McQuay ALP-037A Installation Manual

BULLETIN NO. IM 269-2

OCTOBER, 1984

FORM NO. 4154631

SEASONCON

PACKAGED AIR COOLED CONDENSING UNIT

MODELS ALP-037A THRU 107A,

067B THRU

159B, &

179A

WkIJUR\I

AIR connmonlnG

13600 Industrial Park Blvd.. P 0.

60~

1551, Minneapolis, MN 55440

INTRODUCTION

General description. Nomenclature

Inspection....................................

INSTALLATION

Handling....................................

Location......................................

Service access Vibration isolators

REFRIGERANT PIPING

General......................................

Evaporator above condensing unit

Evaporator below condensing unit

Refrigerant piping connections

Liquid line components

Recommended line sizes

Dimensionaldrawings.............

Hot gas bypass components..................

Refrigerant charge..........................

FIELD WIRING

Wire sizing ampacities and

recommended power lead sizes

Compressor and condenser fan motors..........

Thermostat wiring

Typical field wiring for thermostats

Flow switch for chilled water applications

Evaporator fan interlock

for air handler coil installations

UNIT LAYOUT AND PRINCIPLES OF OPERATION

Major component locations

Control center

Sequence of operation

Electrical legend Power schematics

Compressor control schematics..............

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.3 .3

.3,4

4,5

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10,ll

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13,14

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.16 .17

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.20-23

.24-39

START-UP AND SHUTDOWN

Pre Start-up

. .

InitialStart-up Temporary shutdown

Start-up after temporary shutdown..............

Extended shutdown.........................

SYSTEM MAINTENANCE

General...................................

Fanshaftbearings..........................

Electrical terminals Compressor oil level

Condensers................................

Refrigerant sightglass.

SERVICE

Filter-driers Liquid line solenoid valve Thermostatic expansion valve

IN-WARRANTY RETURN MATERIAL PROCEDURE

Copeland compressor. Components other than compressor

APPENDIX

Standard Controls Oil pressure safety controls High pressure control Low pressure control FANTROL head pressure control Optional Controls SPEEDTROL head pressure control

DAMPERTROL head pressure control...........

Part winding start Low ambient start

Compressor lockout

Hotgasbypass...........................

TROUBLE SHOOTING CHART.

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..11::‘:::::::::::::::::::::::..4

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“DAMPERTROL”, “FANTROL”,

“McQUAY”,

of McQuay Inc., Minneapolis, Minnesota.

“SEASONPAK”, and “SPEEDTROL” are registered trademarks

INTRODUCTION

GENERAL DESCRIPTION

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 wired before evacuation, charging and testing. Each unit consists of twin air cooled condensers with integral subcooler sections, multiple accessible hermetic compressors, complete discharge piping and suction connections for connection to any air or water cool-

NOMENCLATURE

ALP-089BD

ing evaporator.

The electrical control center includes all safety and operating controls necessary for dependable automatic operation except for the cooling thermostat since this is somewhat depended upon the unit application. Compressors and fan motors are fused in all three conductor legs and started by their own three pole contactor.

TTT 1-TT

Refrigerant Circuits

Dual; S = Single)

Propeller Fan

INSPECTION

When all 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 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.

Design Vintage Nominal Capacity (Tons)

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 sheetmetal cabinet and end

frame (see Figure 1).

Never allow any part of the unit to fall during unloaing or

moving as this may result in serious damage.

To lift the unit, 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).

Due to the vertical condenser design, it is recommended that certain precautions be taken before installation to orient the unit 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 deflecting fence should be considered.

The clearance requirements for these units are given in

Figure 3.

Each end of the unit must be accessible after installation for

periodic service work. Compressors, filter-driers, and manual

liquid line shutoff valves are accessible from the control center

end of the unit through removable access panels on unit sizes 089,106, and 126 through 179 and hinged side access doors on unit sizes 037 through 078, 091, 098 and 107. All operational, safety, and starting controls are located in the unit control center. Capped connections for field service gauges are

also located inside these enclosures.

CAUTION: Disconnect all power

2V2”

diameter lifting holes are provided in

LOCATION

SERVICE ACCESS

condenser fan drives.

the unit while servicing

Figure 1. Suggested Pushing Arrangement

BLOCKING

Figure 2. Suggested Lifting Arrangement

SPREADER

ACROSS FULL WIDTH

MUST UiE HOLES FOR ALP-0898 THRU

159B. (NOTE CONTROL BOX

LOCATION.)

THESE RIGGING

REQ’D.

lM269 I

Page 3

REFRIGERANT PIPING

GENERAL McQuay type ALP condensing units are adaptable to either chilled water or air handling air conditioning applications, The only restriction on applications is that the evaporator be selected for a system using refrigerant 22.

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.

EVAPORATOR BELOW CONDENSING UNIT Figure 7 shows an installation where the evaporator is installed below the condensing unit. It is shown for an air

han-

dling 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

crosssectional 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 6. Evaporator Above Condensing Unit

Filter-drer

Solenoid valve

Slghtglasslmolsture indicator

d”

Thermal

expansion Suction Ime. pttched Liquid

line

Vlbratton

absorber

Double suction riser (see Note 3)

A&:

valve

toward compressor

NOTES:

1. Piping

shown IS for one circut; second

2. All

pIping

3. Trap for double

and pIpIng components are by others

suction riser

clrcult IS slmllar

should be as small in the

Figure 7. Evaporator Below Condensing Unit

horizontal

dlwctlon as ilttlngs

WIII

allow

AIR FLOW

REFRIGERANT PIPING CONNECTIONS

Refrigerant piping connections must be made at the control center end of the unit. Suction and liquid lines should be routed through the compressor end access panels on units ALP-089B, 106B,

1268 thru 1598, and

179A

and out the

tom through the side access panels above the compressor

McQuay has available a “Liquid Line Accessory Kit” for each ALP unit size. Components selected for these kits were selected on the basis of a total combined pressure drop of 7 psi (includes 100 ft. of tubing). Table 5 shows the ordering number to be used for each ALP unit size. The components in these kits are:

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lM269

side access door on units ALP-037A thru and 107A. When piping, allow room for mounting the

nect

on this same access panel. Figure 8 gives connection

bot-

locations and sizes for all ALP models.