McQuay ALP-019A Installation Manual

SEASONCON”

Packaged air cooled condensing unit

McQuay

GROUP

McQuay-PERFEX

Models

Inc. 13600 Industrial Park Blvd., P.O. Box 1551, Minneapolis, Mn.

ALP-O16A

thru -033A

55440 @

McQUAY

type ALP SEASONCON air cooled condensing units are designed for outdoor installations and are compatible with either air handling or chilled water systems. Each unit is completely assembled and factory

INTRODUCTION

consists of an air cooled condenser with integral subcooler section, piping and suction and liquid connections for connection to any air or water cooling evaporator.

an unloading compressor, complete discharge

wired before evacuation, charging and testing. Each unit

NOMENCLATURE

A L P-033 A-S

Nomtnal

Capacity

(Tons)

INSPECTION

When the equipment is received, all items should be

carefully checked against the bill of lading to insure a complete shipment. All units should be carefully inspected for damage upon arrival. All shipping damage should be

INSTALLATION

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

HANDLING Care should be taken to avoid rough handling or shock due

to dropping the unit. Do not push or pull the unit from anything other than the base, and block the pushing vehicle away from the unit to prevent damage to the sheet metal

cabinet. (See Figure 1.)

To lift the unit, provided in the base of the unit. Spreader bars and cables should be arranged to prevent damage to the condenser coils or unit cabinet. (See Figure 2.)

LOCATION Due to vertical condenser design, it is recommended that the unit is oriented so that prevailing winds blow parallel to the unit length, thus minimizing effects on condensing pressure. If it is not practical to orient the unit in this manner, a wind deflector should be constructed.

Units are designed for outdoor application and may be mounted on a roof or concrete slab (ground level installation). Roof-mounted units should be installed level on steel channels or an l-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. See Table 1 for unit weights. Concrete slabs used for unit mounting should be installed level and be properly supported to prevent settling. A one-piece concrete slab with footings extended below the frost line is recommended.

TABLE 1. UNIT WEIGHTS

ALP MODEL

016A 019A 023A 027A 033A

2-1/2-inch

diameter lifting holes are

OPERATING WEIGHT (LBS.)

1122 1383 1471 1600 1866

reported to the carrier and a claim should be filed. The unit

serial plate should be checked before unloading the unit to

be sure that it agrees with the power supply available.

FIGURE 1.

GOOD PUSHING ARRANGEMENT -CABINET DAMAGE UNLIKELY

SUGGESTED PUSHING ARRANGEMENT

FIGURE 2.

PAGE 3

ACCESS

It is necessary to provide adequate clearance on all sides of

the

unit for service access and satisfactory performance.

Necessary clearances are shown in Figure 3.

VIBRATION ISOLATORS

Vibration isolators are recommended for all roof-mounted installations or wherever vibration transmission is a potential problem. Table 2 lists spring and rubber-in-shear isolators for all ALP unit sizes. Table 3 shows isolator loads

FIGURE 3.

CLEARANCE AROUND UNIT

and the maximum allowable load for each isolator. Figure 4 shows isolator locations in relation to the unit control

“A-‘MIN.

CLEARANCE

FOR AIR INLET

panel. Figure 5 gives dimensions that are required to secure each

Each unit base frame is provided with the necessary holes

to accept the

isolator.

-i%q

Acc~~~~~N

pQ%z-

TABLE 2.

’

ALP LOCATIONS

UNIT SIZE ORDERING NUMBER 016A 019A 023A 027A 033A

FIGURE 4.

ALP

MODEL

016A 019A 023A 027A 033A

CLEARANCE

FOR DISCHARGE

DIMENSIONS (IN FEET)

3 3 3 5

3 3 6

CONTROL PANEL

4 4

3 3 3 3 3

D 4 4 4 4 4

McQUAY

isolator selection to the mounting surface.

0.50-inch

diameter positioning pin of each

ISOLATOR SELECTIONS

1,2.3

& 4

SPRING-FLEX

877-2164036-25 877-2164030-26 877-2164030-26 877-2164030-26 877-2164030-27

RUBBER-IN-SHEAR

ORDERING NUMBER

a77-216397Aal 877-216397A-01

877.216397AJJl 877-216397Aal a77-216397A-03

ISOLATOR LOCATIONS

By removing the access screens, access can be gained to the compressor, refrigerant lines, refrigerant components, condenser fans and SPEEDTROL components. All other controls are located in the unit control panel. They are protected by a keylocked, weatherproof enclosure which contains an internal “dead front” door for protection of service personnel from high voltage starting controls while servicing low voltage operational controls.

FIGURE 5.

ISOLATOR DIMENSIONS

(IN.)

Spring-Flex Isolators

ADJUST MOUNTING SO UPPER HOUSING CLEARS LOWER

TABLE 3.

LATO R LOADS

IS0

0.50 DIA.

ACOUSTkAL NONSKlD

NEOPRENE PAD

HOUSING

AND NOT MORE

”

Rubber-In-Shear Isolators

,600

Dia. Pin

Mounting Molded

Neoorene

L4.12---

-\1’2.5”7

5.50

2 Holes

PAGE

ALP UNIT SIZE LOCATION 016A 019A 023A 027A 033A

ISOLATOR LOADS AT

EACH MOUNTING LOCATION

1.2,3

4 SPRING-FLEX 281 346

368 400 467

MAXIMUM LOADS ALLOWABLE

FOR EACH ISOLATOR SELECTION

RUBBER-IN-SHEAR 450 600 600 600 750

525 525 525 525 750

REFRIGERANT PIPING

McQUAY adaptable to either chilled water or air handling air conditioning applications using refrigerant 22. Refrigerant

piping to and from the unit should be sized and installed

according to the latest

type ALP SEASONCON condensing units are

ASHRAE

Guide. The following

discussion is for use as a general guide to sound, economical and trouble-free piping. The correct application of the principles discussed here is the responsibility of the

installer.

EVAPORATOR ABOVE CONDENSING UNIT

Figure 6 shows an installation where the evaporator is installed above the condensing unit. It is shown for an air handling installation, but all components shown are recommended for chilled water installations except that a refrigerant distributor is not usually required for shell-and-tube evaporators.

FIGURE 6.

Evaporator Above Condensing Unit

-G-AIR

FLOW

EVAPORATOR BELOW CONDENSING

UNIT

Figure 7 shows an installation where the evaporator is installed below the condensing unit. It is shown for an air handling installation, but all components shown are recommended for chilled water installations except that a refrigerant

distributor is not usually required for shell-and-tube evaporators. Note that a double suction riser is shown for this arrangement.

Risers

“A + B”

are sized so that their combined cross-sectional internal area will allow full load unit operation without excessive pressure drop (see notes, Table

4). Riser

“B” is sized to provide adequate suction gas velocity for proper oil return at minimum load conditions. This riser becomes effective only when the trap shown in

riser “A” fills itself with oil. It should be emphasized that the trap shown in riser “A” should be designed to contain a minimum internal volume to keep the total system oil

requirements at a minimum. Table 4 gives recommended

line sizes for both single and double suction lines and for

liquid lines.

FIGURE 7.

Evaporator Below Condensing Unit

LEGEND

a Filterdrier

b Solenoid valve c

Sightglasslmoisture indicator

d Thermal expansion valve

Suction line, pitched toward compressor f Liquid line g Vibration absorber

NOTES: All piping and piping components are by others.

TABLE 4.

ALP UNIT SIZE

016A-S

019A-S 1318-l 318 2118 023A-S 1518-l

027A-S 1518-l 318 2118 1l/8

033A-S 1518-l 518 2118 1 118

Note: Liquid and suction lines based on a recommended pressure

drop of 3 PSIG

RECOMMENDED LINE

DOUBLE

+y;.?l

118-l

l/8 1518

318 2 118 1l/8

12OF)

per 100 ft.

SINGLE

SUCTION

equrvalent

SIZE

LIQUID

718 718

length.

e-AIR

FLOW

LEGEND

a Filterdrier b Solenoid valve c

Sightglass/moisture d Thermal expansion valve e

Suction line, pitched toward compressor f Liquid line g

Vibration absorber

A+8 - Double suction riser (see note 2)

NOTES:

1. All piping and piping components are by others.

2. Trap for double suction riser should be as small in the horizontal direction as fittings will allow.

indicator

REFRIGERANT PIPING CONNECTIONS

Refrigerant piping connections should be made through the holes provided in the base frame on access screen side of the unit.

PAGE 5

LIQUID LINE COMPONENTS McQUAY

each ALP unit size. Table 5 shows the ordering number to be used for each ALP unit size. The components included in these kits are:

has available a “Liquid Line Accessory Kit” for

TABLE 5. LIQUID LINE ACCESSORY KITS

ALP LIQUID LINE

UNIT ACCESSORY KIT

SIZE ORDERING NUMBER 016A-S

019A-S 023A-S 027A-S

033A-S

886-368903641

886366903641

8863689039-01 886-368903841 aa6-36890384x2

FILTER-

DRIER VALVE GLASS

718 718 718 718 718 718 7/a 7/a 7/a 7ta

Replaceable core type filter-drier.

Filter-drier core element.

Refrigerant Refrigerant

Expansion valve.

CONNECTION SIZES O.D.

SOLENOID SIGHT-

7/a

718 718

solenoid valve.

sightglass/moisture

(IN.1

7ta 7/a

indicator.

EXPANSION VALVE

718 7/a 718 718 718

OUT

318

3/a

318

3/a

FIGURE 8.

DIMENSIONAL DRAWING

REFRIGERANT CHARGE

Each ALP condensing unit is designed for operation using refrigerant 22. Table 6 lists refrigerant charge required for a condensing unit/cooler combination.

TABLE 6. APPROXIMATE REFRIGERANT CHARGE

PAGE 6

ALP

MODEL

016A-S

019A-S 023A-S 027AS 033A-S

Refrigerant

will require

charge is for a

an additional charge.

‘R-22 REFRIGERANT

CHARGE (LBS.)

32 37 53

close-coupled

system. A remote cooler

ADDING REFRIGERANT CHARGE

On systems that have been refrigerant, an

insufficient

previously

charge is indicated by bubbling in the sightglass. On uncharged systems, the system should be leak tested and evacuated before charging. Upon charging

a system, the discharge and suction shut-off valves on the compressor should be open and there should be normal water flow through the cooler.

CAUTION: Do not make any safety controls inoperative during the charging operation: cooler damage from freezing may result.

1. Back seat the liquid line shut-off valve and connect the charging hose to the

1/4-inch

flare connectron.

2. Install pressure gauges and review start-up instructions.

3. Purge the charging hose and open the to allow refrigerant

into

the system.

charged with

charging

cylinder

Turn the liquid line shut-off valve in three turns to

‘4.

permit a back flow of refrigerant into the subcooler. After refrigerant stops flowing into the system, close the

5. liquid line shut-off valve. Start the compressor to charge the system.

If the amount of refrigerant has been predetermined,

6. add this amount and check the sightglass afterward.

If the amount of charge is unknown, close the charging cylinder valve every five minutes, open the liquid line shut-off valve and check for proper charge by examining the sightglass. Continue charging and checking the sightglass until it is clear.

NOTE: Fluorocarbon refrigerants should not be released to the atmosphere. For a means of recovery, refer to the following section.

REMOVING REFRIGERANT CHARGE To prevent freeze-up when removing the refrigerant for

ALP installations on water chiller systems, either drain the water or circulate the water. If water cannot make sure the cooler heater is energized. Do not remove refrigerant rapidly since this can cause freeze-ups. Have a sufficient number of refrigerant containers and a scale for weighing them. The containers should be clean, dry and empty.

gauge manifold from the compressor discharge valve service port to the container and purge the iines. Note the capacity

of the container. Place the container in ice to cool the

container so the fusible plug does not melt as the

refrigerant condenses. Operate the compressor normally. Turn the discharge service valve in three turns to open the gauge manifold. Do not close off the discharge valve to the condenser. Discharge gas can enter the container and

condense.

overfill. When the container is filled use additional ones.

FIELD WIRING

WARNING: USE ONLY COPPER CONDUCTORS IN MAIN TERMINAL BLOCK.

Wiring should be done in accordance with all applicable codes and ordinances. Warranty is voided if wiring is not in accordance with specifications. An open fuse indicates a short, ground or overload. Before replacing a fuse or

restarting a compressor or fan motor, the trouble must be

found and corrected.

All standard units require a 115 volt power supply for

the control circuit. If the optional control circuit

transformer is ordered, the control circuit is powered off the main power supply.

unit installation. Items that require field wiring are liquid

line solenoid and the cooling thermostat, as well as the unit power

supplies.

drained,

To transfer the refrigerant to a container, connect the

Frequently weigh the container so as not to

Figure 9 shows typical field wiring that is required for

SV1,

optional hot gas bypass solenoid

SV5

FIGURE 9.

TYPICAL FIELD WIRING

““ll Ml,”

PB1

Since it is impossible for

installation that an ALP condensing unit may be used on, we do not factory install a thermostat. We do, however, provide numbered terminals inside the unit control center

McQUAY

to anticipate the type of

THERMOSTAT WIRING

to which a thermostat may be connected. These terminals are shown and labeled “Terminals For Thermostat” on the

electrical schematics. Figure 9 shows typical field wiring for

a thermostat with temperature controlled unloading.

PAGE 7

+ 16 hidden pages