McQuay AFD 202 Installation Manual

Installation, Operation, and Mai ntenance 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: January 2005 Supersedes: IOM AFSD

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

Product Offering

056

CIRCUIT

ROUGH

DUTY

OPTION

FEED

OPTION

MODEL

AFS

SIZE

070

OLTAGE

OPTION

CONTROL

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:

S Voltage for 208/230 motors not less than 195 volts or more than 253 volts. S All other voltages must be within 10% of nameplate ratings. S 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.

ever 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

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

AFS = 4 ft. AFD = 6 ft.

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".

1 IN. MIN.

AIR FLOW

STACK

(BY OTHERS

IF SUPPLIED)

AFS = 4 ft. AFD = 6 ft.

AFS = 3 ft.

AFD = 4 ft.

AFS = 6 ft. AFD = 8 ft.

AIR

FLOW

AIR FLOW

2 FT. MAX.

FS = 4 ft. FD = 6 ft.

AIR FLOW

FS = 3 ft. FD = 4 ft.

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

°°°°

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

Copper Tube Head ft/100 ft. Equiv. Length

Figure 2, Typical Piping

FLUID COOLER

EXPANSION

TANK

VENT AND FILL VALVE

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 duri ng l ow am bi ent. Consult glycol vendor recommendations for specific f reeze 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

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