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

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

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Manufactured in an ISO certified facility.

"McQuay" is a registered trademark of 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

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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

Figure 4. ACU 075D to 150D Dimensions (all dimensions in inches)

0.6" Diameter Mounting Holes

7.9

1.4

Liquid

Lifting

Brackets

Suction

Power Entry

2.4

7.9

2.0

22.9

5.7

5.9

Figure 5. ACU 200D to 300D Dimensions (all dimensions in inches)

0.8" Diameter Mounting Holes

1.6

12.8

Dimension

(inches)

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)

45.6

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

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

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