause personal injury. Wear protective gear and avoid contact with them.
IM-799 Page 3
Component Location
Condenser Fan and Motor
Access (Access Panel
Removed)
Lifting Holes
(units are skid
mounted)
Direct Drive
Condenser
Fans
Control Box
Access Panel
Factory Provided
Holes For
Optional Spring
Vibration Isolation
Condenser Fan
Motor
Power and Control Connection
Knock Outs
Control Box
Compressor Motor
Protector
Compressor
Access
Extended Liquid and Suction Lines
For Easy Connection
Page 4 IM-799
Extended High and Low Pressure
Schrader Connections
Handling
Be careful to avoid rough handling of the unit. Do not push or pull the unit from anything other than the shipping skid sup­plied with the unit to avoid damage to the sheet-metal cabinet and end frame (see Figure 1).
Figure 1. Suggested Pushing Arrangement
Lifting instructions vary for single circuit (Models 075 to 150) and dual circuit (Models 200 to 300) units. Models 200 to 300 require spreader bars to help prevent cabinet damage (Figure
2).
Figure 2. Suggested Lifting Arrangement
Models 075 to 150 Models 200 to 300
The fan deck with the condenser fans and motors can be removed from the top of the unit.
Vibration Isolators
Vibration isolators are recommended for all roof-mounted installations, or when vibration transmission is a consideration.
Initially, the unit should be on shims or blocks at the listed free height. When all piping, wiring, flushing, charging, etc. is completed, adjust the springs upward to loosen the blocks or shims so they can be removed.
A rubber anti-skid pad is part of the isolator. Installation of spring isolators requires flexible piping connections and at least three feet of flexible conduit to avoid straining the piping and transmitting vibration and noise.
Figure 3. McQuay Spring Isolator Option
Location
Unit Placement
ACU units are for outdoor applications and can be mounted on a roof or at 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 Table on page 14.
Since its operation is affected by wind, the unit should be located so that the Control Box is perpendicular to the prevail­ing wind. If this is not practical, field fabricated wind deflec­tors may be required.
Service Access
Each end of the unit must be accessible after installation for periodic service. Motor protector controls are on the compres­sor. Most operating, equipment protection, and starting con­trols are located in the unit control box. (See page 7 for details.)
ACU Model Spring Weight Color
075D to 150D (4) 175 lb. Red
200D to 300D (4) 600 lb. Orange
Notes:
1.5.50" free height
2.300 lb./in. mounting construction
3.Base: 2.0" x 4.50" with two (2).562 mtg holes at 3.5 c/c
4.Includes adjustable leveling bolt with slot and.50 locking nut, acoustical non-skid neoprene pad.
IM-799 Page 5
Dimensions
.7
H
Figure 4. ACU 075D to 150D Dimensions (all dimensions in inches)
0.6" Diameter Mounting Holes
W
7.9
7.9
1.4
1.4
W
Liquid
Lifting
Brackets
Suction
Power Entry
2.4
7.9
2.0
22.9
A
5.7
5.9
Figure 5. ACU 200D to 300D Dimensions (all dimensions in inches)
0.8" Diameter Mounting Holes
1.6
1.6
12.8
12.8
3
Dimension
(inches)
H
H
W
A
Liquid, suction and hot gas connection sizes are found in Table 3 ­ACU 075 to ACU 300 Physical Data.
Hot gas bypass connections are inside the cabinet. A 2" knock out is provided.
075D-100D 125D 150D
37.2 37.2 41.2
38.6 42.6 42.6
13.8 13.9 13.9
Dimension
(inches)
H
45.6
A
Liquid, suction and hot gas connection sizes are found in Table 3 - ACU 075 to ACU 300 Physical Data.
Hot gas bypass connections are inside the cabinet. A pair of 2" knock outs are provided.
Model Size
Model Size
200D-250D 300D
48.3 56.4
44.0 52.1
90.2
Liquid
Power Entry
3.1
7.5 A
7.9
15.4
39.539.5
Suction
Spring Isolator
Page 6 IM-799
Installation Instructions
S P
G
Location For Installation of Condensing Units
As condensing temperature rises, evaporating temperature rises and cooling capacity drops. In order to achieve maximum cooling capacity, the selected location should fulfill the follow­ing requirements
A. Sufficient clearance must be provided for proper operation,
service and maintenance. To avoid short circuiting con­denser air, the minimum distance between adjacent AHU units is 40 inches. Do not install a unit above another.:
AIR DISCHARGE
C
SPACE
A
ERVICE
A
ANEL
Dimension Minimum Clearance
A 24”
B 42”
C 59”
B
B
C. Must be well ventilated so that the unit can draw and dis-
tribute plenty of air, which helps lower the condensing tem­perature.
D. Must be capable of bearing the weight of the unit and iso-
lating noise and vibration.
E. Should be protected from direct sunlight. If necessary, use
an awning for shade.
F. Avoid annoying neighbors with the hot air discharge and
operating sound level.
G. Must not be susceptible to dust or oil mist.
CAUTION
If the condensing unit is operated in an atmosphere containing oils (including machine oils), salt (coastal area), sulphide gas (near hot spring, oil refinery plant), such substances can cause failure of the unit.
Sound Isolation
The ultra-low sound levels for the ACU condensing units is sufficient for most applications. However, there will be appli­cations where sound generation can be an issue. The most effective isolation method is to locate the unit away from sound sensitive areas. Avoid locations beneath windows or between structures where normal operating sounds can be objectionable. Reduce structurally transmitted sound by isolat­ing refrigerant lines, electrical conduit and the unit itself. Use wall sleeves and rubber isolated piping hangers to reduce transmission of refrigerant flow noise into occupied spaces. Use flexible electrical conduit to isolate sound through electri­cal conduit. Spring isolators are effective in reducing the low amplitude sound generated by scroll compressors and for unit isolation in sound sensitive areas.
B. Avoid obstructing airflow into or out of the unit. Remove
obstacles that block air intake or discharge.
OBSTACLE BLOCKING
AIR OUTLET
Field Piping
For satisfactory operation and performance, note the follow­ing for the field piping arrangements of the complete refriger­ant cycle:
A. Liquid loops or oil traps must be provided according to the
position of the outdoor and the indoor units (depending on whether the indoor unit is above or below the outdoor unit).
OBSTACLE BLOCKIN
AIR INLET
B. Provide the field supplied expansion valve as close to the
indoor unit (evaporator) as possible.
C. Field supplied sight glass and filter drier must be assembled
and mounted next to the expansion valve.
IM-799 Page 7
Maximum Pipe Length and Maximum Number of Bends
When piping is too long, the required refrigerant quantity increases and both the capacity and reliability decrease. As the number of bends increase, system piping resistance to the refrigerant flow increases, which lowers the cooling capacity and the may cause compressor failure. If the height difference between the evaporator and the condenser is excessive, the cooling capacity drops, the lubricating oil return is diminished and compressor efficiency is adversely affected.
Always choose the shortest piping path and follow the recom­mendations shown Figures 6 and 7:
Maximum Elevation Maximum Length
Maximum Number
of Bends
Figure 7. Maximum Total Piping
OUTDOOR UNIT
T H G
I E H
N O
I T A V E L E
M U M
I X A
M
G N
I P
I P
L A
'
T
5 1
O
1
T M
U M
I X A
M
INDOOR
UNIT
65’ 115’ 8
CAUTION
1. Warranty will be revoked if the height, length and/or the number of bends of the refrigerant piping system installed is beyond the limits set out above.
2. Bends must be carefully made to avoid crush-
ing the pipe. Use a pipe bender.
Figure 6. Maximum Piping Elevation)
T H G
I E H
N O
I T A V E L
OUTDOOR UNIT
E M
U M
I X A
M
Condensing Unit Below Coil
N O
I T A V E L E
G
'
N
5
I
6
P
I P
M U M
I X A M
INDOOR
UNIT
INDOOR
UNIT
Condensing Unit Above Coil
Vacuuming and Charging
Vacuuming is necessary to eliminate all moisture and air from the system. Model ACU condensing units are provided with Schrader valve fittings and charging nipples for this purpose.
Vacuuming
After the system piping is properly connected, connect the flexible hoses to the correct charging nipples as shown in the diagrams. Use standard servicing valves and pressure gauges (gauge manifold) to connect the flexible hose to the vacuum pump. Vacuum the air conditioner system to at least 500 microns Hg.
Figure 8.
Liquid Line
Vaccum Pump
Suction Line
Page 8 IM-799
Charging
Before charging, the vacuum must be held at 500 microns Hg for at least 15 minutes. After this period, the vacuum can be broken by charging the unit with R-22 refrigerant. Operate the unit for 15 minutes and monitor the running current and suc­tion and liquid line pressures to verify that the refrigerant charge is the correct quantity. Suction and discharge pipe pres­sures should be in the region of 75 psig and 275 psig, respec­tively. After verifying that the system is correctly charged, remove flexible hose from the charging nipples and replace the caps.
Figure 9.
R22
Liquid Line
Charging Hoses
Most field-charging is accomplished using standard service hoses. Hoses are made in different colors with different work­ing pressures and different leak rates; but the most important feature required for the charging hose is the presence or absence of Schrader valve depressors. Schrader valve depres­sors severely restrict the flow through the service hoses. This slows evacuation and vapor charging dramatically. In most cases, the Schrader valve depressor can be removed; but it is recommended that you have two sets of hoses - one with and one without Schrader valve depressors.
Suction Line
Field Charging Precautions
Scroll compressors have a very high volumetric efficiency and they can quickly pump a deep vacuum if there is insufficient refrigerant in the system, or if refrigerant is added too slowly. Operation with low suction pressure will quickly lead to very high discharge temperatures. While this process occurs, the scrolls are not being well lubricated because they depend on the oil mist in the refrigerant for lubrication. A lack of lubrica­tion leads to high friction between the scroll flanks and tips and generates additional heat. The combination of the heat of compression and heat from increased friction is concentrated in a small, localized discharge area where temperatures can quickly rise to more than 300°C. These extreme temperatures can damage the Scroll spirals and the orbiting Scroll bearing in less than one minute, especially on larger compressors. Dam­age that occurs during field charging may occur in the first few hours of operation, or it may become evident some time later.
Other typical field charging problems include undercharging, overcharging, moisture or air in the system, etc. Each of these problems can also cause compressor failure.
Equipment
Minimal equipment is required for field charging. The mini­mum equipment required for satisfactory field charging includes:
• Set of service gauges
•Hoses
• Vacuum pump
• Vacuum gauge
• Scales
• Thermometer
Hose with Schrader
valve depressor
Hose without Schrader
valve depressor
Hose selection is important depending on whether the system is being evacuated or charged. Charging liquid from the cylin­der into the liquid line should be carried out using an open hose connected to an unrestricted fitting. This will reduce charging time.
Typical Service Valves on ACU Units
Schrader
Core
Model ACU Has
Suitable Connection
Schrader Valve With
Core In Place
Schrader Valve With
Core Removed
Schrader valves provide easy system access for pressure read­ing and the addition of refrigerant. They provide a restriction that slows the speed of liquid charging into the suction side. They also provide a reasonable connection for evacuation on the 6 to 13 ton circuits used on the model ACU.
IM-799 Page 9
How Much Refrigerant?
Proper refrigerant charge is determined by several factors:
1. The best criteria is condenser subcooling. It should be 12°F to 18°F. Add charge if subcooling is insufficient.
2. Suction super heat should be 12°F to 18°F. High super heat is a potential indicator of low charge.
3. Bubbles in the liquid line sight glass are a potential indica­tor of low charge.
4. The charge can be calculated by adding the operating charge for the condensing unit, piping and evaporator:
Condensing Unit Operating Charge
ACU Model Size 075 100 125 150 200 250 300
Operating Charge (lbs.) 9 1215182 x 112 x 142 x 17
Field Piping Operating Charge
Liquid Line Suction Line
Piping Diameter 5/8" 7/8" 1-1/8" 1-3/8" 1-5/8"
Lbs. of R-22 / 100 ft. Pipe Length 7.1 24.0 0.8 1.3 1.8
Evaporator Operating Charge
The evaporator operating charge is determined by the evapora­tor manufacturer.
CHARGING PROCEDURES
Evacuate the system to 500 microns Hg. (67Pa). The quality of the vacuum cannot be determined by time. A reliable vacuum gauge must be used. A battery-powered model similar to the gauge shown below is practical since it avoids the necessity of finding a correct power outlet.
Charging Cylinder on Scale
Close-up of Scale
Turn the refrigerant cylinder upside down, purge the charging hose and charge liquid through the liquid line charging port until refrigerant no longer flows, or until the correct charge has been weighed in. If additional charge is required, start the sys­tem and slowly bleed liquid into the suction side until the sys­tem is full.
Charge liquid in a "controlled" manner into the suction side until the system is full. This recommendation does not
hold true for reciprocating compressors where liquid charging into the suction side can cause severe damage.
Carefully monitor the suction and discharge pressures. Do not allow the suction pressure to fall below 25 psig (1.7 bar) at any time during the charging process.
CAUTION
Manifold Gauge will show cylinder pressure rather than suction pressure if the cylinder valve and Manifold valve "A" are both open. This can result in inaccurate suction pressure readings.
There are many ways of charging liquid in a "controlled man­ner" into the suction side:
1. Use valve A on the manifold gauge set
2. Use the valve on the refrigerant cylinder
3. Charge through a Shrader valve
4. Use a hose with a Shrader valve depressor
5. Charge into the suction side at some distance from the com­pressor.
6. All of the above
Page 10 IM-799
Check to make sure compressor is running the right direction. The compressor can run in the wrong direction on starting. If this happens, reverse any two phases and start again. Short­term reverse rotation will not damage the compressor, but pro­longed reverse rotation can severely damage the equipment.
All compressors have internal discharge temperature protec­tors that are very effective in preventing exceptionally high discharge temperatures during charging. The Size ACU 300 protection module will trip and lock the compressor out for 30 minutes. It is not normally necessary to wait 30 minutes for the module to reset. When the compressor has cooled down, the module can be reset by breaking the power supply to the con­trol circuit. The ACU 075 - 250 motor protection devices have no anti-cycle timers and compressors will restart after they cool. Do not use a jumper wire to bypass the protection mod­ule and continue charging the system. This will cause damage to the equipment and premature failure even if the compressor runs after the jumper is removed and the protector is back in
the circuit.
All compressors displace some oil during operation. Oil is car­ried into the compressor with suction gas; and that same gas entrains oil present on the compressor walls as it is being com­pressed. The sum of the two is then pumped into the discharge piping.
More oil is displaced at compressor start-up than during the normal running periods. If a compressor experiences excessive starts because of recycling pumpdown control, the oil can be pumped out and trapped in the condenser with the refrigerant charge. This oil cannot return regardless of the adequacy of the piping system. To a lesser extent, a similar problem occurs when the equipment is oversized for the available cooling load.
In short, exercise extreme care to verify that both piping and controls are suitable for the application such that displaced oil is returned to the compressor moderately. Note that oil loss to the system can be due to a hang up in the evaporator, as well as in the piping.
Piping Works and Flaring Technique
• Do not use contaminated or damaged copper tubing. Gen­erally, do not remove plastic, rubber plugs or brass nuts from the valves, fittings, tubings or coils until it is time to connect suction or liquid line into valves or fittings.
• If any brazing work is required, pass nitrogen gas through the coil and joints while the brazing is being done. This will eliminate soot formation on the inside walls of the copper tubing.
• Cut the pipe in stages, advancing the blade of the pipe cut­ter slowly. Extra force and a deep cut will result in more distortion of the pipe and more burrs (Figure 10)
Figure 10. Proper Cutting Technique
Cutting
Cutrting Copper Tube
CAUTION
Never jumper motor protectors. Damage and premature equipment failure will result.
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 (slug) can be equally damaging to a com­pressor.
1/4 Tube
Remove Burr
• Remove burrs from the cut edges of the pipe as shown in Figure 10. This will help avoid leaks that result from unevenness on the flare. Hold the end of the pipe down­ward to prevent metal chips from entering the pipe.
• Flare nuts are mounted on the connection parts of the con­densing unit. Insert them onto the copper pipe.
• Fix the pipe firmly on the flare die. Match the centers of both the flare die and the flaring punch, and fully tighten the flaring punch.
IM-799 Page 11
Suction Lines
Use ASHRAE for guidelines in sizing and routing piping with one exception. See the 2002 ASHRAE Handbook Refrigera­tion Edition, Chapter 2 for tables and guidelines. The single exception is piping direct expansion cooling coils located above the compressors. In all cases, regardless of whether the equipment has pumpdown control or not, place a trap in the suction line equal to the height of the coil section. 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 can range between 900 and 4000 feet per minute. Where objectionable noise in or adjacent to occupied space 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, deter-
mine the minimum tons for the circuit.
Add "B" and "C" above to obtain the total equivalent feet. Use the ASHRAE table for R-22. 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 than that determined in "A" above.
.
CAUTION
Avoid excessive pressure drop:
• It reduces compressor capacity.
• It increases power consumption.
• It can affect the performance of both the evapora­tor and the expansion valve previously selected for the application.
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 and 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 Tables.
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.
• An oil separator can be installed in the discharge line.
Note: In horizontal refrigerant gas lines, oil return to com-
pressors is provided by sizing lines at a velocity above the minimum recommended and pitching the lines in the direction of refrigerant flow.
To determine the actual line loss:
1. Modify the table tons by the value for the design condens­ing temperature.
2. Use the formula in the notes 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
Page 12 IM-799
Underground Refrigerant Lines
e
McQuay does not recommend installing suction lines under­ground. If job conditions require that they be located below ground, a suitably sized suction accumulator must be installed ahead of the compressor to interrupt liquid refrigerant slugs at start-up.
Figure 12. DX Coil Piping (Condensing Unit Below Coil)
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P
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o
T
Long Vertical Riser Installation
Where job conditions require refrigerant gas lifts of more than 25 feet, McQuay recommends installing a short trap half-way up the riser or at not more than 20 foot intervals. These traps are required to capture and hold small quantities of oil during off cycles.
Figure 11. DX Coil Piping (Condensing Unit Above Coil)
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Liquid
to Coil
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P
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Su cti on Trap Short as Fittings Permit
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A
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Expansion Valv Control Bulb Str ap To Lin e and Insulate
A
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F
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Expansion Valve Control Bulb Strap To Line and Insulate
Hot gas bypass valve
an d so len oid
valve located as
close to condensing
unit as possible.
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B
G
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Liquid
to Coil
Suction Trap Short as Fittings Permit
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Hot gas bypass valve
and solenoid
valve located as
close to condensing
unit as possible.
G
H
Liquid
to Coil
Liquid
to Coil
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P
C
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T
o
C
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P
B
Suction Trap Short as Fittings Permit
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Suction Trap Short as Fittings Permit
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Expansion Valve Control Bulb Strap To Line and Insulate
A
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Expansion Valve Control Bulb Strap To Line and Insulate
Special Precautions When Mounting TXV Bulb
• The TXV bulb should be clamped to the suction line near the evaporator outlet. If possible, it should be mounted on a horizontal run.
• Clean the suction line completely before clamping the bulb in place.
• Clamp the bulb to a free draining suction line.
• Insulate the bulb from ambient.
Note: The TXV bulb must be fixed at the suction line at
8 o'clock or 4 o'clock.
Figure 13. TVX Bulb Placement
IM-799 Page 13
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 cannot be available in a liquid line at start-up if:
A. 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.
B. Liquid refrigerant is permitted to gravitate from the liquid
line to the condenser because of the relative location of components.
In the event A or B 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. As the line becomes heated, refrigerant trapped in the confined space will increase in pressure. The check valve should include a pressure relief device, relieving from the line side 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.
If liquid lines are short, they may be of smaller diameter than the size indicated in the current ASHRAE Refrigerant Hand­book. As indicated above, the designer must size the liquid line to verify that pure liquid will reach the inlet of the expansion valve. If the condenser is sized to produce 10ºF of subcooling, and each degree represents 3.05 psi with R-22, the liquid line and its refrigerant specialties can have pressure losses totaling 10 x 3.05 psi (or 10 x 2.2) and still satisfy the objective of delivering pure liquid to the expansion valve.
In calculating the pressure losses, or gains, note that each foot of rise in a liquid line results in an approximate 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, sight glasses, etc.
When calculating condenser subcooling, note that saturated condensing pressure should be read at the same point in the system where the liquid refrigerant temperature is obtained.
Page 14 IM-799
Physical Data
Table 1: ACU 075 to 300
Model Nominal MBH EER At ARI Casing Weight (lb.) Sound Power (dBA)
Tubes Fins Rows 1222223 FPI 20161616141614
Condenser
Compressor
Electrical
Refrigeration
Face Area (Sq. Ft.) 24.7 24.4 27.4 30.4 42.0 50.4 50.4 Fan RPM 540 540 480 480 480 480 480 Motor HP [1] 0.5 [1] 0.5 [1] 0.6 [1] 0.6 [2] 0.6 [2] 0.6 [2] 0.6 Fan Dia (in.) 32323636363636 Copeland Model [1] ZR 72 [1] ZR 94 [1] ZR 125 [1] ZR144 [2] ZR 108 [2] ZR 125 [2] ZR 16 Over Load Protection In line In line In line In line In line In line Module Voltage Compressor RLA each 10 16.4 19.2 19.6 17.3 19.2 25 Compressor LRA each 74 95 125 125 114 125 167 Fan Motor FLA each 1.6 1.6 1.9 1.9 1.84 1.84 1.84 Unit Ampacity 14.1 22.1 25.9 26.4 42.6 46.9 59.9 Unit Maximum Fuse Size 20.0 35.0 45.0 45.0 55.0 65.0 80.0 Unit Recommended Fuse Size 20.0 30.0 35.0 40.0 50.0 60.0 70.0 Voltage Compressor RLA each 20.7 32.1 42 47 33.6 42 47.1 Compressor LRA each 172 203 247 245 225 247 350 Fan Motor FLA each 3.1 3.1 3.9 3.9 3.79 3.79 3.79 Unit Ampacity 29.0 43.2 56.4 62.7 83.2 102.1 113.6 Unit Maximum Fuse Size 45.0 70.0 90.0 100.0 110.0 140.0 160.0 Unit Recommended Fuse Size 40.0 60.0 80.0 90.0 100.0 120.0 140.0 Cond. Unit Charge (lb. R-22) 9 12 15 18 2 x 11 2 x 14 2 x 17 Suction Connection (in.) 1 1-1/8 1-3/8 1-3/8 2 x 1-1/8 2 x 1-3/8 2 x 1-3/8 Liquid Connection (in.) 1/2 5/8 5/8 5/8 2 x 5/8 2 x 5/8 2 x 5/8 Hot gas Connection (in.) 1-1/4 1-1/4 1-1/4 1-1/4 2 x 1-1/4 2 x 1-1/4 2 x 1-1/4
075D 100D 125D 150D 200D 250D 300D
75 100 125 150 200 250 300
12.1 10.4 11.7 11.6 11.6 11.7 11.2 Galvanized steel with powder coat finish
374 405 434 590 1036 1116 1340
64 64 66 67 70 70 70
3/8" grooved copper tube with 0.013" wall
0.005" aluminum fin with electro-plated coating
Direct drive with propeller blades
460-60-3 amps
220-60-3 amps
Notes for "Electrical Data Single-and Multi-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.
2. The control transformer is furnished and no separate 115V or 24V power is required.
3. "Recommended Fuse Sizes" are selected at approximately 150% to 175% of the largest compressor RLA, plus 100% of all other loads in the circuit.
4. Must be electrically grounded according to national and local electrical codes.
Voltage Limitations:
Within ±10 percent of nameplate rating.
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.
Notes for "Field Wiring Data"
1. Requires a single disconnect to supply electrical power to the unit. This power supply requires short circuit protection in accor­dance with local codes.
2. All field wiring to unit power block must be THW type copper wire.
IM-799 Page 15
Wiring Diagram
Figure 14. ACU 075D to 150D Typical Wiring Diagram
F I E L D
P O W E R
U P P L Y
B R O W N
B L A C K
F I E L D S U P P L Y
C B
{
G R N - Y E L E Q U P G R N
B R O W N
B Y P A S S T I M E R
2 3
B L A C K
L O G I C
N / O P E N
L P S
B L A C K
1
B L U E
B L A C K
Y E L L O W
C
B L A C K
B L A C K
Y E L L O W
B L U E
Y E L L O W
B L A C K
C
T R A N S F O R M E R
3 . 1 5 A M P
B R O W N
F U S E
T 2
T 3
R E D
Y E L L O W
Y E L L O W
C
Y E L L O W
B R O W N
2 4
B R O W N
T 1
R E D
D E L A Y T I M E R
L O G I C
N / C L O S E D
C
H P S
B L U E
B L A C K
B L A C K
B L A C K
Y E L L O W
B L U E
R E D
W H I T E
B L U E
C H
T 1
C M
T 2
T 3
L 1
O F M
L 2
L 3
F I E L D S U P P L Y
T H E R M O S T A T
R
Y
W
G
C
S W I T C H
I F C
T H
I F C
LEGEND
1) CM - COMPRESSOR MOTOR
2) C - CONTACTOR COMPRESSOR
3) OMF - OUTDOOR FAN MOTOR
4) LPS - LOW PRESSURE SWITCH
5) HPS - HIGH PRESSURE SWITCH
6) CH - CRANKCASE HEATER
7) TB - TERMINAL BLOCK
- CONNECTOR BUD
8)
9) GND GROUND
10) IFC - INOOR FAN CONNECTOR
11) TH - THERMOSTAT
12) CB - CIRCUIT BREAKER
13) ----- FIELD CONTROL WIRE
NOTE FOR 24V CONTROL
Page 16 IM-799
Figure 15. ACU 200D to 250D Typical Wiring Diagram
F I E L D S U P P L Y
T H 2
S W I T C H
T H E R M O S T A T
I F C
T H 1
T 1
C H
B L A C KB L A C K
B L A C K
Y E L L O W
C H
B L A C K
B L A C K
C M 2
T 3
T 2
B L A C K
Y E L L O W
C 1C 2
T 1
C M 1
T 2
B L A C K
Y E L L O W
L 1
O F M 2
L 3
L 2
B L U E
T 3
B L U E
B L U E
R E D
W H I T E
L 1
O F M 2
L 3
L 2
R E D
B L U E
W H I T E
R
Y 1
Y 2
Y E L L O W
Y E L L O W
G
W 1
D E L A Y T I M E R 2
B Y P A S S T I M E R 2
B R O W N
C
W 2
Y E L L O W
T 3
T 2
B R O W N
L O G I C
N / C L O S E D
T 1
O R A N G E
L O G I C
N / O P E N
2 3
B L U E
H P S 2
B L U E
1
O R A N G E
B R O W N
B L A C K
L P S 2
B L A C K
B R O W N
I F C
C
R E D
B L U E
B L A C K
Y E L L O W
Y E L L O W
B L A C K
Y E L L O W
F U S E
3 . 1 5 A M P
R E D
Y E L L O W
T 3
T 2
L O G I C
N / C L O S E D
C
B R O W N
LEGEND
1) CM - COMPRESSOR MOTOR
2) C - CONTACTOR COMPRESSOR
3) OMF - OUTDOOR FAN MOTOR
T 1
T R A N S F O R M E R
2 4
B L A C K
T B 1
B L U E
Y E L L O W
L 1
L 2
Y E L L O W
B L A C K
L 3
C
B R O W N
C
D E L A Y T I M E R 1
Y E L L O W
O R A N G E
B L U E
H P S 1
B L U E
1
O R A N G E
4) LPS - LOW PRESSURE SWITCH
5) HPS - HIGH PRESSURE SWITCH
6) CH - CRANKCASE HEATER
7) TB - TERMINAL BLOCK
- CONNECTOR BUD
8)
9) GND GROUND
10) IFC - INOOR FAN CONNECTOR
11) TH - THERMOSTAT
12) CB - CIRCUIT BREAKER
13) ----- FIELD CONTROL WIRE
C B
F I E L D S U P P L Y
G R N - Y E L E Q U P G R N
{
F I E L D
P O W E R
S U P P L Y
L O G I C
2 3
B Y P A S S T I M E R 1
B R O W N
B R O W N
N / O P E N
B L A C K
L P S 1
B L A C K
B L A C K
NOTE FOR 24V CONTROL
IM-799 Page 17
Figure 16. ACU 300D Typical Wiring Diagram
T H 2
S W I T C H
T H E R M O S T A T
F I E L D S U P P L Y
I F C
T H 1
T 1
C H
B L A C KB L A C K
B L A C K
Y E L L O W
C H
B L A C K
B L A C K
C M 2
T 2
B L A C K
Y E L L O W
C 1C 2
T 1
C M 1
T 2
B L A C K
Y E L L O W
L 1
T 3
B L U E
T 3
B L U E
O F M 2
L 3
L 2
B L U E
R E D
W H I T E
L 1
O F M 2
L 3
L 2
R E D
B L U E
W H I T E
R
Y 1
Y 2
Y E L L O W
Y E L L O W
G
W 1
D E L A Y T I M E R 2
B Y P A S S T I M E R 2
B R O W N
C
W 2
Y E L L O W
T 3
T 2
L O G I C
N / C L O S E D
B L A C K
T 1
O R A N G E
L O G I C
N / O P E N
2 3
C O T P 2
B L U E
H P S 2
B L U E
1
O R A N G E
B R O W N
B L A C K
L P S 2
B L A C K
B R O W N
I F C
C
Y E L L O W
R E D
B L U E
B L A C K
Y E L L O W
Y E L L O W
B L A C K
T R A N S F O R M E R
B L U E
Y E L L O W
B L A C K
T B 1
L 1
L 2
C B
F I E L D S U P P L Y
Y E L L O W
B L A C K
L 3
G R N - Y E L E Q U P G R N
C
Y E L L O W
F U S E
3 . 1 5 A M P
R E D
2 4
Y E L L O W
B R O W N
C
{
F I E L D
P O W E R
S U P P L Y
Y E L L O W
T 3
T 2
L O G I C
N / C L O S E D
T 1
D E L A Y T I M E R 1
C
Y E L L O W
LEGEND
B L A C K
C O T P 1
1) CM - COMPRESSOR MOTOR
2) C - CONTACTOR COMPRESSOR
3) OMF - OUTDOOR FAN MOTOR
4) LPS - LOW PRESSURE SWITCH
5) HPS - HIGH PRESSURE SWITCH
O R A N G E
B L U E
H P S 1
B L U E
1
O R A N G E
6) COTP - COMPRESSOR OVER TEMPERATURE PROTECTION
7) CH - CRANKCASE HEATER
8) TB - TERMINAL BLOCK
- CONNECTOR BUD
9)
10) GND GROUND
11) IFC - INOOR FAN CONNECTOR
L O G I C
N / O P E N
B R O W N
B L A C K
12) TH - THERMOSTAT
13) CB - CIRCUIT BREAKER
14) ----- FIELD CONTROL WIRE
2 3
B Y P A S S T I M E R 1
B R O W N
L P S 1
NOTE
B L A C K
B L A C K
FOR 24V CONTROL
Page 18 IM-799
Start-up and Shutdown
Pre Start-up
1. Verify there is no shipping damage and no detectable refrigerant leaks.
2. The evaporator air filters must be checked for cleanliness and replaced as necessary.
3. Open all electric disconnects and check all electric connec­tions for tightness.
4. Verify field-installed refrigerant piping is installed per the Refrigerant Piping instructions and includes a liquid line sight glass, filter drier and expansion valve. Verify the expansion valve bulb and equalizer lines are installed in accordance with page 13 and the manufacturer's instruc­tions.
5. Verify that thermostat connections for one stage (sizes 075 to 150) and two stages (size 200 to 300) of control have been connected to unit terminals R, G, C and Y (or Y1 and Y2)
6. Check compressor oil level. The oil level should be visible in the oil sightglass.
7. Check voltage of the unit power supply and make certain voltage is within ±10% of nameplate rating. Check unit power supply wiring for proper ampacity and a minimum
insulation temperature of 75 using a phase sequence meter.
8. Verify all mechanical and electrical inspections have been completed according to local codes.
9. Disconnect the thermostat connection to terminal Y (or Y1 and Y2) to prevent compressor operation. Turn on the main power disconnect switches. This will energize crank­case heaters. Wait at least 24 hours before starting up unit.
o
C. Check for proper phasing
Start-up
1) Start the air handling equipment by turning on the system through time clocks, service switches, et.
2) Verify the evaporator is loaded:
a) The DX coil must have full airflow and entering air tem-
perature must be similar to design conditions.
b) The chiller must have full water flow and entering water
temperature must meet design conditions.
c) Ambient temperature must exceed 70°F.
3) Set the thermostat to call for no cooling and reconnect the Y (size 075 to 150) or Y1 and Y2 (size 200 to 300) thermo­stat connections.
4) Charge the system as instructed in Vacuuming and Charg-
ing.
5) Set the thermostat to call for full cooling and watch the condensing unit cycle on. Immediately verify proper phase and rotation.
a)The condenser fans must rotate in the proper direction.
b)The compressor discharge pressure must exceed the suc-
tion.
6) After a few minutes, verify the suction pressure is approxi-
mately 75 psig and discharge pressure is approximately 275 psig Record these pressures, ambient temperature and evaporator load temperatures for future reference.
7) Verify suction superheat is 12°F to 18°F or adjust the
expansion valve as necessary.
8) Verify subcooling is 12°F to 15°F.
9) Verify low pressure equipment protective devices trip at 18
psig by turning off the supply fan.
10)Verify high pressure equipment protective devices trip at
426 psig by turning off the condenser fans.
IM-799 Page 19
System Maintenance
General
On initial start-up and periodically during operation, it will be necessary to perform certain routine service checks. Among these are taking electric leg readings.
Lubrication
No routine lubrication is required on the ACU units. The fan motor bearings are of the permanently lubricated type and require no lubrication.
Electrical Terminals
Normal heating and cooling of the wire will cause terminals to loosen. Retighten all power electrical terminals every six
months.
WARNING
Electric shock hazard. Disconnect and tag-out all sources of power to the unit before continuing with following service to avoid risk of severe per­sonal injury.
Condensers
Condensers are air-cooled and constructed with 3/8" (9.5mm) O.D. internally finned copper tubes bonded in a staggered pat­tern into slit aluminum fins. No maintenance is ordinarily required except occasionally removing dirt and debris from the outside surface of the fins. Use locally purchased foaming con­denser coil cleaners for periodically cleaning the coil. Con­denser cleaners may contain harmful chemicals. Wear protective gear and read and follow manufacturer's safety instructions. Take care not to damage the fins during cleaning. Thoroughly rinse all chemical cleaners from the coils.
Refrigerant Sight Glass
Observe the refrigerant sight glass monthly. A clear glass of liquid indicates adequate sub-cooled refrigerant charge in the system to provide proper feed through the expansion valve. Bubbling refrigerant in the sight glass indicates the system is short of refrigerant charge. Sub-cooling should be verified to prevent overcharging. Refrigerant gas flashing in the sight glass could also indicate an excessive pressure drop in the line, possibly due to a clogged filter-drier or a restriction elsewhere in the system. The sight glass indicates what moisture condi­tion corresponds to a given element color. If the sight glass does not indicate a dry condition after about 12 hours of opera­tion, the refrigerant and oil should be tested for moisture.
Troubleshooting
If any malfunction of the condensing unit is noted, immedi­ately switch off the power supply to the unit. Check the fol­lowing fault conditions and causes for simple troubleshooting tips.
Motor Protection Devices - The compressor motor protec­tion device varies based on unit size. All motor protection devices trip all 3 power phases on any trip and have an auto­matic reset once acceptable temperatures and currents are experienced.
1.Model 075- An internal line break, current sensing pro­tection device is provided that trips on high current or compressor temperatures. An internal thermal disk is pro­vided that picks up the discharge refrigerant temperature and increases the sensitivity to the compressor tempera­ture. No anti-cycle timers are provided.
2.Models 100-250- Same as Model 075 but no thermal disk is provided.
3.Model 300- An internal pilot duty temperature sensing protection device is provided that also responds indi­rectly to excessive current. These overloads have a con­trol module with 30-minute anti-cycle timers. The compressor can be restarted prior to the 30-minute time delay by breaking control power to the module and re-set­ting it, provided the compressor has cooled sufficiently.
Low Pressure Equipment Protection Device
The low pressure equipment protection device trips at 18 psig +/- 7 psig. Likely causes are insufficient charge, insufficient evaporator air (or water) flow or dirty filters, low ambient operation (50° F is the minimum allowed), an undersized or malfunctioning expansion valve, or a liquid line blockage at start-up.
High Pressure Equipment Protection Device
The high pressure equipment protection device trips at 426 psig +/- 22 psig. Likely causes are excessive charge, blocked or recycling condenser air flow, a condenser fan failure, or high ambient operation (115° F is the maximum allowed).
If the fault persists, contact your local service provider.
This document contains the most current product information as of this printing. For the most up-to-date product information, please go to www.mcquay.com.
www.mcquay.com • 800-432-1342
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