McQuay AFD 054 Installation Manual
Installation, Operation, and Maintenance Manual
IOM AFSD-1
Direct Drive Fluid Coolers
Type AFS 005 Through AFS 107
Type AFD 046 Through AFD 212
Group: Chiller
Part Number: 331375001
Effective: February 2007
Supersedes: January 2005
Table of Contents
Product Offering ........................................................................................................3
Introduction................................................................................................................4
Installation ..................................................................................................................4
Unit Location .....................................................................................................................................5
Holding Charge ..................................................................................................................................5
Sound Vibration .................................................................................................................................6
Walls or Obstructions .........................................................................................................................6
Multiple Units ....................................................................................................................................6
Units in Pits........................................................................................................................................6
Decorative Fences ..............................................................................................................................6
General...............................................................................................................................................7
Piping Installation ..............................................................................................................................7
Glycol Charge ....................................................................................................................................9
Mixing Glycol and Water ...................................................................................................................9
Glycol Sludge Prevention...................................................................................................................9
Fluid Circulating Pump ......................................................................................................................9
Physical Data ............................................................................................................10
Dimensional Data .....................................................................................................12
Electrical Data..........................................................................................................14
Electrical Wiring ..............................................................................................................................14
Wiring Diagrams..............................................................................................................................17
Start Up.....................................................................................................................18
Prestart .............................................................................................................................................18
Filling and Purging the System.........................................................................................................18
Temperature Control ........................................................................................................................18
Maintenance .............................................................................................................29
Cleaning Instructions........................................................................................................................29
Manufactured in an ISO certified facility
Illustrations cover the general appearance of McQuay International products at the time of publication and we reserve the right to
make changes in design and construction at anytime without notice.
2 Direct Drive Fluid Coolers IOM AFSD-1
2004 McQuay International
AFS
07042A
C
VOLTAGE
CONTROL
ROUGH
OPTION
056
CIRCUIT
Product Offering
MODEL
SIZE
OPTION
OPTION
DUTY
FEED
OPTION
Model
AFS - 1140 RPM fan motors, single-row of fans
AFD - 1140 RPM fan motors, double row of fans
Size
Models 005 through 021 – 1/3 horsepower motors, 1140 RPM fan motors
Models 023 through 212 – 1 ½ horsepower motors, 1140 RPM fan motors
Voltage Option
42 = 208/230 volts / 60 Hertz / 3-phase
27 = 460 volts / 60 Hertz / 3-phase
37 = 575 volts / 60 Hertz / 3-phase
Special – 208 volts / 60 Hertz/ 1-phase, 208/230/380/460 volts/50 Hertz/3-phase
Control Option
A = Fan Cycling Thermostat with Control Transformer (120V)
E = Control Transformer Only (120V)
Y = None
Rough Duty Options
A = Totally enclosed motors
B = Sealtite Wiring
C = PolyGuard fin coating with totally enclosed motors and Sealtite wiring
D = ElectroFin coating with totally enclosed motors and Sealtite wiring
E = PolyGuard Only
F = ElectroFin Only
G = Copper Fins Only (not available on 5 or 6-fan length models)
H = Copper Fins with totally enclosed motors and Sealtite wiring
Circuit Feed Option
Equals the number of feeds (from the header to the first pass of tubes) from capacity tables.
IOM AFSD-1 Direct Drive Fluid Coolers 3
Introduction
Carefully check each shipment against the bill of lading and account for all items. Report any shortage
or damage to the delivering carrier. Damaged material is the delivering carrier’s responsibility. Do not
return to the manufacturer without prior approval.
Be careful when uncrating, to prevent damage. Heavy equipment should be left on units shipping base
until it has been moved to the final location. This equipment must be installed in accordance with
accepted industry standards. Failure to meet the following conditions may void the warranty:
1. System piping must be installed following industry standards for good piping practices.
2. Inert gas must be charged into piping during welding.
3. System must be thoroughly leak checked before initial charging.
4. Power supply to system must meet the following conditions:
Voltage for 208/230 motors not less than 195 volts or more than 253 volts.
All other voltages must be within 10% of nameplate ratings.
Phase imbalance not to exceed 2%.
5. All controls and equipment protection circuits properly connected per wiring diagram.
6. Factory installed wiring must not be changed without written factory approval.
7. Relief valves must meet all code requirements.
Installation
Inspection
When the equipment is received, carefully check all items against the bill of lading to check for
a complete shipment. Check all units for damage upon arrival. All shipping damage must be
reported to the carrier and a claim must be filed with the carrier. Check the unit’s serial plate
before unloading the unit to be sure that it agrees with the power supply available. Physical
damage to unit after acceptance is not the responsibility of McQuay International.
Handling
Note: Installation and maintenance are to be performed only by qualified personnel who are
familiar with local codes and regulations, and experienced with this type of equipment.
Avoid rough handling shock due to impact or dropping the unit. Do not push or pull the unit.
Never allow any part of the unit to fall during unloading or moving, as this can result in serious
damage.
Improper lifting or moving unit can result in property damage, severe
personal injury or death. Follow rigging and moving instructions carefully.
DANGER
4 Direct Drive Fluid Coolers IOM AFSD-1
Figure 1, Unit Rigging
Unit Location
Units are designed for outdoor application and may be mounted on a roof or concrete slab
(ground level installation). Install roof mounted units on steel channels or an I-beam frame to
support the unit above the roof. Use of vibration pads or isolators is recommended. The roof
must be strong enough to support the weight of the unit. For ground level installation, mount
units on a one-piece concrete slab with footings extending below the frost line. Be certain
concrete slabs are installed level and are properly supported to prevent settling. Locate the
unit far enough away from any wall or other obstruction to provide sufficient clearance for air
entrance. Do not attach more than two-feet of ductwork to the fan outlet. Avoid air
recirculation conditions that may be caused by sight screening, walls, etc. and keep unit fan
discharge away from any building air intakes. Do not install unit where exhaust or ventilation
equipment will affect entering air temperature or foul coils.
Holding Charge
The unit is shipped with a holding charge of dry nitrogen under nominal pressure.
IOM AFSD-1 Direct Drive Fluid Coolers 5
Sound Vibration
AFS = 4 ft.
AFD = 6 ft.
AFS = 4 ft.
AFD = 6 ft.
AFS = 3 ft.
AFD = 4 ft.
Install units away from occupied spaces, utility areas, corridors and auxiliary spaces to
reduce the transmission of sound and vibration to occupied spaces. The fluid piping should
be flexible enough to prevent the transmission of noise and vibration from the unit into the
building. If the fluid lines are to be suspended from the structure of the building, use
isolation hangers to prevent the transmission of vibration. Where piping passes through a
wall, pack fiberglass and sealing compound around the lines to minimize vibration and
retain flexibility. The unit must be secured in its final location. Holes are provided in the
base runner for this purpose
Vertical airflow type units should be located no closer than the width of the unit from a wall
or other obstruction. It two or more units are to be positioned in the same area, a similar
distance should be maintained between adjacent units. Sufficient free area should be left
around and below unit to avoid air restriction to coil.
Walls or Obstructions
Locate the unit to ensure that air can
circulate freely and not be recirculated. For
proper air flow and access, all sides of the
unit must be at least the distance shown away
from any wall or obstruction. Increase this
distance whenever possible. Be sure enough
room is left for maintenance through access
doors and panels. Overhead obstructions are
not permitted. When enclosed by three walls
the unit must be installed as indicated for
units in a pit.
AIR FLOW
Multiple Units
For units placed side by side, the minimum
distance between units is as shown. If units
are placed end to end, the minimum distance
between units is 4 feet.
Units in Pits
The top of the unit should not be more than
two feet below the top of the pit, and side
minimum distance on all four sides as
shown.
Decorative Fences
Fences must have 50% free area, with 1 foot
undercut, at least the width of condenser
minimum clearance, and must not be higher
than the top of unit. If these requirements
are not met, unit must be installed as
indicated for "Units in Pits".
AIR FLOW AIR FLOW
AFS = 6 ft.
AFD = 8 ft.
1 IN.
MIN.
STACK
(BY OTHERS
IF SUPPLIED)
AFS = 4 ft.
AFD = 6 ft.
AFS = 3 ft.
AFD = 4 ft.
AIR
FLOW
AIR FLOW
2 FT. MAX.
6 Direct Drive Fluid Coolers IOM AFSD-1
General
1. Structure supporting unit must be designed to support both the unit and the fluid.
Table 1 provides weight of fluid per gallon. Provide suitable flashing of the roof, if this
is a roof installation. For ground level mounting, a concrete pad is recommended.
Mounting holes permit the units to be bolted down to withstand wind pressures.
Provide adequate clearance for unobstructed air flow to coils.
2. Level mounting is necessary to ensure proper fluid distribution through the coil as well
as flooded suction for the pump.
Table 1, Fluid Weight Per Gallon at 130
Percent Glycol
0 (Water) 8.25 8.22
10 8.33 8.29
20 8.50 8.37
30 8.58 8.42
40 8.80 8.49
50 8.82 8.53
Pounds per Gallon
Ethylene Glycol
°°°°
F
Pounds per Gallon
Propylene Glycol
3. Water piping must comply with local codes. Correct pipe sizing will help reduce
pumping power and operating costs.
4. In case of doubt, consult the manufacturer for the dry cooler fluid pressure drop at the
specific conditions on your job.
5. Provide sufficient valves and unions to permit easy access to parts subject to wear and
possible repair or replacement.
6. After fluid piping is completed, all joints should be leak tested.
7. Where city water make-up is required, follow local codes, making certain that
disconnecting provisions are provided.
8. Select wire in accordance with nameplate data and local codes.
Piping Installation
The piping system should provide maximum leak prevention. Weld or sweat joints should
be used where possible. The fact that glycol solutions or other heat transfer fluids will leak
where water will not, must be taken into account.
The glycol system should not employ an automatic fill with a pressure-reducing valve. This
is because a slight leak would lead to dilution of the mixture and possible freeze potential.
Any refill should be controlled so as to maintain the proper glycol-to-water ratio.
Table 2 shows pressure drops for various pipe sizes at flow rates commonly used with a
typical dry cooler. These pipe sizes are not necessarily always correct for the run from the
condenser to the dry cooler. Proper pipe size will depend on available pump head. This can
be determined by subtracting from the total available pump head at design flow, the
condenser pressure drop and the dry cooler pressure drop. Allow some safety factor for last
minute pipe fittings added to the system and for eventual fouling of the system.
a) Glycol piping requires no insulation except when fluid temperature will be below
ambient dewpoint temperatures.
b) Vents are required at all high points in the piping to bleed air when filling the system.
If fluid coolers are at high points, vent valves should be installed at each fluid cooler.
c) It is recommended that gate valves be installed on both sides of the pump to prevent
loss of fluid in the event the pump should require repair or replacement. Shut-off
valves are also recommended at water cooled condensers in case the condensing unit is
to be moved or requires maintenance involving the coolant system.
IOM AFSD-1 Direct Drive Fluid Coolers 7
Table 2, Pressure Loss in Feet of Water
Flow
gpm
15 1 1 1/8 17.6 15.0
20 1 1 1/6 30.2 23.1
25 1 1 1/8 34.6
25 1 1/4 1 3/8 11.5 12.6
30 1 1/4 1 3/8 16.3 17.4
35 1 1/4 1 3/8 21.8 23.0
40 1 3/8 - 26.3
40 1 112 1 5/8 13.0 12.9
45 1 1/2 1 5/8 16.5 15.7
60 - 1 5/8 - 26.3
60 2 2 1/8 7.9 7.0
80 2 2 1/8 13.7 12.0
100 2 1/2 2 5/8 8.5 6.1
150 2 1/2 2 5/8 18.6 12.9
200 3 3 1/8 10.7 9.1
250 3 3 1/8 16.5 13.7
300 3 1/2 3 5/8 11.1 9.2
300 4 4 1/8 5.9 4.9
350 4 4 1/8 7.9 6.5
400 4 1/8 10.2 8.2
Pipe
Size Steel
in.
Type “L”
O.D. Copper
in.
Schedule 40 Steel
Head ft/100 ft
Equiv. Length
Figure 2, Typical Piping
FLUID COOLER
EXPANSION
TANK
VENT AND
FILL VALVE
Copper Tube
Head ft/100 ft.
Equiv. Length
WATER COOLED
CONDENSER
DIVERTING
SHUT-OFF
VALVE
VALVE
CIRCULATING
PUMP
SHUT-OFF
VALVE
REFRIGERATION
COMPRESSOR
EVAPORATOR
WATER CHILLER
TXV
CHILLED WATER
HEAT EXCHANGER
FOR SUPPLEMENTAL
FREE COOLING
NOTE: Isolation valves, vents, drains and other piping specialties are not shown, but are
required for a fully operational system.
8 Direct Drive Fluid Coolers IOM AFSD-1
Glycol Charge
The amount of ethylene glycol required depends upon the following:
• The holding volume of the system that includes the holding capacity of the heat source,
the interconnecting piping and the dry cooler.
• Percentage of glycol required by volume to provide protection at the design minimum
operating temperature.
Table 3, Percentage of Glycol to be Added by Percent Volume
Freeze Point °°°°F (°°°°C)
Percent Propylene Glycol
Percent Ethylene Glycol
Use as a guide only. Proper precautions need to be taken to prevent freeze damage during low ambient. Consult
glycol vendor recommendations for specific freeze protection for your location.
30 (-1) 20 (-7) 10 (-12) 0 (-18) -10 (-23) -20 (-29) -30 (-34)
4 16 25 32 38 44 48
5 19 29 36 42 47 51
Mixing Glycol and Water
Regardless of the strength of the mixture, you MUST premix the glycol and water prior to
adding it to the system. The chemical reaction between the two will release oxygen, which
is extremely undesirable in a close-loop system.
CAUTION
For dry coolers operating without a glycol mixture, adequate fluid freeze protection of
some type is necessary during ambient air temperatures below 32°F.
Glycol Sludge Prevention
Glycol systems may be subject to sludge formation in coils, due to one or more of the
following causes:
• Reaction of the corrosion inhibitor with galvanized piping (zinc).
• Reaction of the glycol with chromate type water additives.
• Reaction of the glycol with pipe dope, cutting oils, solder flux, and other system dirt.
Glycol manufacturers offer a specially inhibited glycol (formulated for snow melting
systems) that does not react with zinc. This glycol is also suitable for heat transfer systems.
Glycol manufacturers also provide inhibitor check services on a regular basis.
Consequently, good glycol system design requires the following precautions:
• No galvanized piping is to be used.
• System piping must be thoroughly cleaned and flushed with a heated trisodiurn
phosphate solution before filling with the water/glycol mixture.
• Chromate inhibitor treatment must not be used.
• The glycol manufacturer should provide inhibitor check service and supply additional
inhibitor as required.
Fluid Circulating Pump
Mechanical seal type pumps must be used for glycol systems. Gland type pumps would
cause glycol waste and, if used with a pressure reducing valve, will lead to dilution of the
glycol mixture and eventual freeze-up.
IOM AFSD-1 Direct Drive Fluid Coolers 9
Loading...