McQuay ALP-045C Installation Manual

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TABLE OF CONTENTS

INTRODUCTION

General Description . . . . . . . . . . . . . . . . . . . . . . . . . ...3

Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3

INSTALLATION

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4

Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4

Clearance Requirements . . . . . . . . . . . . . . . . . . . . . ...4

Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . ...4.5

REFRIGERANT PIPING

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6

Recommended piping arrangements . . . . . . . . . . . . ...7

Refrigerant piping connections . . . . . . . . . . . . . . . . ...7

Recommended line sizes . . . . . . . . . . . . . . . . . . . . . ...8

Holding charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8

Pressure testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8

Leak testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8

Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

Charging the system . . . . . . . . . . . . . . . . . . . . . . . . . ...9

Hot gas bypass components.. . . . . . . . . . . . . . . . . ...9

Refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

Weight of refrigerant in copper lines.... . . . . . . . . ...9

Pressure-vacuum equivalents . . . . . . . . . . . . . . . . ...10

PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . ...10.11

DIMENSIONAL DATA . . . . . . . . . . . . . . . . . . . . . ...12.13

FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . ...14.15

Wire sizing ampacities . . . . . . . . . . . . . . . . . . . . . . ...16

Compressor and condenser fan motors . . . . . . . . ...17

Thermostat wiring and capacity reduction . . . ...17.18

Water piping for chilled water applications , . . . . . ...18

Flow switch for chilled water applications . . . . . . . ...18

Evaporator fan interlock

for air handler coil installations . . . . . . . . . . . . . ...19

UNIT LAYOUT&PRINCIPLES OFOPERATION

Major component locations . . . . . . . . . . . . . . . . . . ...19

Control center . . . . . . . . . . . . . . . . . . . . . . . . . . ...19.20

Electrical legend . . . . . . . . . . . . . . . . . . . . . . . . . . . ...21

Unit disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...21

Sequence of operation . . . . . . . . . . . . . . . . . . . . . . ...22

TYPICAL WIRING SCHEMATICS

Power schematics . . . . . . . . . . . . . . . . . . . . . . . ...23-39

Control and safety schematics . . . . . . . . . . . . . ...40-42

Thermostat schematics, . . . . . . . . . . . . . . . . . . ...43-45

Wiring schematic decision tables.. . . . . . . . . . ...46.47

STARTUP&SHUTDOWN

Pre-startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...48

Initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...48

Temporary shutdown . . . . . . . . . . . . . . . . . . . . . . . . ...48

Startup after temporary shutdown . . . . . . . . . . . . . ...48

Extended shutdown . . . . . . . . . . . . . . . . . . . . . . . . . ...48

SYSTEM MAINTENANCE

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...49

Fan shaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . ...49

Electrical terminals . . . . . . . . . . . . . . . . . . . . . . . . . ...49

Compressor oil level . . . . . . . . . . . . . . . . . . . . . . . . ...49

Oil Equalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...49

Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...49

Refrigerant sightglass . . . . . . . . . . . . . . . . . . . . . . . ...49

SERVICE

Filter-driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...50

Liquid line solenoid valve . . . . . . . . . . . . . . . . . . . . ...50

Thermostatic expansion valve . . . . . . . . . . . . . . . . ...50

IN-WARRANTY RETURN MATERIAL PROCEDURE

Copeland compressor . . . . . . . . . . . . . . . . . . . . . . . ...51

Components other than compressors . . . . . . . . . . ...51

APPENDIX

Standard Contr61s:

Oil pressure safety control . . . . . . . . . . . . . . . . . . . ...51

High pressure control . . . . . . . . . . . . . . . . . . . . . . . ...52

Low pressure control . . . . . . . . . . . . . . . . . . . . . . . . ...52

FANTROL head pressure control . . . . . . . . . . . ...52.53

Compressor lockout . . . . . . . . . . . . . . . . . . . . . . . . ...53

Compressor motor protector . . . . . . . . . . . . . . . . . . ...53

Optional Controls:

SPEEDTROL head pressure control . . . . . . . . . . . ...54

Compressor unloaders . . . . . . . . . . . . . . . . . . . . . . ...54

Low ambient start . . . . . . . . . . . . . . . . . . . . . . . . . . ...54

High ambient unloader . . . . . . . . . . . . . . . . . . . . . . ...54

Part winding start . . . . . . . . . . . . . . . . . . . . . . . . . . ...54

Phase/voltagemonitor . . . . . . . . . . . . . . . . . . . . . . ...55

Hot gas bypass (field installed) . . . . . . . . . . . . . . . ...55

ALP controls, settings&functions . . . . . . . . . . ...56. 57

Troubleshooting chart . . . . . . . . . . . . . . . . . . . . ...58.59

Page2/lM269

“FanTrol”, “McC!uay”, “

of McQuay Air Conditioning, McOuay International, Minneapolis MN

G 1995 McOuay Air Conditioning. McQuaylnternational. Minneapolis. MN

“Bulletin illustrations cover the general appearance of Mc@ay International products al the time of publica! ior,

and we reserve the right to make changes in design and construction at any time without notice”

SeasonCon” and “SpeedTrol” are registered trademarks

INTRODUCTION

GENERAL DESCRIPTION

McQuay type SeasonCon air cooled water 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, and comes complete and ready for installation. 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 cooling evaporator.

NOMENCLATURE

INSPECTION

When the equipment is received, all items should be careful-

Iy 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 car-

rier and a claim should

be filed. The unit serial plate should

The electrical control center includes all safety and operating controls necessary for dependable automatic operation except for the cooling thermostat since this is somewhat dependent on the unit application. Condenser fan motors are fused in all three conductor legs and started by their own three-pole contractors. Compressors are not fused but may be protected by optional circuit breakers, or by field installed fused disconnect.

be checked 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.

NOTE: Unit shipping and operating weights are available

in the physical data tables on pages 10 and 11.

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 unloading or

Figure 1. Suggested Pushing Arrangement

BLOCKING REQ’D. ACROSS FULL WIDTH

moving as this may result in serious damage.

To lift the unit, 21/2” diameter lifting holes are 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).

Figure 2. Suggested Lifting Arrangement

,,,,,.,, 8,,

FIECOMMENWO (uSE CAUTION)

MO,, NUMBER 0, F..% FROM, H,SO,A. R U,,(NC METHOD R, MA, NS THE SAME

LIFT UNIT OWL Y AS SHOWN

(NOTE .0.,,0, 80., ’0,.,,0.,

IM 269 I Page 3

HOLES

LOCATION

Care should be taken in the location of the unit to provide proper airflow to the condenser, minimizing effects on condensing pressure.

Due to the vertical condenser design of the ALP-120 thru 230 chillers, it is recommended that the unit is oriented so that prevailing winds blow parallel to the unit length, thus

minimizing the effects on condensing pressure, If it is not practical to orient the unit in this manner, a wind deflector should be constructed.

Minimum clearances as shown in Figure 3 will prevent most discharge air recirculation to the condenser which will have a significant effect on unit performance,

SERVICE

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 on each side of the unit adjacent to the control box. High pressure, low pressure, and motor protector controls are on compressor. Most other operational, safety and starting controls are located in the unit control box.

Figure 3. Clearance Requirements ALP-045C thru 230C

6 !7. MIN. CLEARANCE

4 FT. MIN.

CLEARANCE au

FOR SERVICE

ACCESS

FOR AIR INLET

i-~ ~ti

6 FT. MIN. CLEARANCE

FOR AIR INLET

6 FT. MIN.

CLEARANCE

FOR AIR

INLET

VIBRATION

Vibration isolators are recommended for all roof mounted installations or wherever vibration transmission is a consideration. Table 1 lists spring isolators for all ALP unit sizes. Figure 4 shows isolator locations in relation to the unit control center. Figure 5 gives dimensions that are required to secure each

ACCESS

On all ALP units the condenser fans and motors can be removed from the top of the unit. A complete fan/motor assembly should be removed for service.

CAUTION: Disconnect all power to unit while servicing condenser fan drives.

NOTES:

(1)Minimum clearance between units is 12 feet, (2) Units must not be installed in a pit that is deeper than the height of the unit (3) Minimum clearance on

each side is 12 feet when installed in a pit.

ISOLATORS

McQuay isolator selection to the mounting surface. Table 3 shows the isolator loads at each location shown in Figure 4, and the maximum loads for each McQuay selection are shown in Table 2.

Table 1. Vibration Isolators (Spring)

ISOLATOR LOCATIONS

SUE

045C CP

055c CP

t=!=

------ ..-— — ——, .

Cl CPI.!17 I CP1.W I CP1-28 I CP1-32 I CP1-32 I CF

Iooc,-..-.,- .. --,-..--, ----, - -11OCICP1-32

120C I CP1-27

~ CP2-27

Page 4 I IM 269

CP1-32 CPI-32 CP1-32 CP2-27

CP1-32 CP2-27 CP2-27

CP1-27 CP1-27 CPI-32 CPI-32

CPI-32

CP2-27 CP2-27

‘1-28

CP1-32

Table 2. Spring-flex Isolators

TYPE COLOR

P+.25 RED 4n927A-25

----

tiP1-26

CP1-27 ORANGE

CP1-28

CP1-31 CPI-32

CP2-25

CP2-28

CP2-27

CP2-28

CP4-27

CP4-28 CP4-31

CP4-32 WHITE 580513A-32

MAX. LOAD EACN

0-=.)

2200

2400

3000

4400

5200

McOUAY

PART

NUMBER

PURPLE

GREEN

WHITE

GRAY

RED

PURPLE

ORANGE

GREEN

ORANGE

GREEN 58051 3A-26 3600

GRAY

477927A-26

477927A-27 477927A-26

4n927A-31 1100 4n927A-32 4n929A-25 900

477929A-26

4n929A-27

477929A-26 4n929A-31 4n929A-32 2600 580513A-26 58051 3A-27

58051 3A-31

450

600 750

900

1300

1200 1500 1800

Figure 4. Isolator Locations

Table 4. Isolator Locations

—c—

Table 3. Isolator 1m=~=

ALP

? UNIT

SIZE 1

: 045C

055C

~ 070C

Osoc

‘ 090C

100C

‘ 11OC

120C

, 135C

, 150C

wbc

185C

: 205C

230C

ISOLATOR LOADS AT SACH FAOUNTING LOCATION (l-SS.)

.“”””

556 706 736 831 859 867 945

986 1135 1279 1327 1376 1423 1569 1643

2 555 687 720 845

934 946 952

1062 1108 1144 1375 1553 1596

3 441 428 466 618

621 806 643

1051 1115 1128 1205 1399 1510

4 556 706 736 631 659 945 986

1135 1279 1327

1378

1423 1569 1643

5 555 687 720 845 867 934

946 952

1062 1108

1144

1375 1553 1598

6 441 426 466 618 620 621 806 643

1051 1115

1128

1205 1399 1410

VIBRATION MOUNT LOCATION DIMENSIONS

Figure5. Spring Isolators

ORDERING NO.

477927A-26 THRU 477927A-32

(INCHES)

ORDERING NO.

477929A-25 THRU 477929A-32

ORDERING NO.

580513A-26 THRU 580513A-32

Ls.oo --- I

7,,0 ~

0,50 Dia. Positioning

Acoustical No..Skid Neoprene Pad

Adjust Mounting So Upper Housing Clears Lower HousinQ By At Least IW and Not More

2“%Ezili

6 F

Acoustical No..Skid Neoprene Pad

_ 10.25 .—~

Adjust Mounting so Upper Housing Clears Lower Housing By At Least 114” and Not

More Than 1/2”.

~ Acoustical Non:Skid

Neoprene Pad

IM 269/ Page 5

REFRIGERANT

PIPING

GENERAL Piping design, sizing and installation information presented in ASHRAE Handbooks should, where applicable, be followed in the design and installation of piping. 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 R-22.

REFRIGERANT PIPING Piping between the condensing unit and the cooling coil must

be designed and installed to minimize pressure drop, prevent liquid refrigerant carryover to the compressor and to assure a continuous return of compressor oil from the system.

Piping sketches and tables are not intended to provide information on all of the possible arrangements. For example, when dual circuit evaporators are used with an unloading compressor, two liquid line solenoid valves may be used to reduce coil capacity with compressor unloading. Note especially that dual circuit evaporators should not be piped with common liquid and suction lines to more than one compressor circuit. Separate evaporators, evaporator circuits and piping must be run for each compressor circuit.

Piping recommendations include:

The use of type K or L clean copper tubing. All joints should

be thoroughly cleaned and brazed with high temperature solder.

Piping sizes should be based on temperature/pressure limitations as recommended in the following paragraphs, Under no circumstances should pipe size be based upon the coil or condensing unit piping connection size. Suction line piping pressure drop should not exceed the

3. pressure equivalent of 2° F (3 psi) per 100 feet of equivalent pipe length. After the suction line size has been determined, the vertical suction risers should be checked to verify that oil will be carried up the riser and back to the compressor. The suction line(s) should be pitched in the direction of refrigerant flow and adequately supported. Lines should be free draining and fully insulated between the evaporator(s) and the compressor. Table 7, page 8, shows piping information for units operating at suction temperatures between 40F and 45 F and a condenser entering air temperature of 95F. If operating conditions are expected to vary substantially from these operating levels, the pipe sizing should be rechecked. Vertical suction risers should be checked using Table 5

4. to determine the minimum tonnage required to carry oil up suction risers of various sizes:

5. The liquid line should be sized for a pressure drop not to

exceed the pressure equivalent of 2° F (6 psi) saturated temperature. The liquid line(s) on all units must include

a liquid solenoid valve wired into the circuit as shown on the applicable unit wiring diagrams.

The control circuit for all compressors has been designed to include a pumpdown cycle. The use of a liquid line solenoid is required for proper unit operation. In addition, a filter-drier should be located between the liquid line service valve and the solenoid valve and a combination moisture indicator/sightglass should be located in the liquid line ahead of the expansion valve.

Suggested piping arrangements are shown on page 7. All multiple compressor units require a separate refrigerant circuit for each compressor. The figures shown are for an air handling installation, but all components shown are recommended for chilled water vessel installations except that a refrigerant distributor is not usually required for shell and-tube evaporators.

If dual suction risers are used:

Double risers are sized so that their combined crosssectional internal area will allow full load unit operation without excessive pressure drop (see notes, Table 7). Riser “A” 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 “B” fills itself with oil. It should be emphasized that the trap shown in riser “B” should be designed to contain a minimum internal volume to keep the total system oil requirements at a minimum. Table 7 gives recommended line sizes for both single and double suction lines and for liquid lines.

The combined cross-sectional areas of the two risers

must be capable of maintaining adequate refrigerant velocity for oil return at full unit tonnage, The extra riser should be of a smaller diameter than

the main riser. The extra riser must include its own trap at the bottom and should enter the main suction header at twelve o’clock. The trap serving the extra riser must be as short as fit-

tings permit. A “U” fitting or the combination of a 90’ standard “L” and a 90C street-L is recommended, The suction line leaving the coil should also include a

trap if the expansion valve control bulb is to be on the horizontal section leaving the coil outlet, See the piping sketches on page 7.

Table 5. Minimum tonnage (R-22) to carry oil up

suction riser at 400 F saturated suction.

Min. Tons

NOTE: When compressor minimum tonnage is less than shown in the above

1.50 2.50 3.80 7.60 13.10 204 29.7 41.3

table for a given line size. double suction risers will be required

Table 6. Equivalent feet of straight tubing for copper fittings and valves

I 90” Lono Radius I 1.0 I

.“-

TEES

VALVES

FITTING TYPE

90” Standard

90” Street 45” Standard

A6. .Wrss! 13 15 91 30

-h, .-

Full Size Reducing

Globe Valve, Open Gate Valve, Open 0.7 Angle Valve, Open 7.0 9.0

518

1.6 2.0

2.5 3.2 4.1

0.8 0.9

-.”

1.0

1.6 2.0

18 22 29

718 1%

2.6 3.3 4.0 5.0 6.0

1.4 I 1.7

“.-

1.4 1.7 2.3 2.6 3.3

0.9

I 2.3 I 2.6 I 3.

1,3

.,.

2.6 3.3 4.0 5.0 6.0

1.0

Page 6 I IM 269

1yf 1V*

5.6

1.7

---

38 43 55 69 84

1.5

15 18 24 29 35

6.3

2.1 2.6 3.2

34 45 57 64 7.3 I 85

---

1.8 2.3 2.8 3.2

2y* 2%

8.2

---

4.1 5.0 5.9 6.7

10.0 12.0 15.0 17.C

..- ----

4.1 5.0 5.9 6.7

31/s 3%

7.5 9.9

4.0

.-. .

7.5 9.0

100 120

4.0 4.5

41~

10.0

4.7

10.0

41 47

[

..-

Figure 6. SINGLE CIRCUIT EVAPORATOR – RECOMMENDED PIPING

If Row Split Coils Are Used, Duplicate The Piping

CONDENSING UNIT AaOVE THE EVAPORATOR

CONDENSING UNIT BELOW THE EVAPORATOR

LlOU10

TO COIL

“L___

SUCTION TRAP SHORT AS FITTINGS PERMIT

EXPANSION VALVE CONTROL BULB STRAP TO LINE AND lNSUIATf

SUCTION TRAP ~ SHORT AS FITTINGS PERMIT

Figure 7. DUAL CIRCUIT EVAPORATOR (FACE SPLIT) – RECOMMENDED PIPING

SUCTION TRAP ~ SHORT AS FITTINGS PERMIT

NOTES:

1. Piping shown is for one compressor circuit; second circuit is similar. Must have separate piping for each compressor circuit.

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

3. The thermal expansion valve equalizer line should be placed just past the thermal sensing bulb on the side or top of the pipe.

4. A separate expansion valve is required for each distributor and mounted per manufacturer’s recommendations. (See additional notes under recommended line sizes, Table 7)

L CXP4NSION VA1bl

CONTROL BULR 5TRAP To LINE AND INSULATE

ION vALVE CONTROL BuLBS STRAP TO LINE AND INSULATE

REFRIGERANT PIPING CONNECTIONS

Refrigerant piping connections will be made at the com-

pressor end of the unit. Suction and liquid lines should be

routed through the compressor enclosure on each side of the

unit. When piping, allow room for the unit disconnect and field

wiring to the unit. Figures 8 and 9 show piping connections

and sizes for each ALP model.

IM 269 I Page 7

Table 7. Recommended line sizes

COMPRESSOR CIRCUIT #1

ALP UNIT SIZE

055C 13&15h 070C 080C 090C

100C 15/&2~h

11OC

120C 2%J—25/8 135C 27+2Y8 3X? 150C

DOUBLE

.A9*_,4

1%-1 ye

1%-15h 15h—21A I

5~—2y8

15y&2y3

214—25A

170C 21h—25h 1MC 27’s-2y8 31~

205C 21&31~ 3% 230C

NOTES: Recommended line sizes shown in the above table are based on the unit

operating conditions between 40F and 45 F saturated suction temperature and condenser entering air temperature of 95F, per 100 ft. equivalent length 4. of tubing. When design conditions vary, the table values should be rechecked.

1. Liquid and suction lines based on a recommended equivalent pressure drop of 2F (3 psi for suction line, 6 psi for liquid line) per 100 ft. of equivalent length,

2. When refrigerant required to charge a circuit exceeds the pumpdown capacity of that circuit the use of a separate refrigerant storage receiver will be required. The pumpdown capacity (shown in Table 10) is based on the condenser 90% full at 90” F.

3. Wherever vertical rise occurs in the suction piping, the minimum tonnage

2%-31~

SINGLE

slJ~*,oN LIQulD

~,,

21h

z~~ 1% 15.3 21A 278

278

25~ 13~

2% 13~

37h 1ye 33.0 58.9

31~

11A

1% 14.7

1ah 16.6 37.6

1ye 21.3

1ye 33.4 66.7 1ye 33.9 73.6 2%-2Y8

1ya 37.9 82.5

1ye 34.4 90.4 21A 35.9 21A 40.0

MINIMUM

PART LOAD

CAPACITY

(TONS)

12.9 19.4

33.2

38.1

FULL LOAD

CAPACITY

(TONS)

23.8

29.0 15/’-21h

42.5 15/+2~h

48.9

56.1

99.8 21/&31~

111.1

COMPRESSOR CIRCUIT #2

DOUBLE SINGLE

,A,9_”

B“ SUCTION

1y&l

5/4

1y&l ya

15/*-21h

1y~—zl~

1y*—21h 2J&278 2J/4-25/a 3%

21&2y~ 37h

21A—25A 3Ys

21&31/s

fer oil entrainment should be checked and where necessary double suction rlsers should be utilized. See Table 5, page 6, Wherever vertical rise occurs in the suction piping on a system with hot

gas bypass, double suction risers may not be needed as the velocity of suction gas is increased at minimum load condtions. Total equivalent feet for a given piping layout must include the equivalent

length of straight pipe for fittings, valves and specialties added to the total run of straight pipe. Piping design, sizing and installation information presented in ASHRAE

Handbooks should, where applicable, be followed in the design and stallation of piping.

‘QU’D

214 11A 15.5 23.6 21A 11A 18.5 29.1 2% 1ya 17.9 35.3 2% 1Y* 16.6 37.6

2% 1ye 21.3 278 13h X3.2 48.9 278 1ye 38.7 56.1 31A 1ya 33.0 58.9

35h 21A 35h

1ya 33.4 66.7 15~ 339 73.6

1y’ 37.9 82.5

15h 34.4 904

21A

.... .... . ... I I

mlnlmum

PART LOAD

-. -.-—.. GAPAUI I Y

m-)

35.9 998

40.0 111.1

FULL LOAD

CAPACITY

(TONS)

42.5

in-

HOLDING CHARGE The Model ALP condensing unit is shipped with a holding charge of refrigerant. At the time the unit was received a visual inspection of the unit piping should have been made to be sure no breakage had occurred or that fittings might have been loosened. A pressure check should indicate a positive pressure in the unit. If no pressure is evident, the unit will have to be leak tested and the leak repaired. This should be noted and reported to your McQuay sales representative or freight carrier if the loss is due to shipping damage.

PRESSURE TESTING

No pressure testing is necessary unless damage was in-

Page 8 / IM 269

curred during shipment or rigging, Damage may be determined by a visual inspection of the exterior piping assuming

no breakage has occurred or fittings have loosened, Pressure gauges should show a positive pressure. If no pressure is evident on the gauges, a leak has probably occurred releas-

ing all or part of the refrigerant charge, In this case, the unit should be leak tested to locate the leak.

LEAK TESTING

In the case of loss of the refrigerant holding charge, the unit should be checked for leaks prior to charging the complete system. If the full charge was lost, leak testing can be done by charging the refrigerant into the unit to build the pressure

to approximately 10 psig and adding sufficient dry nitrogen to bring the pressure to a maximum of 125 psig. The unit should then be leak tested with a Halide or electronic leak detector. After making any necessary repair, the system should be evacuated as described in the following paragraphs.

CAUTION: Do not use oxygen to build up pressure. A serious explosion could be the result.

EVACUATION After it has been determined that the unit is tight and there are no refrigerant leaks, the system should be evacuated. The use of a vacuum pump with a pumping capacity of approximately 3 cu. ft./min, and the ability to reduce the vacuum in the unit to at least 1 millimeter (1000 microns) is recommended.

A mercury manometer, electronic or other type of micron

gauge should be connected to the unit at a point remote from the vacuum pump, For readings below 1 millimeter, an electronic or other micron gauge should be used. The triple evacuation method is recommended and is par-

2. ticularly helpful if the vacuum pump is unable to obtain the desired 1 millimeter of vacuum. The system is first evacuated to approximately 29 inches of mercury. Enough refrigerant vapor is then added to the system to bring the pressure up to O pounds. Then the system is once again evacuated to 29 inches of

3. vacuum. This procedure is repeated three times. This method can be most effective by holding system pressure at Opounds for a minimum of 1 hour between evacuations.

The first pull down will remove about 90% of the noncondensibles, the second about 90%0 of that remaining from the first pull down and after the third only 1/10 of 10% non-condensibles will remain.

Table 12, page 10, shows the relationship between pressure,

microns, atmospheres, and the boiling point of water.

HOT GAS BYPASS COMPONENTS

McQuay offers a “Hot Gas Bypass Accessory Kit” for each ALP unit size. Each kit includes a solenoid valve, a hot gas bypass valve and an instruction drawing. See page 55 for hot gas bypass operation.

Table 9. Hot gas bypass kits

COMPRESSOR

KIT

S86-580698A-01 866-580898A-01 886-580698A-02 886-5S0898A-01 886-5S0698A-02 886-580898A-01 886-580896A-02

LINE SIZES

% ~8

1IA

1*A

11A

REFRIGERANT CHARGE Each ALP condensing unit is designed for use with R-22.

Table 10 lists approximate refrigerant charges for operation of the unit. Additional refrigerant will be needed for the system piping and evaporator. Estimated total operating charge should be calculated before charging system. See Table 11 for weight of refrigerant in copper lines.

CAUTION: Total operating charge per circuit should not exceed the condenser pumpdown capacity

per circuit. A liquid receiver on each refrigerant circuit could be used in this situation. Refer to the ASHRAE Handbook for the design and installation of piping and components.

Table 10. Approximate refrigerant charge

CHARGING THE SYSTEM

Model ALP condensing units are leak tested at the factory and shipped with a holding charge of refrigerant. In the event the refrigerant charge has been lost due to shipping damage, the system should be charged with enough refrigerant to raise the unit pressure to 30 psig after first repairing the leaks and evacuating the system.

After all refrigerant piping is complete and the system has

been evacuated, it can be charged as described in the paragraphs following. Connect the refrigerant drum to the gauge port on the liquid shutoff valve and purge the charging line between the refrigerant cylinder and the valve. Then open the valve to the mid-position.

If the system is under a vacuum, stand the refrigerant drum with the connection up and open the drum and break the vacuum with refrigerant gas. With a system gas pressure higher than the equivalent of

3. a freezing temperature, invert the charging cylinder and elevate the drum above the condenser, With the drum in this position, valves open and liquid refrigerant will flow into the condenser. Approximately 75% of the total requirement estimated for the unit can be charged in this manner. After 75% of the required charge has entered the con-

4. denser, reconnect the refrigerant drum and charging line to the suction side of the system. Again purge the connecting line, stand the drum with the connection up, and place the service valve in the open position.

IMPORTANT At this point charging procedure should be interrupted and prestart checks made before attempting to complete the refrigerant charge. See startup procedures on page

48.

NOTE: It is recommended that the total operating charge per

circuit be stamped on the unit nameplate for future reference.

146

45 45 60

60 60

.-JC

070C 080C

090C 1Ooc

230C

NOTE: Condenser pumpdown capacity is based on ANS1/ASHRAE Standard

15-1976 rating of 90°/0 full of liquid at 900F. To convert values to the older

ARI standard (80% full at 800 F), multiply pumpdown capacity by 0,888.

19 19 45 19 19 45

26 26 26 26 60

26 28

99 99

148

Table 11. Weight of refrigerant R-22 in copper lines

(Pounds Per 100 Feet of Type L Tubing)

Weight of Refrigerant, Lba.

0.054 3.84

0.100

112

0.162 7.12 .605 .156

0.336 24,0 1.26 .323

11A 0.573 40.8 1% 0.872

1% 1.237 88.0 2~~ 2.147 25/8 3.312 31~ 3% 6.398 4% 8.313 592.0 31.1 8.00

4.728 336.0 17.7 4.55 6.750

7.12 .374 .096

62.1

153,0

236.0 12.4 3.18 4.720

456.0 24.0 6.15 9.140

.202

2.14

3.26 .839

4.62 1.190 1.770

8.04

. . —.

Suction Gee

(Superheated to 65” F)

.052

.550

2,06 3.060

.077

.143 .232 .480 .620

1.250

11.190

IM 269 I Page 9

Table 12. Pressure-vacuum equivalents

50 100 150 200

300

500 1,000 0.019 759.00 2,000 0.039

4,000 0.078 6,000

8,000 0.156 10,000 0.193 15,000 0.290 745.00 29.330 20,000 0.387 30,000 50,000 0.967

100,000 200,000 3.670 560.00 22.050 600,000 760,000 14.697 0

0 760,00 29.921

0.001 759.95 29.920

0.002

0.003

0.004

0.006 759.70 29.910

0.009

0.117 754.00 29.690

0.580

1.930 860.00 25.980

9.670 260.00 10.240

759.90

759.85

759.80

759.50 29.900

758.00 29.840

756.00 29.760

752.00 29,600

750.00

740.00 29.130 730,00

710.00 27.950

29.920

29.920 1/5,100 —33

29.910

29.880

29.530

28.740

PHYSICAL DATA

— —

1/15,200 1/7,600 — 40

1/3,600 1/2,500 — 21 1/1 ,520 — 12 1/760 1 1/380 15

1/189

1/127 1/95 1/76 1/50 1138 72 1125 84 1/15 101 2/1 5 125 114 213 192

1 Atmosphere 212

— 50

— 28

152

29 39 46 52 83

NDITIONS,TONS 0 T CIRCUITS

ER COMPRESSOR

C)DTlntd Al CTAC!KIC

“, ,, W! .-L “In”,, .”

CONDENSERS- HIGH EFFICIENCYFIN AND TUSL . ,, - ....,, ....-”..,.- ““””””— .

COIL FACE AREA, SQUARE FEET I 28.9 28.9 1 43.3 43.3I433 FINNED HEIGHT FINS PER INCH

CO&NSEiFANS-lili.. . ..... . ... . . .. . .._

NUMBEROF FANS – FAN DIAMETER,INCHES 4–26 NUMBEROF MOTORS– HORSEPOWER 4– 1.0 4– 1.0 FAN AND MOTORRPM 1100 FAN TIP SPEED, FPM 7760

TOTAL UNIT AIRFLOW, CFM 28,460 29,640 42.030

NOTES: @ Nominal capacity based on 950F ambient air and 450F saturated suction temperature @ Capacity reduction sequence depends on how the thermostat is connected. @ Cylinder bore for 50 hp: 2,6875; for 40 hp: 2.9375 (inches).

Cylinder stroke for 50 hp: 2.3438; for 40 hp: 2.1875 (inches).

X FINNED LENGTH, INCHES I4OX1O414OX1O4140x156140x156140x156140x156140x208140x208140x208140x206]40x206 140x208l~x208 140x208

X ROWS D)EEP

IECTDRIVE PROPELLERTYPE

43.0

2 2

4 4

12.500012.667512.6875 2,9375 2.9375 2.6875 2.6875

0-28-50-78-100 O-27-5C-77-I00

NA NA NA

IF TVDC WITU lhlTC130Al Cl lRf!!l Cm

I 12X2 16x2

52.9

25 30 30 35 34

4 4 4

.ziwu-r+luu U-z< -sY-u 1- ! w

1 16x2

4–26

1100 1100 1100 1100 1100 7760 7760

0-28-50-78-100

16x2 j 12X2 16x2I16x2

64.1 2

43.9 [ 58.5

6 6 6 6 6 8 8

43.3 I 57.8

6–26 8–26 8–26 8–26 10–.2%

6– 1,0

75.3

58.5 j58.5 I 585

35 40 40 54 547

2.6875 2,9375 2.9375 2.6675 2..5875

O-3366-83-1OQ

G17-33-50- o-17-32-5c- &25-50-6?- 0-25-50.6S

67-83-100

57.6

16x2I16x2

8– 1.0

7760

54,240 54,240 54,240

65.1

2 2 2

K13-8&83-l 00 0.25-50-75-103 O-25-5C-75-1OO

67-83-100 75-88-1oo 75-88-1OC

I 57.6 57.8 I 57.8 57.8 1 57.8

16x2 1 16x2 16x2 [ 12X3

8–1.0

7760 7760

97.7

I 585 5&5 1862 I 862

8– 1.0

112.1

608C

2.9375 2.9375

10– 1.0

llCO

n60

62.CCO

57.8

12x3

Page

10 / IM 269

Table 14.

1200

Of&l I ckt.2 I CkLl I ckt.2

UNIT CAPACllY@ARlCONDITIONS,(TONS)@ NUMBEROF REFRIGERANTCIRCUITS

UNIT OPERATING[ PUMPDOWNCAPACITY, 900/0FULL @ 90”F CABINET DIMENSIONS,L X W X H, INCHES UNIT WEIGHT, LBS. ADD’L WEIGHT IF COPPERFINNED COILS, LBS.

: COfdPfE880f?8 - COPELAMETICFULLY AGGRiWI%t

NOMINALHORSEPOWER NUMBEROF CYLINDERS PER COMPRESSOR CYLINDERBORE, INCHES CYLINDERSTROKE, INCHES OIL CHARGE PER COMPRESSOR

~ CAPACITY REDUCTIONSTEPS - PERCENTOF COMPRESSORDISPLACEMF”’

STANDARDSTAGING

) HEIGHT X FINNED LENGTH, INCHES ~0 X206~0 X206~0 X208180 X208~0 X208160X206~0 X208180X2C

CHARGE,LBS. R-22

. ... . .. . ... . .. --------- - --. ., ..--. .—. -

117.8 1334> 147.2

56.1 ] 56.1 70.2

86.2 86.2 141 229X83X 59 229X83X 92

5860 6783 7099

stmi.ntnsmIw

35-25

8-4

2.6875 2.6875

=1211375 ]2187512167521875121675121875 12~875lNote3INote312~ 12~

~60-1361160-136 ~6Ll136~

0-13-60-80-100 or

.,,\

1103 1236

35-25 35-25

6-4 6-4

2.6875

.“7.

U-L(-55-73-1OO

0-27-55-82-100

I1400CAC

ALP MODELNUMBEN

135C 150C

EI+T(NOTE Q

Cftt.1 I CW2 1 Cfrt.1 I CM.2

—

2. 2

70.2 )0.4 70,4 73.2 73.2 141 141 ‘1 .141 141

229X83X 92 229X83X 92 229X83X 92 263X83X 92 263X83X 92

1388

35-35 35-35

6-6

2.6675 2.6875

0-25-50-75-100

40-40 40-40

35-35

6-6 6-6 8-8 8-6 6-6 8-8

2.9375 2.9375

2.6675

170C

164.9 2 2

141

\7299

1388, 2060

0-17-33-42- 0-14-27-41-

50-75-100 54-77-100

105C

Cfd.1 ckt.2

180.8

88.5 98.5 96.5 98.8

68.5 203 203

6005

50-40 50-50

50-40

Note 3 2.6875 2.6675

Note 3

2060 220C’

Cld.1 ckr.2 Ckt.1 citt.2

199.5 222.1

230

9081 9301 2429 2429

0-12-24-37- 0-13-25-37-

49-73-100

2 2

I 98.8

230 I 230

230

50-50

60-60

8-6 8-8 M

2.9375

2.3436 2.3438

50-75-100

60-80

2.9375

TOTAL UNIT AIRFLOW, CFM

NOTES: 0 Nominal capacity based on 95°F ambient air and 45°F saturated auction temperature. @ Capacity reduction sequence depends on how the thermostat is connected. COCylinder bore for 50 hp: 2.6875; for 40 hp: 2.9375 (inches)

Cylinder stroke for 50 hp: 2.3438; for 40 hp: 2.1875 (inches)

62,000

76,500

87,480

67,480

81,960

Table 15. Major Components

COMPRESSOR CONTACTOR DESIGNATION FOR COMPRESSOR

4D-20 hp 4D-25 hp 4D-30 hp 6D-35 hp

Eli

090C

1Ooc

I1OC

Osoc

6D-35 hp

6D-40 hp 8D-50 hp

BD-60 hp

120C 6D-35 hp

135C

150C 6D-35 hp

w$:$~k.i,

...

NOTES:

1. All units have two independent refrigerant systems.

2. Compressors 1 and 3 used on Circuit 1 of 4-compressor units. Compressors 2 and 4 used on Circuit 2 of 4-compressor units.

3. Compressors 3 and 4 of 4-compressor units do not use unloaders.

G:. ,.

-$’”*W “t ..’5:.$% “ $

6D-35 hp

6D-40 hp

8D-50 hp 6D-50 hp

6D-60 hp

4D-25 hp 4D-30 hp

6L-W” ,IV

6D-40 hp ] — 8D-50 hp 6D-60 hp ] — 6D-35 hp 6D-35 hp 6D-35 hp 6D-35 hp ] 6D 8D-40 hp 6D-40 hp 6D-40 hp 8D-50 hp 6D-50 hp 8D-50 hp 8D-60 hp 8D-60 hp

— — —

1 1 1

— —

4D-25 hp

— — —

—

4D-25 hp

)-35 hp 6D-40 hp 6D-40 hp MI–M5 M2—M6 8D-50 hp 8D-60 hp

M1—M5 M2—M6 — MI—M5 M1—M5 M2—M6 —

Mi—MK

,.! . . , ...- ..M1—M5 M2 MI—M5 M2—M6 —

MI–M5 M2—M6 — MI—M5 M2—M6 I —

MI—M5 M2—M6 M3—M7 M1—M5 M2—M6 MI–M5 M2–M6

M1—M5 M2—M6

MI—M5 M2—M6

M2—M6 —

M7—M6

&flJ6 — —

95,820

M3—M7 M4—M6 M3—M7 M4—M8 M3–M7 M4—M6 M3–M7 M4—M6 M3–M7 M4—M8

— —

95,620

— — —

M4—M8

IM 269 / Page 11

Figure 8. Dimensional Data — ALP-045C thru 120C

~ 2.5

,—

ABINET

DIA. LIFTING HOLES

AIR DISCHARGE

,o~

Eli/

Lli J

2.0 TYP. -’~

SPACING FOR

1.00. DIA ISOLATOR MOUNTING HOLES (6)

Mac

Ossc 070c Oaoc Osoc 100C 226.7 11OC 226.7 5.7 120C

122.7

175.7

228.7 7.2 7.2 22.6

228.7 7.2

226.7

39.2

9.0

9.5

8.7

5.7

9.0 21.6

8.7 22.6

7.2 22.6

7.2 24.6

5.7 27.2

39.2 23.6

22,3 38.3

22.6 43.6 22,6 43.6

22.6 46.5 24,6 46.5

27.2 46,5

27.2 46.5

23.8 97.5

11OC

120C

00 00 00 00

61,6 22,8 43,6 52,2

43.6 52,2

46.5 52,2

46.5 52,2 46,5 52.2 46,5 52.2 97,5 93.7

FAN ARRANGEMENTS

080C 090C 1Ooc

070C

00 00

1ye

15h 2% 21A 2% 21A 21/i 21A 21A 25A 2% 25h

1ye

278 278 2%

055C

00 00

045C

% %

7% % % % 7%

11A 11A

CENTEROF lSOIATOR

7/8 % % 7/8

‘h

1~~ 11A

51.0

65.0

66.0

64.0

63.0

80.0

81.0

85.9

13.0 43.0

13.0 58.0

13.0 56.0

13.0 58.0

109.0

162.0

215.0

Page 12/ IM 269

Figure 9. Dimensional

CONTROL

CENTER

lid

1-8-’4

cONTROL POWERENTRY

KNOCKOUTFOR !4If CONDUIT,

BOTHSIDES OF UNIT

— ALP-135C thru 230C

Data

2.5,1 DIA. LIFTING HOLES

FAN ARRANGEMENTS

150C

135C

———

170C 185C

00 00 00

205C 230C

00 ::

00 00 00 00

II 4

CKT. 2 SUCTION CONNECTION,2%11

(4)

Dimensions in Inches

AK!

DISCHARGE

+~ 2.O’TYP.

SPACINGFOR

1.00~ DIA. iSOiATOR MOUNTING HOLES(6)

LENGTH ‘ “.

23SC

263.4

B ‘. ~ 6 ‘ ;.3 :’ “

39.0

24.6

101.4

100.3

ISOLA’TO,RLOCATIONS

ii ‘ ‘

13.0

“,.:”’.s-’’ ,”:

95.0

249.7

IM 269 / Page 13

FIELD WIRING

Wring must comply 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.

Copper wire is required for all power lead terminations at

the unit while either aluminum or copper can be used for all

other wiring.

ALP units may be ordered with internal power wiring for either single or multiple point power connection. If single point power connection is ordered, a single

block or non-fused disconnect switch is provided and wiring

within the unit is sized

in accordance with the National Elec-

large power terminal

trical Code. A single field supplied disconnect is required, An optional factory mounted transformer may be provided,

If multiple point wiring is ordered, three power connections,

Figure 10. Typical field wiring diagram for ALP-045C

L),,mnn,d

,Ph,––-r,l--r,l

~“w::z:::---~;j;j

By O!her.

Termna-

PB 1

U“,!Ma!”

Bl,ck

one per compressor circuit plus one for condenser fans, are required and wiring with the unit is sized in accordance with

the National Electrical Code. Separate field supplied discon-

nects are required for each of the three circuits. A single power block is provided for all of the condenser fans and the

optional 115V control transformer.

CAUTION: Internal power wiring to the compressors for the single point versus the the multiple point option are different. It is imperative that the proper field wiring be installed according to the way the unit is built.

Figures 10, 11 and 12 show typical field wiring that is required for unit installation, Items that require field wiring are liquid line solenoids (SVI and SV2), optional hot gas bypass solenoid (SV5) and the cooling thermostat as well as the unit power supply.

— 080C with 4 steps of capacity control

Condense,U.(I Comrx-m”

●nd Fan

M.!ors

F.,,(F,]

L..i—,

cont..! stop SW!ch,,,,

510

T,rm<na!, For

T1’,mmsta!s

8 yl+

2!3

slag, 4 G+ >N;

Co”d,n,>ngU“ 1

control,

236

PSI ,,,

,,2

~—@+w&”-–@Y ---

‘Lp’Occ’’OcO”” la”””’

camp, .1

217

Page 14 / IM 269

●NOTE: Standard M separate Pcwr supply c,rcaI1s for ccc:rols

LEGEND:

@ FIELD WIRING TERFIINAL

———

— FACTORY WIPING

‘-— OPTIONAL FACTORv WIRING

FIELD WIRING

BK BLACK WIRING (LINE)

WHITE WIRING (NEUTRAL)

Figure11.Typicalfield wiring diagram for ALP-080C –

10C with 6 steps of

capacitycontrol

D!mmcec! B, Olht.

—

.--” . . ...%

Si’+-:-::--?: ! :

CO.,*

stop

S.”ch,e%)

Nom mm.”.w!m. m .?4

5?0 m 0“.,.11 t,-. dock .“d !!0. ,.,,,.

t 570

L-#J;.i ~ 2aii.-e-.jNn

m 1

U“ll u.,.

TWm..( B-k

—--—

..-’3,”.!!

_ ,

OPI’.”.,~“-

Ca.tr.i Tr..,tc.me!

C.tatncec “.<1 C.m,re’t.m

. . . F.. ..,.-

---—--i”

----4

Figure 12. Typical field wiring diagram for ALP-120C –

ym;:w. ,OA m-

—*W m

NOTE: For ALP-120C, 135C, and 150C, R3 and R4 would replace the compressor un-

loaders for compressors 3 and

4 of those size units. See page

43 for a typical diagram.

?’(9a No,.)

,.” p,,

L.i —, —,

‘aMld Stw S“llchl”)

~ NOTE R.Mv. .1”. - .“d

—.-—--

s, 0,.,.,,.11 ,he dock sw lb. ,wl,ch

Stm

Stw.e 3

w+- ‘z

CW2

213

Stls+ 4

(+ ~c- ‘~

,13

S,qw 5

@:I-o- Y

230C with 8 steps of capacity control

~+TF&y_

C4nds.sing U“(I

Cantmh

R78

R17

ALP , 8SC–2W Only

117

..—

c-w .,

Sting. 6

SW.9 7

SW+ a

IM 269 / Page 15

Table 16. Wire Sizing Ampacities

3PH, 60 HZ

ALP MODEL

045C

055C

070C

090C

1Ooc

Iloc

120C

135C

150C

170C

185C

205C

230C

ELEC. POWER

POWER SUPPLY O

208 230 184 460 @

208 1 278

208 230

5ktt

208 412 230 412 460 @ 207

460 (B 575 203

208 230 460 ~ 575 222

206 708 230

4600

575 266 208 767

230 767 460 @ 575

206 230 460 @ 575

Single Point

Power Supply

184

I 93

292 292

246

533 533 267

652 331

385

314 926

926 455 373

WIRE SIZE AMPS @

Muitlple Point Power Supply O

Elec. Ckt. 1 Elec. Ckt. 2 Elec. CM. 3

Fene & tintrols Cornpr.Cti. 1 hmpf. m. 2

25.6 79

25.6

12.8

12.7

25.6 96 133

25.6

12.6 49 66

12.7 39

33.6 I 133 140

33.6 16,8 16,7 45

41.6

41.6 140

20.8 70 21,5

41.6

41.6 175 175 (1) 3“

20.6

21.5

41.6

41.6 221

20.8 110 110 (1) 2V2°

50.6 217

25.3

26.3

50.6 217

50.6

25.3

26.3

58.6 252 252 (1) 4“

58.6 252

29.3 126 126 (1) 21/2“

30.7 101 101

58.6

58.6 315 315 (2) 3“

29.3 160 160 (1) 3“

30.7

56.6 359 359 (2) 3“

58.6 346

29.3 175 175 (1) 3“

66.6 452 452 (2j 4“

33.3 225 225 (1) 4“

35.6 180

79 39 49 (1) 11/’4”

33 39

133

66 70

140

56 56

191

69 69

221 221

109 109 (1) 2v2 “

87 87

217

109

344

122 122

133 (1) 23/2”

140

191

221

217

252 252

126 (1) ZV2°

101

252

344

346

180 (1) 3“

POWER ENTRY HUB

QUANTIYY & i

Slngb Point

Power Supply

(1) 2“

ilj 2

‘l’ ,,,

(1) 23/2”

(1) 11A” (Ij IIA,I

[1)2M”

{lj 2Th” (1) lvz”

(1) l!~,,

(1)2V2“

(1) 2V2“

~1j 1VZ” (1) 11/4,,

(1) 3“

~lj 2

1) 11/2”

(1) 4“ (1) 4“

~lj 4!s

(1) 2“ (1) 49’

ilj 4’

‘1’ 2<,

(1) 4“ (1) 21/2,,

(2) 3“

21/2,,

~1j

(2) 3“

mm. Point

Power supply

(1) 2“ (1) 2“ (1)

l%”

~lj lIA.

(1) 272” (1) 27/2“

(1)lYz”

11) 11~”

(1) 3“ (1) 3“ (1) 2’”

Jl) 1

1/2,,

(1) 3“

(1) 3“ (;) :“

(1) 4“ (1) 4“ (1) 2“

, 2.,

(1) 4“ (1) 4“ (1) 21/2“ (lj 2v2 r’

(2) 21A” (1) 1“ (2) 2Y2“ (1) 1 “ (1) 2V2“

jl j 21/2,,

(2) 2“ (1) 1’” (2) 2“ (1) 1“ (1) 21/2“

(1) 21/2“ (1)1’’(1)2’’(1)2 ?>”

(1)1’’(1)2’’(1)2Y” (1) 2Vz” ~lj z~hn

(1)1“(2) 2V2“

(1) 1“ (2)

(1) (1) 21,2,,

(1) 1“ (2) 3“ (1) 1“ (2)3” [1) 3“ [1) 21/2”

[1) 1“ (2) 3“ (1) 1“ (2) 3“

ilj 3 [1) 1“ (2) 3“

[1) 1“ (2) 3“’ [1) 4’” [1) 3~/’2“

:1) 1“ (2) 4“ :1) 1“ (2) 4“ ‘1) 4“ ;1) 4“

2Y, “

3“

ELECTRICAL DATA NOTES

0 ALLOWABLE VOLTAGE LIMITS:

Unit nameplate 208V/60Hz/3Ph: 187V to 253V

(except ALP-090C: 180V to 220V)

Unit nameplate 230V/60Hz/3Ph: 187V to 253V

(except ALP-090C: 207U to 253V) Unit nameplate 460V/60Hz/3Ph: 414V to 506V Unit nameplate 575V/60Hz/3Ph: 517V to 633V Unit nemerYate 360V/50Hz/3Ph: 342V to 418V

@ Compressor RLA values are for wire sizing purposes only and do not reflect

normal operating current draw If unit is equipped with SPEEDTROL motors,

the first motor on each refrigerant circuit is a 230V single phase, 1 hp

RLA of 5.6 amps

with an

@ Compressor LRA for part winding start are for the first winding. If the unit

Page 16 / IM 269

motor,

is equipped with SPEEDTROL motors, the first motor on each refrigerant circuit is a 230V single phae, 1 hp motor, with an LRA of 145 amps Unit wire size amps are equal to 125% of the largest compressor-motor

(!3

RLA plus 100o1oof RL4 of transformer Wre size amps for separate 115V control circuit po;er is 12 amps for all units shown.

Quantity and size of power entry hub(s) provided with unit

E’

Single fxJint ~wer supply requires a single fused disconnect to supply electrical power to the unit. Multiple point power supply requires three independent power circuits with

separate fused disconnects Data also applies to 380V/50Hz/3Ph units

all other loads in the circuit includnq control

Table 17. Compressor and Condenser Fan Motors

XEO ROTOR AMPS @

COMPRESSORS

056C

“ 070C

080c

beoc

100C

11OC

.1200 ““”

f35c

160C

170C

185C

206C

Z30C

,.,’

(1) 31 (1) 39

208 (4) 4.0

230 (4) 4.0 4600 575

208 (6) 4.0 230 (6) 4.0 46063 (6) 2.0 575 (6) 2.2

208 (8) 4.0 230 (8) 4.0 460 @ (6) 2.0 575 (6) 2.2

206

230 (6) 4.0 460 @ (6) 2.0 575 (8) 2.2

208 (8) 4.0 230 460 @ (8) 2.0

575

208 (lo) 4.0 230

. .

460 @ (lo) 2.0 575

208 230 (lo) 4.0 460 @ (lo) 2.0 575

208 (lo) 4.0 230 460 @ 575

208 230 (12) 4.0

460 @ (12) 2.0

575

208 (12) 4.0 230 (12) 4.0 460 @ (12) 2.0 575

206 230 (12) 4.0 460 @ (12) 2.0 575

208 (14) 4.0

230 460 @ (14) 2.0 575

208 (14) 4.0 230 (14) 4.0 460 @ (14) 2.0 575 (14) 2.2

(4) 2.0 (4) 2.2

(8) 4.0

(8) 1.6

(lo) 4.0

(10) 1.6 (lo) 4.0

(1o) 2.2

(lo) 2.0 (lo) 2.0 (lo) 2.2

(12) 4.0

(12) 2.2

(12) 2.2 (12) 4.0

(12) 2.2

(14) 4.0

(14) 2.2

REFER TO PAGE 16 FOR ELECTRICAL DATA NOTES

(1) 26 (1) 31 (1) 77 (1) 106

(1)77 (1) 106

(1) 39 (1) 53

(1) 31 (1) 36 10.3 (1) 106 (1) 112

(1) 106(1) 112 (1) 53 (1) 56 9.9 (1) 36 (1) 45 10.3

(2) 112 (2j 112

(2) 56

%--t-ik

i2i 71

{2j 66 (2) 201

(2) 201 17.0

%--HE

(2j 56 (2j 39

(2) 45 (2) 31 10.3

w--l--+

i4i 56 (4j 45

(4)

153

h--l-+

I I

10.3

17.0

9.9

10.3

17.0

9.9

7.9

(2j 565 (2) 283 (2) 156

{2j 405 (2) 1070

(2) 1070 (2) 656

(2j 565 (2j 428 @j 340 @j 250 (2) 283 (2) 214

(2) 230 (2) 172 (3) 565 (1) 426

(3) 565 (1) 428 (3) 340 (1) 250 (3) 283 (1) 214 (3) 156 (1) 117 (3) 230 (1) 172 (3) 138 (1) 103

(4) 565 (4) 565 (4) 230 i4i 283 i4j 230 i4j 138

(4) 660 (4) 400

(zj340

(2j 262 (2) 654

(2) 156(2) 117 (2) 138 (2) 103

(3) 340 (1) 250

(4) 340

I i4i 156

km--l-L

i4j 510 I i~ 330

THERMOSTAT WIRING

Since it is impossible for McQuay to anticipate the type of

installation that an ALP condensing unit maybe used on, we mostat so that as successive stages of cooling are called for, do not provide a thermostat. We do, however, provide the compressors in the unit will be started to alternately innumbered terminals inside the unit control center to which a thermostat maybe connected. These terminals are shown and labeled “Terminals For Thermostat” on the electrical show typical staging sequences for 4, 6 and 8 step schematics. thermostats.

On a two-circuit unit it is important to connect the ther-

crease the condenser load from refrigerant circuit 1 to circuit 2. This is illustrated in Table 17. Figures 10, 11 and 12

IM 269 / Page 17

Table 18. Capacity reduction

UNIT WrTH STANDARD

ELECTRICAL COMPONENT

ENERGIZED SUCTION PRESSURE CONTROLLED

UNIT

ALP

SIZE

Svl +Ul

45C, 055C

070C

Sot, Oeoc SVl+Comp. l, U2(Ul da-energized) Ooc,

20C, 135C SVI + Comp. 1 (UI, U2 de-energized)

150C SV2 + Comp. 2 (U1, U2 de-energized)

70C, 05C, 230C

NOTES:

1. Compressor staging for units with suction pressure controlled unloaders and unloaders controlled from a remote source (discharge air, return water, efc ) is the same

2. See page 54 for more information on unloaders controlled from suction pressure.

SV2 + U2

SV1 (Ul de-energized) SV2 (U2 de-energized) SV1 +Comp. 1, Ul, U2 SV2 +Comp. 2, Ul, U2

11OC SV2+Comp.2, U2(Ul da-energized)

SVl+Comp, 1 (Ul, U2 de-energized) SV2 + Comp, 2 (Ul, U2 de-energized) SVI +Comp, 1, Ul, U2 SV2 +Comp. 2, Ul, U2

SVI + Comp. 1 + Comp. 3 (R3 energized) SV2 + Comp. 2 + Comp. 4 (R4 energized) SV1 +Comp. 1, I-H, U2 SV2+Comn. 2. U1. U2 SV1 + Comp, 1 (U1, U2 de-energized) SV2 + Comp. 2 (Ul, U2 de-energized)

1S5C

SV1 + Comp. 1, U1, U2 + Comp. 3 (R3 energized) SV2 + Comp. 2, UI, U2 + Comp. 4 (R4 energized) SV1 + Comp. 1 + Comp. 3 (Ul, U2 de-energized) SV2 + Comp. 2 + Comp. 4 (Ul, U2 de-energized)

CAPACITY REDUCTION

UNLOADERS

Stage 1 Stage 2 Stage 3 Stage 4 Stage 1 Stage 2

— —

Stage 3 Stage 5 Stage 4 Stage 6 Staga 1 Stage 1 Stage 2

— —

Stage 3 Stage 4 Stage 6 Stage 1 Staoe 2 Stage 3 Stage 3 Stage 4

— —

Stage 5 Stage 6

UNtTS WITH OPTiONAL CAPACITV REDUCTION

—

— —

Stage 1 Stage 2 Stage 3 Stage 4

Stage 2 Stage 3 Stage 4 Stage 5

Stage 1

Staae 2

Stage 4 Stage 5 Stage 6 Stage 7 Stage 6

WATER PIPiNG FOR CHILLED WATER APPLICATIONS

Due to the variety of piping practices, it is advisable to follow the recommendations of local authorities. They can supply the installer with the proper building and safety codes required

for a safe and proper installation.

FLOW SWITCH FOR CHILLED WATER APPLICATIONS

A WATER FLOW SWITCH MUST BE MOUNTED in either the entering or leaving water line to insure that there will be adequate water flow and cooling load to the evaporator before the unit can start. This will safeguard against slugging the compressors on startup. it also serves to shut down the unit in the event that water flow is interrupted to guard against evaporator freeze-up.

A flow switch is available from McQuay under ordering

number 860-175033B-O0. it is a “paddle” type switch and

adaptable to any pipe size from 1” to 6“ nominal. Certain

Table 19. Flow switch minimum flow rates

NOMINAL PIPE SIZE

(INCHES) ACTIVATE SWITCH (GPh3)

11A

11/2

21/2

3 30.00 4 39.70 5 58.70 6 79.20

MINIMUM REQUIRED FLOW TO

6.00

9.80

12,70

18.80

24.30

minimum flow rates are required to close the switch and are listed in Table 18. installation should be as shown in Figure

13. Electrical connections in the unit control center should be

made at terminals 5 and 6. The normally open contacts of the flow switch should be wired between these two terminals. There is also a set of normally closed contacts on the switch

that could be used

dicate when a “no

Figure 13.

for an indicator light or an alarm to inflow” condition exists.

Flow Oireclion

1.00 NPT FIOW Switch

L,,,,, 0,. -M”,rn”nl

Switch

Aiter

~ 5 Pipe Oia -Minimum

eefore %ftch

Page 18 I iM 269

EVAPORATOR FAN INTERLOCK FOR AIR HANDLER COIL INSTALLATIONS

It is important to interlock the air handler evaporator fan with

the condensing unit control to insure that there will be a cool-

ing load on the evaporator before the unit can start to pre-

vent compressor slugging. A pair of terminals for each

refrigerant circuit is available in the unit control center for this

UNIT LAYOUT & PRINCIPLES OF OPERATION

purpose. Remove the jumpers between terminals 111 and 112 for circuit 1 and211 and 212 for circuit 2. Use these ter-

minals for the evaporator fan interlock contacts. Be sure to keep circuits separate by using two contacts on dual circuit machines.

-J

Figure14.

Major Component Locations

The figures below illustrate component locations within the unit for each unit size.

COMPRESSOR No. 1

~ E? I@@@@

COMPRESSOR No. 2

L- -1

TOP VIEW OF UNIT

205C, 230C

COMPRESSOR No. 1

COMPRESSOR

No. 2

CONTROL CENTER

All electrical controls are enclosed in a weatherproof control center with keylocked, hinged access doors. The control center is composed of two separate compartments, line voltage and control voltage, All of the line voltage components, except for the input terminals of the PVM, are

‘\

— COMPRESSOR No. 4

located in the compartment on the right side of the unit. The control voltage components are located on the left side with the live terminals located behind a deadfront panel. This protects service personnel from live terminals when accessing the adjustable and resettable controls.

IM 269 / Page 19

CONTROL CENTER LAYOUTS – ALP-045C thru 11OC

————_

Figure 15. Left Side, 115V Control Section

Figure 16. Right Side, High Voltage Power Section

7 FHmmI

ODDOU

PB2

PB3

————

CBS

CB1

.—— ——— —

II EII

CONTROL CENTER LAYOUTS — ALP-120C thru 230C

Figure 17. Left Side, 115V Control Section

TB5 (40–63)

Raceway

[ TB4(II0-124)(210-224) I I I ~[~

I II

TB6 (70–93)

Raceway

GRD 9

NOTE: PB1, PB2, PB3 are used with multiple point power wiring.

Figure 18. Right Side, High Voltage Power Section

PVM

PB2

n PB3

~mmjm

——————

.——————

—. —

————

——

EIEI

Page 20 / IM 269

EIEI

mIimEIE

NOTE: PB1, PB2, PB3 are used with multiple point power wiring.

ELECTRICAL LEGEND

DESIGNATION

AB Cll, C21

CBI-S

COMPFI.1-4 CP1 CP2 DAC1 DAS1 DW FI F2 FB1–4 FS5 FB6–10 FBI ,2 GFI GRD

HPI, 2

—4

HTRI

HTR5

JB5 JS6

LP1 , 2 Ml–lo MI1-27 MJ MPI-4 MTR1 1-27 NB NSS

OP1–4

PBI–3 PC1–4 PC5, 6

PC8–10 PC12-22 Psi, 2 PVM

DESCRIPTION STD. LOCATION

ALARM SELL

CAPACITORS FOR SPEEDTROL MOTORS

CIRCUIT BREAKERS, COMPRESSOR MOTORS COMPRESSORS 1 THRU 4 CENTRAL PROCESSOR CENTRAL PROCESSOR SATELLITE DISCHARGE AIR CONTROL DISCHARGE AIR SATELLITE DISCONNECT SWITCH, MAIN FUSE, CONTROL CIRCUIT FUSE COOLER HEATER FUSEBLOCKS, COMPRESSOR MOTORS FUSE SLOCK, CONTROL POWER FUSESLOCKS, FAN MOTORS

FREEZESTATS, CONTROL GROUND FAULT INTERRUPTOR GROUND

HIGH PRESSURE CONTROLS

HEATERS, COMPRESSOR CRANKCASE

HEATER, COOLER BARREL

JUNCTION SOX FOR COOLER HEATER JUNCTION SOX FOR HEAT RECOVERY

LOW PRESSURE CONTROLS CONTRACTORS, COMRPESSOR CONTRACTORS, FAN MOTORS

MECHANICAL JUMPERS

MOTOR PROTECTORS, COMPRESSOR

MOTORS, CONDENSER FANS NEUTRAL SLOCK NIGHT SETBACK OIL PRESSURE CONTROLS POWER SLOCK, MAIN PRESSURE CONTROLS, SPECIALS PRESSURE CONTROLS, HI AMSIENT UNLOAOER PRESSURE CONTROLS, SUCTION UNLOAOER PRESSURE CONTROLS, FANTROL PUMPDOWN SWITCHES PHASE VOLTAGE MONITOR

FIELD MOUNTEO

BACK OF CONTROL SOX OR ON BULKHEAD CONTROL SOX

BASE OF UNIT CONTROL SOX CONTROL SOX CONTROL SOX CONTROL SOX CONTROL SOX CONTROL SOX CONTROL BOX

CONTROL SOX CONTROL BOX CONTROL BOX SUCTION LINE NEAR COOLER CONTROLSOX CONTROLSOX ON COMPRESSOR ON COMPRESSOR WRAPPEO AROUNO COOLER

SARREL NEAR COOLER ON SASE RAIL UNOERSIOE OF COIL ON lNTERMEOIATE TUSE SHEET ON COMPRESSOR CONTROL BOX CONTROL SOX CONTROL BOX COMPRESSOR JUNCTION BOX CONOENSER SECTION CONTROL BOX CONTROL SOX CONTROL SOX CONTROL SOX CONTROL SOX OR ON UNIT ON COIL HEADER

CONTROL SOX ON COIL HEADER CONTROL SOX CONTROL SOX

DESIGNATION

Rl, 2 R5–8 R9–12 R13, 14 R3, 4, 17, IS R19 R21 ,22

R23-30 RS14 51 S2-4 S5 SC1l, 12

SL1 Svl , 2 SV5, 6 SV1O, 20

Svll, 21 T1

T2 T3 TS2

TS3 TB4-6 TCI TC2 TCIO TC11 TC12 TC12-25 TOI-4 T05–S T09, 10 TO1l, 12, 13 TO14 T015, IS T017; 18, 19 T020–24

U1, 2

OESCFNPTION

RELAYS, RESET OR ALARM RELAYS, SAFETY RELAYS, STARTING RELAYS, LOW AMBIENT START RELAYS, CAPACITY CONTROL

RELAY, HEAT RECOVERY RELAYS, HI AMBIENT, HI RETURN SUCTION UNLOAOERS RELAYS, SPECIALS RESET SWITCHES SWITCH, CONTROL STOP SWITCHES, LEAO-LAG SWITCH, HEAT RECOVERY SPEEO CONTROLS

SOLENOIO 000R LOCK SOLENOIO VALVES, LIc2UI0 LINES SOLENOIO VALVES, HOT GAB BYPASS SOLENOIO VALVES, WATER CONOENSER (NORMALLY OPEN) SOLENOIO VALVES, AIR CONOENSER TRANSFORMER, MAIN CONTROL TRANSFORMER, 24V CONTROL TRANSFORMER, FAN SPEEOTROL TERMINAL BLOCK, 120V, FIELO TERMINAL BLOCK, 24V. FIELO TERMINAL BLOCKS, CONTROL THERMOSTAT, UNIT THERMOSTAT, COOLER SARREL THERMOSTAT, SPECIAL THERMOSTAT, HIRETURN WATER UNLOAOER CONTROLSOX THERMOSTAT, SPECIAL THERMOSTATS, FANTROL TIME OELAYS, COMPRESSOR LOCKOUT TIME OELAYS, COMPRESSOR PART WINOING CONTROL BOX TIME OELAYS, LOW AMSIENT TIME OELAYS, COMPRESSOR SEQUENCING TIME OELAY, ALARM BELL TIME OELAYS, FREEZESTAT TIME OELAYS, HEAT RECOVERY TIME OELAYS, SPECIAL UNLOADERS

WATER &

S70. LOCATION

CONTROL BOX CONTROL BOX CONTROL BOX CONTROL SOX CONTROL SOX CONTROL BOX CONTROL SOX

CONTROL BOX CONTROL BOX CONTROL SOX CONTROL SOX CONTROL BOX SACK OF CONTROL SOX OR ON BULKHEAD CONTROL SOX CONOENSER SECTION CONOENSER SECTION CONOENSER SECTION

CONDENSER SECTION CONTROL SOX CONTROL SOX ON BULKHEAD CONTROL BOX CONTROL BOX CONTROL BOX CONTROL SOX ON COOLER cONTROL sox OR ON UNIT

CONTROL SOX OR ON UNIT CONTROL BOX CONTROL BOX

CONTROL BOX CONTROL SOX CONTROL SOX CONTROL SOX CONTROL SOX CONTROL SOX ON COMPRESSORS

Figure 19. Recommended Unit Disconnect Location

HINGEO 000RS ON CONTROL CENTER

NOTE: MOUNT DISCONNECT ON STATIONARY PANEL SO THAT IT 00ES NOT INTER. FERE WITH HINGED 000RS OR WITH AIR INTAKE INTO COIL.

S.00 MIN.

4’

IM 269 I Page 21

NORMAL SEQUENCE OF OPERATION

The following sequence of operation is typical for ALP SEASONCON air cooled condensing unit, models ALP-045C through ALP-230C (items in italics apply only to Mode/s

ALP-720C thru ALP-230C). The sequence varies somewhat

depending upon options.

Startup

stop switch S1 closed, 115V power is applied through the control circuit fuse F1to the compressor crankcase heaters HTR1, HTR2 (HTR3, HTR4), the compressor motor protectors MP1,

MP2 (MP3, MP4) and the primary of the 24V control circuit transformer. The 24V transformer provides power to the contacts of the low pressure controls LPI and LP2 and the com-

pressor lockout time delays TDI and TD2.

When the remote time clock or manual shutdown switch

turns on the chilled water pump, the flow switch closes and

115V power is applied to the relay contacts on the unit ther-

mostat. The unit will automatically operate in response to the

unit thermostat provided the manual pumpdown switches PS1 and PS2 are closed (in the ‘(auto” position); the compressor

lockout time delays TD1 and TD2 have closed, energizing the safety relays R5, R6 (Rz R8); and the freezestats FS1 and

FS2, high pressure controls HP1 and HP2, and compressor motor protectors MP1, MP2 (MP3, MP4) do not sense failure conditions.

On a call for cooling, the unit thermostat energizes the liquid line solenoid valve SV1 for refrigerant circuit #1. This opens the valve and allows refrigerant to flow through the expansion valve and into the evaporator. As the evaporator refrigerant pressure increases, the low pressure control LPI closes. This energizes the compressor starting relay R9, starting the compressor via the compressor contractors Ml and

With the control circuit power on and the control

—

M5. Closing the R9 contacts also energizes the condenser

fan motor contacts Mll, M12, M13 and M14, starting the fan

motors.

As additional stages of cooling capacity are required, the

unit thermostat energizes the liquid line solenoid valve SV2

of the refrigerant circuit #2. After the compressor sequenc-

ing time de/ay TD77 has closed, the same starting sequence is initiated in refrigerant circuit #2.

If still more cooling is required, the unit thermostat will start the remaining compressors and then de-energize unloader solenoids until the capacity requirement is met.

Pumpdown energize unloaders and unload the compressors, and then de-energize the liquid line solenoid valves SV1 and SV2, causing the valves to close, When the compressor has pumped most of the refrigerant out of the evaporator and into the condenser, the low pressure controls LPI and LP2 WiIIopen, shutting down the compressors and the condenser fan motors, If refrigerant leaks into the evaporator, the increse in pressure will cause the low pressure control LPI or LP2 to close, This will energize the compressor starting relays R9 or R1O and start the compressor, which will quickly pump the refrigerant out of the evaporator and into the condenser (recycling pumpdown).

A compressor which repeats recycling pumpdown every 5

minutes indicates a malfunction due to the temperature con-

trol or a system cause. A build up of heat in the compressor without proper cooling of suction gas could cause a

mechanical failure in the compressor. McQuay recommends

corrective measures be taken if the compressor recycles

repeatedly within 15-minute intervals. “

— As the unit thermostat is satisfied, it will

CANADIAN

Canadian units which are CSA listed and are equipped for multiple point power connections have a sticker (see figure at right) next to the wiring diagram in the control box, This notifies the installer that local authorities may require the unit to be connected to a single electrical power source. Check with local authorities for requirements.

CSA LISTING

Although this unit may

be provided with options requiring more than one source of electrical supply, some electrical inspection authorities may require this unit to be connected to a single external electrical supply.

Page 22 / IM 269

TYPICAL POWER WIRING DIAGRAMS

SINGLE POINT, WITHOUT SPEEDTROL

ALP-045C ALP-045CI055C —

— 2081230V, AL, PW

380/41 514601575V, AL, PW

Ill

P%l

F“=E

L_L_T*’”

,,..,

+&t-t-.+’ ,

.!, 0“ ““ITS WITH

s.0/.13/4.0 /57,“-AL.

!.”.

...

=%l=’=z

FB6

Ml!

.--,,,—

—,!, —

—,, ,—

FB7

M!2

m=’== =

ila---”

—,, s—

1“

f’”’%+y:[

7+”k @~; - –

COMPR

=0 V./50-60 HZ

FROM 0S1 Q& PBI

+1++ “ b.’+ ’:2

, ‘-tam “ *.A%

o+”’L,

“--l=+ ~~

“*M

L1— L2

T( 12

—

I F05

—

ALP-055C, 2081230V

./,

,eo/41s/4eon73 v-AL.

INCLUDESCB6 FORCOMPRESSOR

0“ ““11s WITH

200 V /60 HZ

FROM 0S1 sx PO!

U- L2

,1 TZ

—

FROM DSI E PB1

U- LZ

,2 I

—

4AG.1+

““’+mky:,

!15 v.

I ,05

—,,.—

—l, s—

FROM 0S1 E PBI

u- L2

,1 12

“,H3H2H4

kid

FROM 0S1 X PBI

F,5

U- L2

,, T2

—

I F,,

I ,,5

575 V/60 HZ

FROM 0S1 S& PE 1

u- ,2

,1 12

—

““’a;:,

,15V

I FB5

— l,e —

—,m -

—,,,—

sz—

—.-,

— ,53 —

—,s.3—

—,,,—

—!s*— —,53—

,.,.

IM 2691 Page 23

MULTIPLE POINT WITHOUT SPEEDTROL

ALP-045 CI055C – 2081230V, AL, PW

380/41 51i601i75V, AL, PW

~:~

PHASE/VOLTAGE

MONITOR

,32

ELECTRICAL CIRCUIT ● 1

Ill

_,, ,—

—!,, —

—r, ,—

7+”2,, ,,”%- ,,,,

cOMPR

e g’

o-l+ ,2 ,, ,2

, ‘+ ‘3 ‘3 ‘3 - “’

‘“+”’L

‘+ L2

12+ L3

I l%%-%

IFe_Y’”

GRO LuG

- C,RC

—FROM Psl — I

l—

,, ,.

“, “3 “, . .

TJi!F

—

.$’”’+3,:3

I ,05

—

—,,.—

—l,, —

—l, ,—

—l,c —

—,,,—

—!,, — —,, , —

—l, o—

—,,.— —,,,—

—l, ,—

Page 24 I IM 269

.,.

SINGLE POINT, WITH SPEEDTROL ALP-045C

ALP-045CI055C

– 2081230V, AL, PW

— 380141514601575V, AL, PW

—,0! —

— ,0,—,!,

11. %&&-t”””

— ,o, —

1+”’,, ,,%+

COMPR.

ALP-055C, 20W230V INCLUDESCB6 FOR COMPRESSOR#2

COMPR

-l+. n

‘+ ‘*

~+”’ ,,

:+ Ls

,/, 0“ u,,, w,,”

SS0/4 lB/4MP7~ U - AL .

7+”2., ,,‘2T-#-

4+ ,, . %i-

‘+ ‘s

o-G”’L,

“i+ L,

“w 3

“/, 0“ WI,,, w,,”

S9./4lS/_O/S7S V.-AL.

,% _*+

+d-

.*&

— ,e7—

— ,o. — — ,.*—

—,lo —

—,, ,—

—,,2=

—,, ,—

—,14—

—,ls —

—,,, —

—1,2—

— ,,, —

— ,,. —

—,3, —

— ,,, —

300 V./X7-60 HZ

FROM DS, QE PB,

,,— ,,

,, ,2

—

l-l

[ ,,5

FROM DSI m PBI

,1— M

,, ,2

—

FROM 0S, QL PB,

,1— u

—

“’td.d:,

““2*;:

,,5 v . . .

I ,,5

,, I F05

~’”’+y,:c

FROM DSI Q& PBI

mm m, Q& PO!

,,—,,

,, ,,

—

“1 “, .2 “.

I ,05

“’”’*Y,

575 v/60 HZ

,,0. 0s, n PBI

L1— .2

,, ,,

—

,,5 v

I ,05

—,,o —

—(51—

— ,,, — — ,,, —

—,,o—

—-,,1—

—1,2—

—,s3—

lM 269 / Page 25

SINGLE POINT, WITHOUT SPEEDTROL ALP-070C, 080C, 090C

ALP-1OOC

– 2081230V, AL, PW

– 380/41514601575V, AL, PW

FB6 Mll

%=’=z

“%5,, WIT”

ALP-070C, 080C, 090C, 208/230V ALP-1oOC,380/415/460/675V INCLUDESCB5 & CB6 FOR COMPRESSORS#1 & #2

‘+q+-

... ... .

FROM M ~ P81

,1— ,2

,( ,2

—

“1 “2 “4

—

~’”’ey~

I ,,5

sOo/4! s/460/,7, v -A,

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c“ !_

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—

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Page 26 / IM 269

MULTIPLE POINT, WITHOUT SPEEDTROL ALP-070C, 080C, 090C, 100C — 208/230V, AL, PW

380/41 514801575V, AL, PW

ELECTRICAL CIRCUIT ● 1

Ill

,,,

n-n-l “or

I 1-

F=E

l- Jxl-

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IM 269 I Page 27

SINGLE POINT, WITH SPEEDTROL ALP-070C, 080C, 090C

ALP-1OOC

– 2081230V, AL, PW

– 380/41514601575V, AL, PW

F“a:

L---,*’”

MONITOR

——

“,. w ““!7s WITH

ssor4!,/4.o/s7, v -m.

ALP-070C, 080C, 090C, 208/230V ALP-100C, 380/415/460/575V INCLUDESCB5 & CB6 FOR COMPRESSORSal & #2

“k,, .“ ““,,, w,, ”

We., !s,+$o,,,s v-.,.

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Page 28 I IM 269

230 V/60 HZ

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—

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SINGLE POINT, WITHOUT SPEEDTROL

ALP-11OC

– 2081230V, AL, PW

380/41 5/4601575V, AL, PW

i ‘VM 4-’”

--i-t

FB6 Mll

-m=’

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z—

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IM 269 / Page 29

MULTIPLE POINT, WITHOUT SPEEDTROL ALP-I 10C

— 2081230V, AL, PW

380/41 514601575V, AL, PW

.—

7+M2L,

COMPR

GE’

380 v/50-60 HZ

—FROM P81 —

-g’” ~,o;g

x, xl

a-b L, T, ,+- ~g

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,1— ,2

,$ ,2

w .2 “4

—

415 v/50HZ

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x. :

—

,,. .,

I ,,5

“ xl ’00+

501+1,=0.

230 V/60 HZ

— ,!?0. PSI —

u- ,,

,, ,2

—

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L502 ~ ~~oz

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Page 30 / IM 269

SINGLE POINT, WITH SPEEDTROL ALP-1 10C

– 2081230V, AL, PW

380141 514601575V, AL, PW

F+

PBI , ,

“~“or‘1~ E;

SPEEDTROLTRANS. IT31

3.30/415 B60/Y75 V. ONLY

SEE c~”fC1lON Dl&ORAUS ABOVE

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FB6

L, ,,

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NL?.&

ALTER”ATC TERII(N,L ❑UM.E*S ‘0” ,PfFO,ROL “O,.”,

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—

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— ,*. —

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IM 269 / Page 31

SINGLE POINT, WITHOUT SPEEDTROL ALP-120C, 135C, 150C, 170C

– 380141514601575V, AL, PW

(ALP-185C, SEE NOTE)

FBB

—— ——

~14 I_E:=

—,c —

— c,—,!,

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— ,.. —

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ALP-120C, 135C, 150C, 170C, 20W230V ALP-185C, 280/415/460/575V INCLUDESCB5, CB7, CB6 6 CB6 FOR COMPRESSORS#l, #3, #2, & #4

““,,, .!, ”

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380 V/SO-60 HZ

mm 0s! 51 PO!

— LZ

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E?E

FROM 0S1 SE PBI

4diIAJ!:l

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115 v

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—,,,,—

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Page 32 / IM 269

SINGLE POINT, WITH SPEEDTROL ALP-120C, 135C, 150C, 170C – 380141514601575V, AL, pw

(ALP-185C, SEE NOTE)

PBI

——

“+””

PVM ,2

+’”

“+32——

lASE/VOLTAGE

I-t “’ii--l-r

—

,Os—

‘-+..,,.0“ “N,,, WT.

380/415/.6 olB75 V- A..

ALP-120C, 135C, 150C, 170C, 2081230V ALP-185C, 280141514601575V INCLUDESCB5, CB7, CB6 & CB8 FORCOMPRESSORS#l, #3, #2, & #4

‘-d? ‘ -%%m-

++4 — 72

COMPR 3

<y -

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,BO/41,/4S0/Y7S V—AL.

COMP R

G- -

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P;.

“+K ‘ T=-+

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‘3+1 = 24

,3 ,3

.,, c., “m,, WITH

,,0/.15/460/575 v – *L .

II Ill

—,,3,-

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FROM 0S1 M PB1

U- L2

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IM 269 I Page 33

MULTIPLE POINT, WITHOUT SPEEDTROL ALP-120C, 135C, 150C, 170C, 185C — 2081230V, AL, PW

380/41 514801i75V, AL, PW

ELECTRIC*L Cllu”ll “ !

Ill

,,, mTn ‘“~

F“”:r

L-x+”

,HASE/VOLTAGE

MON1TOR

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‘++ ,

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COMPR ,

F87 M12

—— ——

Yqy-

380 V/50-60 HZ

—mm PBl —

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ace 46

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ELEC

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—

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—

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Page 341 IM 269

SINGLE POINT, WITHOUT SPEEDTROL

ALP-185C —

COMPR 3

e’

CMPR ,

2081230V, AL, PW

,e”

Ill

qq ‘“y

0s1

PBI ‘I ‘2 ‘3

Ttr,

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se’”

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—

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—

IM 269 I Page 35

SINGLE POINT, WITH SPEEDTROL ALP-I 85C — 2081230V, AL, PW

COMPR 3

COMPR ,

● 9

NOTE

Ml!

——

l,,

—,31

M23

——

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—

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,.. s,,,: -.,, MC-, PS

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—

r,, —

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Page 36 I IM 269

m E3FB5I

“! “2 .4

—

:“2+:: ““’+::

“, !!3 “2 “4

k-d

—

— !so —

—,, ! —

— ,,, —

—.3—

SINGLE POINT, WITHOUT SPEEDTROL ALP-205C, 230C — 2081230V, AL, PW

380141 514601575V, AL, PW

NOTE:

POWER B w, {Pm)

m *O8 *SO”

“MT, ONLY,

,l_ET&

MONITOR

g$ -E?#+

I_.!—— d

FROM DSI Q! ?01

— —_. 1

~g~e

‘ ‘2 J 11-

GRD LUG

FB6 Mll

—— ——

.. ,.,..

-EEFF=-&+

230 V /60 HZ

FROM D51 = ?81

Ill

“,, l-E3

-$U=.

—lo! —

— ,02 —s,s

— !0, —

—m,-

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_.-,!,—

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— l,,A—

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— ,mc -

—ll. —

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380 V /50-60 HZ

FROM .S1 9.E PBI

u-— u

,, ,2

—

“1 “, “4

FROM 0S! E P81

I ,,5

IT-J

“’w,

““z+mkq?

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—,,,—

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IM 269 I Page 37

SINGLE POINT, WITH SPEEDTROL ALP-205C, 230C —

2081230V, AL, PW 380141514601575V, AL, PW

NOT C

,0.,” -w. (m,,

Onm,o.J:,o”

.. —_+ 1 I

Jrt:@$

p: J “ n s

0s1

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NOTE

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—

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— ,,x —

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— !,. —

—,, ,—

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—,s, — — ,.. —

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—

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—,4, —

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—

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Page 38 I IM 269

I KE’”

—,,o —

—,3) —

—-,,, —

—!s, —

—,,!———

—,,*— —,s, —

MULTIPLE POINT, WITHOUT SPEEDTROL

L.Y

I.J

ALP-205C, 230C — 2081230V, AL, PW

380141514601575V, AL, PW

L=F

L-4-’”

pHAsE/ vOLTAGE

MON!TOR

ELECTRICAL CIRCWT * 1

Ill

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lllti2L

2 3

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23+ L,

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EL Ec

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IM 269 I Page 39

ALP-045C, 055C, 070

TYPICAL CONTROL AND SAFETIES WIRING DIAGRAMS

—m~,

5 /y 5.X

—,. o—

e-x

307

‘E%==iL--zf~---z=227

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z, 3

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HTR-I

COMPRESSOR

CIRCUIT # I

4../37, v .,

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“

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-*,c —m,

_,,. _!l*

-108

235

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—*3

—262

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-,’, -

7. *9,

~2,2ai21...:J,_21s=21J

—,4 4

RIO

COMPRESSOR

CIRCUIT # 2

24,

“J

TC23

~ ‘“n’

+“’=+’+2”

,T, ,.

ON .,, -,,0, “,,,, ONLY

.S.J,, n “ .,

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Page 40 I IM 269

ALP-080C, 090C, Iooc, 110C

—

,04

181

J_,,,=,., Q ,W, ~

140co. NC

—,44—

507

+iiL--+

COMPRESSOR

cIRCUIT # I

,1—’2”V’’”J-J

~= TZ

,,. 120 v w,

, “,”

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“’~’’’~’”-

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508

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-,04-

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—220-

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2%=232

LO-PRES5U?E UNL. ~

‘“’+”

RS2

20, +202-2?:

‘z

J_241E#& ~

2.0 co.

“c

COMPRESSOR

CIRCUIT # 2

HTR.2

~+-i:1205::q’

24 vOLTS A, C.

2,.

-260-

239

“

–2s,—,20

-2,2 —

-2.,—2+2

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—267—,7,

-27,–::

-,,4-

-27, —

–,., —gg

-,,6 —!,,

-2@7—

—2,0—,0,

—2s( -!>2

-,,2 —!3,

-2,, — ,38

*7X

206

Q-’”’+

243

ALP-120C, 135C,150C, 170C, 185 C,205C,230C

—504 ~

++,of

—!40—

—340—

—,,.~1,

—H: ~

liJ

::b+342~,

M3-AUX

503

HTR-3

R!!

cOMPRESSOR

343 ~:;:

“’7’”

,l—

‘“’++

,20, /.0/}—.——’

~ ,4,

I .s

-*.c—

—*c2-

-,.3-

-,.. -

-2c5-

—20. -

-,., -

- 22, -

-,, -3!-

-222-

-*23-2J:

-,z*—

-,,,-,,,

-,28 —y,;

—*2,—23-

.Z,. –j::

-*,, —,-

-,, .-

-., ,-

Zcs

-,1--,., ,!3

-2T*—

-,,, —

.7., —:,}.

-?. 1-!,,

-*.2-

-,.,—g?

.2 .$-,..

.,..—

-*,C -..,

-,s —,!2

-,32-.1,

-,33- !2:

—240 —

—.40—

.. ..

M2-AUX

mxz~, ‘

HTR-2

‘“’+ .

L.”’”=””%=

““4+

—444 +~441

—:::+~45 “’

RI 2

RIO

~:;:

2 .22ti,_42,:+

443

300,. !,,4..,,., ,

-,s! -,,0

-z6*—

+-g;

-z., —

_,..

-2,

!—!..

—,,2

—,,.

-2,, -.3.

-,,, —..!

—x

,1,

Page 42 I IM 269

TYPICAL THERMOSTAT WIRING DIAGRAMS

,,4 ,,,

4-STAGE THERMOSTAT — ALP-045C,

JIQE$

WI”,, .,0, $40

R,WVZ

*S,, 10 m,,.,. ,,”s

-!( am n- SWTC” C3”mms.

rTEANib2TA!0Rl

767-$-’’’” ‘-~”’-’’’-’e’’”~~’e’”” --+--’

055C, 070C, 080C, 090C, 100C, 110C

JB===

-,,0 —,,,

-,l!—

-,,2 —

.,,, —

.,!. —

-,,s-

-,!6 -,.,

-,,7 —

-,!, —

-,,, -

-,20 -

%z-Lc ““-

Am 1,0, ““tin ,.,”.

TB4

,11

g ,8.

,s0 ,,3 ~::

1*~* ,,4 ,,,

115

,,, ,8

,, ,,,

118 I Is 120 121 ,22 ,23 ,24

210

,00 2, I

~,, *6.

*SO 2,3 ::i

~9= 214 ,,,

,,, 215 *,, ae

*,7 27s

218 219 m 22,

227. 223 224

4-STAGE THERMOSTAT — ALP-120C,

,[.0”, .,,,s .50, .!0

509 4!S10 TO 1NS74LL TI.E

,,.,. . . . now SW,,.

.0.,.,,,.

I ,,0

PVM

,,,fi~,,,

PH/VOLT. MONITCfl

,,!40”, ..,.

113 @–5TfiGE 3–(+372 ‘D’~373-t4J ‘%”

2,3 219 @–STAGE 4 –(+,72 ‘“%,,,~., ‘:0

I ,8

135C, 150C

L ‘r J

,, S+&

,8 t

,,, ,@3 4B2-

HOTGAS BYPASS

-–+--

,@, 382-

3,4-

.,!0—22,

.,l!—

.3!2 -

.,l, —

.,,. —

.,!, —

-,1.—265 .,17—

.324— 229

.,2,

—*M

TB4

I !0 !!1

l,, ,,.

,,3i::

,,,.

,15

,,6 l,,

3,2

Ila

,,9

,,,

,20 ,,,

,2, ,22

,23 ,24 210

273 ,,,

,,2 2.6 213 X

zg~~ 2,4 ,6,

,,2 215

216 217

.,2 2!E

47, a,

2 4.!

22( 222 2*

224

NOTE: R21 and R22 contacts with optional high head or suction pressure unloading only.

IM 269 I Page 43

6-STAGE THERMOSTAT –

“. . .

.sQ.ul

W!wc, .$0, . . .

Rcw[

.,!0

m ll,,u, ,,., ax. m rLm SWITCH w,.,,,

[T’l%kkm?q

–“J1-& STAGE,–6—MJ

PvM

+kn.

‘VOLT MONITCR ,“0”, .“,.

&STAGE 2 —’&zeo—%LwJ —+ , ,

,,3

@–sTAGF 3–~MJ

ALP-080C,090C, 100C,11OC

1,6

2’22i;”7- 4“8’’”’=

.O “J*’’’-~’”2 ““

L,,, ~––fl=~.

‘“v l_@--!95~

It?

+’==

.,,0 -225

-,!!—

.,,2 —

-,,, —

.,,. —

.,l, —

-m,

.,1,

.,, -—

.,,, —

,*c–

,,z —

,2. —

104

,Ic

<,!

U ,,,

m. ,,, .“’

-~ ● , 1. ,,, ,,5

,* ,, -’

,, ! I I* 7,

,,, ,23 ,2) ,2, ,23 ,24 Ztc

2,. .,, !

k,, 2-

. *r, :T.

-~ 2!4 ,,,

,.. 2!s

*,, ,-s

,, I ,* 2.,

29 .

22 222 m,

6-STAGE THERMOSTAT

PvM

,,,fi~s,,

pH/v0L7 M0N17m

“,”.”, .“,.

— ALP-120C, 135C, 150C, 170C, 185C, 205C, 230C

N0 COWACT

NC COWbCT

‘7 J

,,?+&

E2gE

.s*, —

, !0

+!,

1, ,,,

,,0,13 &

,*S.

, ,,

-,!0 -m

-3 .—

-,!, -

-,!, — ,23

.*I. —

-,!, — .,,, ,W

-,,. —,.,

-,--

-,, — -. , IS

.,*:—

.,*, —

~~, ,8

3-> .$, ,

,,,

,,.

= s“

,,z m

. ‘z .,,

,, -.

= !.

,,. ,22

,24

21.

.2..

*!, :T,

21. ,.,

>17 ?, m

m 22! 222 223 *

~-,

Page 44 I IM 269

,,3

@—5TAGE 5—@72 &373&.,

NO cCNTbCT

213

@—SAGE 6 —~,,, ‘“’’&,,,&MJ 2:

N 0 CONTbCT

,,8

w ‘&

2!8

,2,

M I ,0, 3a2—

., ,

,a, 4e2—

NOTE: R21 and R22 contacts with optional high head or suction pressure unloading only.

-,,4 —,,9

-3,, -,,,

8-STAGE THERMOSTAT – ALP-170C, 185C, 205C, 230C

5, .s

4=J-

-,!0-22,

-,, ,—

-,,, —

-,, ,—

-,,4—

—,,, —

-.,,6-,6,

-,!7—

—,, a—

—3!9—

-,2. —

–3,1-

—3,2 —

-32, —

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-,,,-*’,

-3,6—321

TB4

: m ,,,

l,, .,

,,0 ,,3 :y,

,,~ ● , ,4 ,,,

,!,

,,, !,6 ,,. , ,, lr,,37s

37, ,73 ,19

$77 I*O

,8, ,2 I ,,. ,22

,23 ,2. ,10

,,,

27,

,,2 ,..

,,0 ,13 ;:L

,,3. 2,4 ,.,

,,, 2,3 ,,, 2!,

27.,.70

,,6 ,,,

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.,, 2 t,

507 =73 4,,

22 I ,,4 222 ,,,

NOTE: R21 and R22 contacts with optional high head or suction pressure unloading only.

—327-32s

IM 269 I Page 45

~ Table 20. Drawing Reference Decision Table For ALP-045C thru 230C. 03

. ~ NOTE: Each unit will have three electrical schematics: Power, Safety and Control, and Thermostat.

N m a

Power Schematics for Compressor and Condenser Fan Motors

SINGLE

WITHOUT

20W230V

ALP UNIT SIZE

04s, 066C

120, 136, 160. 177X

120, 135,

11OC

046C

065C

160, mu!

206, 2m

120, 135. ~

120, 136, 160, 1 0(57

11OC 186C

070,080, 090c

1Ooc Iloc

, 0=,.

pAM14#

S231260 343124D 5831 33D 6831420 6033200

683322D 503330D M312ED S831200 583fa30 5031340 6831420 5833220

S833200 583330D 5031220 583130D 5831200 5031380 5033250 583321D 5833290 5031220 5831210 583120D 5831300 5831213D 5833210 5S3327D 5L13329D

MULTIPLEPOINTPOWER

WITHOUT

070, 080,090, 10DC

070, 080, 000, 100C

070, 0s0, 090, 1 Ooc

11OC

045, 066C.

11OC

046, 066C

llDC

120.136, 160, 170, 186C 205, 230C

046, 066C

070, 080, 090, 100C

11OC

120, 136, 160, 170, 186c

205, 230C

5831270 583135D S831430

1383123D 503131 D 58313W2

583120D 5831360 683144D S833240 5033320

5831320 S03140D 1303323D

!M3331D

Table 21. Drawing Reference Decision Table For ALP-045C thru 230C,

Control and Safety Schematics

Table 22. Drawing Reference Decision Table For ALP-045C thru 230C,

Thermostat Control Schematic

WITHOUT

WITH

ALP UNIT SIZE

M5, 055, 070C

080,060,100, 11Oc

045,055, 070C

080,090,100 110C

130 THRU 330C

ORAWING NUMBER

5S3155D.01

5s31560.01

5s333s0-01

5s31530-01

5s31540-01

5333370.01

ALP UNIT SIZE NUMBER

r5”’75c”0’

r?+=’”

130 THRU 330C , ~=354m1

A“

120,135, 150C , 583=3G01

WITH

OUT 6

045 THRU “OC 583174C-01

130 THRU 230C ~351ti1

‘m ‘“Ru ‘oc ‘ 5S3353C.01

ORAWING

CD .

-0

-3

STARTUP AND SHUTDOWN

With all electric disconnects open, check all screw or lug

type electrical connections to be sure they are tight for good electrical contact. Check all compressor valve con-

nections for tightness to avoid refrigerant loss at startup. Although all factory connections are tight before shipment, some loosening may have resulted from shipping

vibration.

On chilled water installations, check to see that all water

piping is properly connected. Check the compressor oil level. Prior to startup, the oil

level should cover at least one-third of the oil sightglass. Check the voltage of the unit power supply and see that

it is within the *1O% tolerance that is allowed. Phase voltage unbalance must be within * 2%. Check the unit power supply wiring for adequate ampaci-

ty and a minimum insulation temperature rating of 75C. Verify that all mechanical and electrical inspections have

been completed per local codes.

PRE-STARTUP

See that all auxiliary control equipment is operative and

that an adequate cooling load is available for initial

startup.

Open the compressor suction and discharge shutoff valves until backseated. Always replace valve seal caps.

Making sure control stop switch S1 is open (off) and pumpdown switches PSI and PS2 are on “manual pumpdown:’ throw the main power and control disconnect switches to “on.” This will energize crankcase heaters. Wait a minimum of 12 hours before starting up unit.

10.

Open all water flow valves and start the chilled water

pump. Check all piping for leaks and vent the air from

the evaporator as well as from the system piping to obtain clean, non-corrosive water in the evaporator circuit.

CAUTION: Most relays and terminals in the unit control center are hot with S1 and the control circuit disconnect on. Do not close S1 until startup.

Double check that the compressor suction and discharge

1. shutoff valves are backseated. Always replace valve seal caps. Open the manual liquid line shutoff valve at the outlet of

the subcooler. Adjustthe dial on temperature controller CP1 to the desired

chilled water temperature. start the auxiliary equipment for the installation.

Check to see that pumpdown switches PSI and PS2 are

n the “manual pumpdown” (open) position. Throw the emergency stop switch S1 to the “on” position. If pressures onthe low side of the system are above 60 psig, the unit will start and pump down. Afterthe compressor lockout timer TDI has timed out, start

TEMPORARY SHUTDOWN

Move pumpdown switches PSI and PS2 to the “manual pumpdown” position. After the compressors have pumped down, turn off the chilled water pump or evaporator fan. It is especially important on chilled water installations that the compressors pump down before the water flow to the evaporator is interrupted to avoid freeze-up.

CAUTION: With the unit left in this condition, it is capable of recycling pumpdown operation. To defeat this mode of operation, move control stop switch S1 to the “off” position.

INITIAL

STARTUP

the system by moving pumpdown switches PSI and PS2 to the “auto pumpdown” position.

After running the unit for a short time, check the oil level in each compressor crankcase, rotation of condenser fans. and check for flashing in the refrigerant sightglass (see “Maintenance”, page 49).

Superheat should be adjusted to maintain between 8 and 12 degrees F.

After system performance has stabilized, it is necessarythat the “Compressorized Equipment Warranty Form” [Form No. 415415Y) be completed to obtain full warranty benefits. This form is shipped with the unit, and after completion should be returned to McQuay’s Service Department through your sales representative.

Close the manual liquid line shutoff valves. After the compressors have pumped down, turn off the

chilled water pump or evaporator fan. Turnoff all power to the unit and to the auxiliary equipment.

Move the control stop switch S1 to the “off” position.

Page 48 I IM 269

STARTUP AFTER TEMPORARY SHUTDOWN Start the chilled water pump. With emergency stop switch S1 in the “on” position, move pumpdown switches PS1 and PS2 to the “auto pumpdown” position.

Observe the unit operation for a short time to be sure that the compressors do not cut out on low oil pressure.

EXTENDED SHUTDOWN

(For startup after extended shutdown, refer to applicable “initial Startup” steps.)

5. Close the compressor suction and discharge valves.

6. Tag all opened disconnect switches to warn against startup before opening the compressor suction and discharge valves.

SYSTEM MAINTENANCE

GENERAL

On initial startup and periodically during operation, it will be necessary to perform certain routine service checks. Among

these are checking the compressor oil level and taking con- on each gauge line. The valves should be closed at all times

densing, suction and oil pressure readings. During operation, except when gauge readings are being taken. On units

the oil level should be visible in the oil sightglass with the com-

pressor running. On units ordered with gauges, condensing, in the plugged ports provided on the suction and discharge

suction and oil pressures can be read from the vertical

FAN SHAFT BEARINGS

The fan shaft bearings are of the permanently lubricated type. No lubrication is required.

ELECTRICAL TERMINALS

CAUTION: ELECTRIC SHOCK HAZARD. Turn off all power before continuing with

following service.

All power electrical terminals should be retightened every six months, as they tend to loosen in service due to normal heating and cooling of the wire.

COMPRESSOR OIL LEVEL

Because of the large refrigerant charge required in an air cooled condensing unit, it is usually necessary to put additional

oil into the system. The oil level should be watched carefully

upon initial startup and for sometime thereafter.

At the present time, Suniso No. 3GS, Calumet R015, and Texaco WF32 oils are approved by Copeland for use in these compressors. The oil level should be maintained at about onethird of the sightglass on the compressor body.

Oil may be added to the Copeland compressor through the oil fill hole in the crankcase. To add oil, isolate the crankcase and pour or pump in the necessary oil. If the system contains no refrigerant, no special precautions are necessary other

supports on each side of the unit adjacent to the compressors.

The gauges are factory installed with a manual shutoff valve

ordered without gauges, Shrader fittings should be installed

King valves on each compressor circuit.

than keeping the oil clean and dry.

If the system contains a refrigerant charge, close the suction valve and reduce crankcase pressure to 1 to 2 psig. Stop the compressor and close the discharge valve.

Add the required amount of oil. During the period the com-

pressor is exposed to the atmosphere, the refrigerant will generate a vapor pressure, retarding the entrance of contaminants. Before resealing the compressor, purge the crankcase by opening the suction valve slightly for 1 or 2 seconds. Close the oil port, open the compressor valves and

restore the system to operation.

OIL EQUALIZATION

Units with four compressors (ALP-120C thru 230C) come equipped with oil equalization lines connecting the crankcases of both compressors in each refrigerant circuit. This allows the oil to move from one compressor crankcase to the other during normal operation, and balance between the two when the compressors are off. This method of equalization prohibits the oil level from dropping below the level of the sightglass. Some difference in crankcase oil levels will still exist during

CONDENSERS

Condensers are air cooled and constructed with 3/8“ O.D. internally finned copper tubes bonded in a staggered pattern into slit aluminum fins. No maintenance is ordinarily required except the occasional removal of dirt and debris from the outside surface of the fins. McQuay recommends the use of

foaming coil cleaners available at air conditioning supply

REFRIGERANT SIGHTGLASS

The refrigerant sightglasses should be observed period- or a restriction elsewhere in the system. On sightglasses

ically. (A monthly observation should be adequate.) A clear glass of liquid indicates that there is adequate refrigerant Kits” listed on page 8, an element inside the sightglass incharge in the system to insure proper feed through the ex-

pansion valve. Bubbling refrigerant in the sightglass indicates that the system is short of refrigerant charge. Refrigerant gas after about 12 hours of operation, the unit should be pumped flashing in the sightglass could also indicate an excessive pressure drop in the line, possibly due to a clogged filter-drier

unit operation.

The oil equalization line contains a manual shutoff valve for isolating a compressor during service work. The ball valves are shipped in the closed position with a tag attached stating “Notice, Valve Shipped In Closed Position. Can Be Opened For Normal Operation.” pressor service, make sure they are opened again for unit operation.

outlets. Use caution when applying such cleaners as they may contain potentially harmful chemicals. Care should be taken not to damage the fins during cleaning. Periodic use of the purge valve on the condenser will prevent the buildup of non-condensables.

ordered from McQuay as part of the “Liquid Line Accessory

dicates what moisture condition corresponds to a given ele-

ment color. If the sightglass does not indicate a dry condition

down and the filter-driers changed.

When valves are closed for com-

IM 269 I Page 49

SERVICE

NOTE: Service on this equipment is to be performed by qualified refrigeration service per-

sonnel. Causes for repeated tripping of safety controls must be investigated and corrected. CAUTION: DISCONNECT ALL POWER BEFORE DOING ANY SERVICE INSIDE THE UNIT.

FILTER-DRIERS

To change the filter-drier, pump the unit down by moving pumpdown switches PSI and PS2 to the “manual pumpdown” position.

UNIT SEE

04SC-2SOC

Move the control switch S1 to the “off” position. Turn off all power to the unit and install jumpers across the terminals shown in the table. This will jump out the low pressure con-

The liquid line solenoid valves, which are responsible for automatic pumpdown during normal unit operation, do not normally require any maintenance. They may, however, require replacement of the solenoid coil or of the entire valve assembly.

The solenoid coil may be removed from the valve body without opening the refrigerant piping by moving pumpdown switches PSI and PS2 to the “manual pumpdown” position.

CIRCUIT NO.

JUMPER ACROSS

TERMINALS

44 to 48

74 to 7a

LIQUID LINE SOLENOID VALVE

trol. Close the manual liquid line shutoff valve(s). Turn power to the unit back on and restart the unit by moving the control switch S1 to the ‘“on” position. The unit will start pumping down past the low pressure setting. When the evaporator pressure reaches O—5 psig, move control switch S1 to the

“off” position.

Frontseat the suction line King valve(s). Remove and replace the filter-drier(s). Evacuate the lines through the liquid line manual shutoff valve(s) to remove non-condensables that may have entered during filter replacement. A leak check is recommended before returning the unit to operation.

The coil can then be removed from the valve body by simply removing a nut or snap-ring located at the top of the coil. The coil can then be slipped off its mounting stud for replacement. Be sure to replace the coil on its mounting stud before returning pumpdown switches PSI and PS2 to the “auto pumpdown” position.

To replace the entire solenoid valve follow the steps in-

volved when changing a filter-drier.

THERMOSTATIC

The expansion valve is responsible for allowing the proper amount of refrigerant to enter the evaporator regardless of cooling load. It does this by maintaining a constant superheat. (Superheat is the difference between refrigerant temperature as it leaves the evaporator and the saturation temperature corresponding to the evaporator pressure.) Typically, superheat should run in the range of 10F to 15F. On valves purchased through McQuay, the superheat setting can be adjusted by removing the cap at the bottom of the valve to expose the adjustment screw. Turn the screw clockwise (when viewed

INLET

EXPANSION VALVE

from the adjustment screw end) to increase the superheat setting and counterclockwise to reduce superheat. Allow time for system rebalance after each superheat adjustment.

The expansion valve, like the solenoid valve, should not normally require replacement, but if it does, the unit must be pumped down by following the steps involved when changing a filter-drier.

If the problem can be traced to the power element only,

it can be unscrewed from the valve body without removing

the valve, but only after pumping the unit down.

POWER ELEMENT

(CONTAINS DIAPHRAGM)

OUTLET

l--+

SPRING

Page 50 I IM 269

ADJUSTMENT SCREW

CAP

IN-WARRANTY RETURN MATERIAL PROCEDURE

COMPRESSOR

Copeland Refrigeration Corporation has stocking wholesalers who maintain a stock of replacement compressors and service parts to serve refrigeration contractors and servicemen.

When a compressor fails in warranty, contact your local sales representative, or McQuay Warranty Claims Depatrment at the address on the cover of this bulletin. You will be authorized to exchange the defective compressor at a Copeland wholesaler, or an advance replacement can be obtained. A credit is issued you by the wholesaler for the returned compressor after Copeland factory inspection of the inoperative compressor. If that compressor is out of Copeland’s warranty, a salvage credit only is allowed. Pro-

vide McQuay with full details; i.e., McQuay unit model and unit serial numbers. Include the invoice and the salvage value credit memo copies and we will reimburse the difference. In this transaction, be certain that the compressor is definitely defective. If a compressor is received from the field that tests satisfactorily, a service charge plus a transportation charge will be charged against its original credit value.

On all out-of-warranty compressor failures, Copeland of-

fers the same field facilities for service and/or replacement

as described above. The credit issued by Copeland on the returned compressor will be determined by the repair charge

established for that particular unit.

COMPONENTS OTHER

Material may not be returned except by permission of authorized factory service personnel of McQuay Air Conditioning at Minneapolis, Minnesota. A “return goods” tag will be sent to be included with the returned material. Enter the information as called for on the tag in order to expedite handling at our factories and prompt issuance of credits.

The return of the part does not constitute an order for

replacement. Therefore, a purchase order must be entered

through your nearest McQuay representative. The order

APPENDIX

STANDARD CONTROLS

NOTE:

The oil pressure safety control is a manually resettable device which senses the differential between oil pressure at the discharge of the compressor oil pump and suction pressure inside the compressor crankcase. When the oil pressure reaches approximately 15 psi above the crankcase suction pressure, the pressure actuated contact of the control opens from its normally closed position. If this pressure differential cannot be developed, the contact will remain closed and energize a heater element within the control. The heater element warms a normally closed bimetallic contact and causes the contact to open, de-energizing a safety relay and breaking power to the compressor.

It takes about 120 seconds to warm the heater element enough to open the bimetallic contact, thus allowing time for the pressure differential to develop.

If during operation, the differential drops below 10 psi, the heater element will be energized and the compressor will stop. The control can be reset by pushing the reset button on the control. If the compressor does not restart, allow a few

PERFORM AN OPERATIONAL CHECK ON ALL UNIT SAFETY CONTROLS ONCE PER YEAR.

OIL PRESSURE SAFETY CONTROL

THAN COMPRESSORS

should include part name, part number, model number and serial number of the unit involved.

Following our personal inspection of the returned part, and

if it is determined that the failure is due to faulty material or workmanship, and in warranty, credit will be issued on customer’s purchase order.

All parts shall be returned to the pre-designated McQuay

factory transportation charges prepaid.

minutes for the heater element and bimetallic contacts to cool

and reset the control again.

To check the control, pump down and shut off all power

to the unit. Open the circuit breakers or the fused discon-

nect for that compressor and install a voltmeter between ter-

minals L and M of the oil pressure control. Turn on power to the unit control circuit (separate disconnect or main unit

disconnect depending on the type of installation). Check to see that the control stop switch S1 is in the “on” position. The control circuit should now be energized, but with the absence of compressor power, no oil pressure differential can develop and thus the pressure actuated contacts of the control will energize the heater element and open the bimetallic contacts of the control within 120 seconds. When this hap-

pens, the safety relay is de-energized, the voltmeter reading will rise to 24V, and the compressor contactor should open.

Repeated operations of the control will cause a slight heat buildup in the bimetallic contacts resulting in a slightly longer time for reset with each successive operation.

Pressure Actuator

Contact

Line Note 1

Line

Note 2

Bimetallic Contacta

NOTES: 1. Hot only when the unit thermostat calls for compressor to run,

2. Hot only when other safety control contacts are closed.

Heater Element

Safety Relay

Neutral

IM 269 / Page 51

HIGH PRESSURE CONTROL

The high pressure control is a single pole pressure activated switch that closes on a rxessure rise. When the switch closes, RI is energized which in turn de-energizes the control circuit, shutting down the compressor circuit. R1 also locks itself in a manually resettable holding circuit through RSI. The switch is factory set to close at 400 psig and open at 300 psig.

To check the control, either block off condenser surface or start the unit with condenser fan motor fuses in only one fan fuse block (FB6) and observe the cutout point of the control on a high pressure gauge.

LOW PRESSURE CONTROL

The low pressure control is a single pole pressure switch that closes on a pressure rise. It senses evaporator pressure and is factory set to close at 60 psig and automatically open at 35 psig. The control has an adjustable range of 20 inches of Hg. to 100 psig and an adjustable differential of 6 to 40 psig. To check the control (unit must be running), move the pumpdown switch(es) PSI and PS2 to the “manual pumpdown” position. As the compressor pumps down, condenser pressure will rise and evaporator pressure will drop. The

FANTROL HEAD PRESSURE CONTROL

FANTROL is a method of head pressure control which automatically cycles the condenser fans in response to condenser pressure and ambient air temperature. This maintains head pressure and allows the unit to run at low ambient air temperatures.

All ALP units have dual independent circuits with the fans for circuit 1 and circuit 2 being controlled independently by the condensing pressure and ambient air of each circuit. Fans

The control is attached to a Shrader fitting and is located

on a cylinder head near the discharge King valve. CAUTION: Although there is an additional pressure relief

device in the systetq set at 450 psig, it is highly recommended that the “control stop” switch S1 be close at hand

in case the high pressure control should malfunction.

After testing the high pressure control, check the pressure

relief device (on the condenser header) for leaks.

lowest evaporator pressure reached before cutout is the cutout setting of the control. Wait for the compressor lockout time delays TDI and TD2 to time out. By moving the pumpdown switch(es) PSI and PS2 to the “auto pumpdown” position, evaporator pressure will rise. The highest evaporator pressure reached before compressor restart is the cut-in setting of the control.

The control is attached to a Shrader fitting and is located

below the suction King valve body.

11 and 21 start with each compressor and fans 12 and 22 cycle on and off in response to condenser pressure. The cutout and cut-in pressures are given in Table 23. Fans 13 and 14 (circuit 1) and fans 23 and 24 (circuit 2) are controlled by ambient temperature and are factory set at the values given in Table 23. Note that the number of fans on each unit varies. FANTROL sensor locations are shown in Figures 20 thru 23.

Table 23. Factory FANT

ALP

UNiT

SIZE Cutin cutout

04sc

Ossc

070C Oaoc 090c

1WC 290 1-’-

Iloc 1200

PC12(Psi)

290 170 290

290

1--

l/ul L3ull/ul —l —j—l—[—

[7cl I 90n I ‘1711 i 71 I CC

290

1,” 290 170 290 170 290 170 290

290 170 290 290 170

13SC 290 170 290

lSOC

170C 290 170 290 170 186C 290 170 290 170 20SC 230C 290 170

NOTES: (1) Wth SPEEDTROL, all units minimum ambient operating temperature drops to O“F. (2) Minimum head pressure on partly loaded compressor is 110 psig; on full load it is 170 psig.

290

170 290 170

290 170

ROL Settings

(Psi) TC13 (“F) TC23 (oF)

PC22

Cutin ~utout Cuths

--’-‘ ‘--

c.. sr”

-“’ ---

LYUII(U

290 170

290 170 290 170

CONDENSER FAN

170

cutout

— — —

r%, ””, ”ti, ”7

70]65170 [65

Oajaolualuo

170

‘e’co’co’co

57152157152 [63

170

49 44 49 55 50 55

170

60 55 57

61 56 61 60 55 60 60 55 60 65 60 65 65 60

Cutin

cutout Cutin cutout

— —

I ccl

fiAl _

44 50 52

56 66 55 65 55 65 60 70

60 70

TC14 (“~

59 60 65

TC24_~@ AMBIENT

STD.MINIMUM

Cutin

— — —

70 75 70 54 69 54 58 63 58 54 59 54 55 60 55 60 62 57

61 66 61 60 65 60 60 65 60 65 70 65 65 70 65 20

cutout

(FANTROL “F) (l)(2) (FANTROL “F) (1)(2)

OPT. STEPS OF CAPAC.

30 40

.aa

20 35

20 20

20 20 20 20 20

–CAUTION–

SPEEDTROL and FANTROL will provide reasonable operating refrigerant discharge pressures to the ambient temperatures listed for them PROVIDED THE COIL IS NOT AFFECTED BY THE EXISTENCE OF WIND.

If wind may occur, and the unit includes vertical condenser coils, it is the responsibility of the system designer

or installer to make other provisions for low ambient control. Consideration should be given to deflecting

awnings, dampers, or a floodback receiver system as required to satisfy specific job conditions.

MINIMUM AMBUENT

30 25 30 30 20 20

20 20 20 20

Page 52 /

IM 269

Figure 20.

High Ambient

Sensors

PC6 6 PC5

Figure 21.

SPEEDTROL Controls -r,

Figure 22.

COMPRESSOR

Compressor lockout consists of an adjustable Oto 6 minute time delay. It is wired in series with the R5 relay that energizes the R9 relay starting the compressor. Its purpose is to prevent rapid compressor cycling when cooling demands are er-

ratic. The circuit illustrated is for the compressor circuit #1

control circuit. The control circuit for compressor circuit #2

is wired the same way. Five minutes is recommended for the

compressor lockout time delay.

When the unit thermostat no longer calls for cooling and

the compressor contractor have opened, the lockout time

delay breaks open the circuit, preventing compressor restart.

The circuit remains open for a period of 5 minutes so that, if the unit thermostat should call for cooling before the delay period has expired, the compressor will not restart. After 5 minutes the time delay will close its contacts to complete the circuit to R5, energizing R9 and starting the compressor. When R9 is energized, another set of contacts will shunt around TD1, allowing TDI to reset open for timing out the next compressor cycle.

Figure

23.

LOCKOUT

To check the control, the compressor must be running in-

itially. Move the pumpdown switch PS1 or PS2 to the “manual purnpdown” position. Immediately after the compressor has stopped running, move the pumpdown switch back to the “auto pumpdown” position. The compressor should not restart

for 5 minutes.

Line

Neutral

“ne‘“%D-----

COMPRESSOR MOTOR PROTECTOR

The solid-state compressor motor protector module incor-

porates a two-minute “time off” relay utilizing the bleed down

capacitor principle. Any time the protection system opens or

power to the module is interrupted, the two-minute “time off’

delay is triggered, and the module will not reset for two

minutes. Once the two-minute period is passed, the motor protector contacts 1 and 2 reset, provided the protection

system is satisfied and power is applied to the module.

NOTE: If the power circuit is broken once the two-minute oeriod is passed the pilot circuit will reset without delay when

power is “reapplied.

24V Line

115V Line

-———.

r 1]

1 I

L:---’d

MP1

●

Control Relay

Neutral

IM 269 I Page 53

APPENDIX

OPTIONAL CONTROLS

SPEEDTROLHEADPRESSURECONTROL(OPTiONAL)

SeeCautiononPage52.

The SPEEDTROL system of head pressure control operates partments. Units with 460 volt power have a transformer in conjunction with FANTROL by modulating the motor speed mounted inside the condenser fan 21 fan compartment to step on fans By reducing the speed of the last fan as the condensing pressure falls, the unit can operate at lower ambient tempera- speed at approximately 105” F and maintains a minimum contures. densing pressure of 170 to 180 psig.

thermally protected motor specially designed for variable the bottom row of the condenser coil. SPEEDTROL controls speed application. The solid-state speed controls SC11 and SC21 are mounted inside condenser fan 11 and 21 fan com-

UNLOADERS CONTROLLED FROM SUCTION PRESSURE: solenoid U1 which increases the compressor capacity. With a decrease in load, the suction pressure drops, pressure control PC8 closes, energizing unloader solenoid U1. This closes the suction port to one cylinder bank and reduces the compressor capacity. Compressor circuit 2 operates the same way,

creases, pressure control PC8 opens, de-energizing unloader

11and 21 in response to condensing temperature. the voltage down to 230 volts for the SPEEDTROL motors.

modulate the motor

The SPEEDTROL fan motor is a single phase, 208/240 volt,

COMPRESSOR UNLOADERS (OPTIONAL)

With an increase in the load, the suction pressure in-

The SPEEDTROL control starts to

The SPEEDTROL sensors are clipped to a return bend on

and SPEEDTROL transformer are shown in Figures 21 and 23.

PC8, cut-in: 64 psig: cut-out: 72 psig PC9, cut-in: 64 psig; cut-out: 72 psig

The cut-in and cut-out pressures can be adjusted to meet field combinations. If the unloader cycles excessively, the differential between cut-in and cut-out should be increased.

LOW AMBlENT START (OPTIONAL)

Low ambient start is available on all units as an option with

To check the control, turn off all power to the unit and

FANTROL and included automatically with optional SPEED- remove the wire(s) leading to the terminals of the low pressure TROL. It consists of a solid-state, normally closed time delay wired in series with a relay. These are both wired in parallel to the liquid line solenoid valve so that when the solenoid valve is energized by the unit thermostat the low ambient start relay is also energized through the time delay, The relay has contacts that essentially short-circuit the low pressure control and

control(s) LPI and LP2. Remove power to the compressor and

jumper across terminals 48 to 50 for circuit 1 and 78 to 80

for circuit 2. Switch the pumpdown switch(es) PSI and PS2 to the “auto pumpdown” position. Energize the control circuit by turning on the control circuit disconnector main power

disconnect (depending on the installation) and the control stop freezestat and allow the compressor to start with the low switch S1. The compressor contractors should pull in instantpressure control open.

Iy and trip back out after the 23/4 minute time delay.

After about 23/4 minutes, the time delay will open and reenergize the relay. If the system has not built up enough evaporator pressure to close the low pressure control, the compressor will stop. The time delay can be reset to its original

StartTimeDelay

Line

LowAmbient

TD9

Low Ambient

StartRelay

Neutral

normally closed position by moving the pumpdown switch(es) PSI or PS2 to the “manual pumpdown” position. Moving the pumpdown switch back to the “auto pumpdown” position will again energize the relay for another attempt at startup. If the

●

system has built up enough evaporator pressure, the compressor will continue to run.

NOTE: Line is only hot when the unit thermostat calls for compressor to run.

HIGH AMBlENT (OPTIONAL)

The high ambient control is a single pole pressure activated switch that closes on a pressure rise to partially unload one or both circuits. It senses condenser pressure and is factory set to close at 375 psig and will automatically reset at 300 psig. To check the control, either block off condenser surface or start the unit with fuses in only one condenser fan fuse-

block (FB6) and observe the cut-in point of the control by monitoring when the compressor unloads. The purpose of the control is to allow the unit to continue operating when the ambient temperature exceeds the design temperature of the unit. High ambient sensor locations are shown in Figures 20 and

22.

PART WINDING

Part winding start is available on all voltage units and consists of a solid-state time delay wired in series with the contactor that energizes the second winding of each compressor motor. Its purpose is to limit current in-rush to the compressors upon startup. As each compressor starts, the contactor of the first motor winding is delayed for 1 second.

Control checkout is best accomplished by observation as each contactor is pulled in to see that the 1 second delay occurs before the second contactor pulls in.

Page 54 I IM 269

START (OPTIONAL)

Line

TO 1

Part Winding

Time Oelay

Compr COntaclOr

(=1 Motor Winding)

COmpr Contactor

(*2 MO1O, Wndingl

Neutral

PHASE/VOLTAGE MONITOR (OPTIONAL)

The phase/voltage monitor is a device which provides protection against three-phase electrical motor loss due to power 1. failure conditions, phase loss, and phase reversal. Whenever any of these conditions occur, an output relay is deactivated, disconnecting power to the thermostatic control circuit, 2. automatically pumping down the unit.

The output relay remains deactivated until power line conditions return to an acceptable level. Trip and reset delays have 3. been provided to prevent nuisance tripping due to rapid power fluctuations.

When three-phase power has been applied, the output relay should close and the “run light” should come on. If the out-

HOT GAS BYPASS (OPTIONAL)

Hot gas bypass is a system for maintaining evaporator pressure at or above a minimum value. The purpose for doing this is to keep the velocity of the refrigerant as it passes

through the evaporator high enough for proper oil return to the compressor when cooling load conditions are light. It also

maintains continuous operation of the chiller at light load con-

ditions. Hot gas bypass kits are described on page 9.

The solenoid valve should be wired to open whenever the unit thermostat calls for the first stage of cooling (see Figures 10 thru 12). The pressure regulating valve that McQuay of-

fers is factory set to begin opening at 58 psig (32° F for R-22) when the air charged bulb is in an 80” F ambient temperature. The bulb can be mounted anywhere as long as it senses a fairly constant temperature at various load conditions. The compressor suction line is one such mounting location. It is generally in the 50° F to 60° F range. The chart below indicates that when the bulb is sensing 500 F to 60° F temperatures, the valve will begin opening at 54 to 56 psig. This setting can be changed as indicated above, by changing the pressure of the air charge in the adjustable bulb. To raise the pressure

put relay does not close, Perform the following tests.

Check the voltages between L1–L2, L1–L2 and L2–L3. These voltages should be approximately equal and within

+ 10% of the rated three-phase line-to-line voltage. If these voltages are extremely low or widely unbalanced check the power system to determine the cause of the problem. If the voltages are good, turn off the power and interchange any two of the supply power leads at the disconnect.

This may be necessary as the phase/voltage monitor is sensitive to phase reversal. Turn on the power. The output relay should now close after the appropriate delay.

setting, remove the cap on the bulb and turn the adjustment screw clockwise. To lower the setting, turn the screw counterclockwise. Do not force the adjustment beyond the range it

is designed for, as this will damage the adjustment assembly.

The regulating valve opening point can be determined by slowly reducing the system load (or increasing the required chilled water temperature setting indicated on the unit thermostat), while observing the suction pressure. When the bypass valve starts to open, the refrigerant line on the evaporator side of the valve will begin to feel warm to the touch.

CAUTION: The hot gas line may become hot enough to

cause injury

in a very short time, so care should be taken

during valve checkout.

On installations where the condensing unit is remote from the evaporator, it is recommended that the hot gas bypass valve be mounted near the condensing unit to minimize the amount of refrigerant that will condense in the hot gas line during periods when hot gas bypass is not required.

Hot Gas Bypass Piping Diagram

Hot Gas 6ypESS

Solenold Valve

1 1, 11

Suction

Line

~&’,,.Bgglve

Bypass Valve

distributors, use Sporlsn suxlllary

sldeporl connector or equlvslent)

Hot Gas Bypass Adjustment Range

g 40 J <

3040506070B41 90100

TEMPERATURE(“F) AT BULB LOCATION

110

IM 269 I Page 55

-0

m co

HIGH PRESSURE CONTROL

LOW PRESSURE CONTROL

COMPRESSOR MOTOR PROTECTOR

fTexaa Instruments)

OIL PRESSURE CONTROL

UNLOAOER PRESSURE CONTROL

FANTROL CONDENSER PRESSURE CONTROL

PUMPDOWNSWITCH PHASEIVOLTAGE

MONITOR RESET SWITCHES

CONTROLSTOPSWITCH

LEAD-LAGSWITCHES

SPEEDTROL HEAD PRESSURE CONTROL

LIQUID LINE

SOLENOID VALVES,

HOT QAS BYPASS UNIT THERMOSTAT

(MASTER)

UNIT THERMOSTAT (SATELLITE)

COMPRESSOR LOCKOUT TIME DELAY

PART WINDING START TIME DELAY

ALP CONTROLS,

Stops compressor when discharge pressure is too high.

(Used for pumpdown.) Stops compressor when suction pressure is too low.

Protects motor from high temperature by sensing winding temperature.

Stops compressor if oil pressure drops below setpoint for 120 seconds.

Unloads compressor circuits if condenser pressure

is too high.

Maintains condenser pressure by cycling the condenser fansin response toambient air temperature (TC) and condenser Drasaure (PC\.

Used to manually pump down compressor circuit.

Protects motor from power failure, phase loss and phase reversal.

Restarts compressor circuit if it cuts out on high

oressure or freezestat.

Shuts down entire control circuit.

Reverses sequence that compressors start in.

Modulates condenser fan speed in resonse to condenser temperature.

Close off liquid line for pumpdown.

Close off hot gas line for pumpdown,

Measures return water temperature tocontrolcom-

pressor staging,

Adds additional stages of cooling to unit thermostat

CPI .

Prevents short cycllng of compressors. TD1—4

Reduces Inrush amp draw on startup,

LP1, 2

MP1—4

OP1—4

PC12, 22 TC13, 14,15 TC23, 24,25

Psi, 2

PVM

RSI—4 NIA Manual

S2–4

Sell, 12 Maintains minimum con-

SV5, 6 NIA

CP1 NIA

CP2 NIA NIA Control box

TD5—8 1 second

AND FUNCTIONS

RESET

Closes at 400 psig. Opens at 300 psig.

Closes at 60 psig. Opens at 35 Psiq.

500 ohms cold to 20,000 ohms hot.

Pressure sensor opens at

15psig oil pressure, If pressure drops below 10, psig, the sensor closes, energizinga 120 second delay before stopping the compressor.

Closes at 375 psig. Opens at 300 psig.

See table with FANTROL settings.

Auto/manual

NIA When conditions return to

On/off Circuit 1 leads Circuit2

Circuit 2 leads Circuit 1

densing pressure of 170 to 180 psig.

NIASvl, 2SOLENOID VALVES,

Adjustable from 300F to 60” F, Should beset between 42° F and 50” F,

Adjustable Oto 6 minutes,

Recommended 5 minute setpoint.

Manual thru RS1,2

Auto

Auto from 2700—4500 ohms

Manual

AutoHIGH AMBlENT

Auto

NIA

an acceptable level.

N/A

NIA

Auto

N/A Control box

LOCATION

On compressor 100 psig. fixed.HPI, 2

On compressor

Compressor junction box 15,000 ohms

Control box 5 psig

On condenser coil header 75 psigPC5, 6

PC12—220n coil header. TC13—25 in control box.

Control box

Control box Control box

DlFPS17Em

30 psig fixed.

See table with FANTROL settings.

NIA

i NIA

NIA

Back of control box or on bulkhead

Condenser section on liquid N/A line after filter-drier and before TEV.

Condenser section NIA

Control box, Adjustable from 1°Fto Sensor in return waterline 3°F per stage. from buildino to chiller.

Control box N/A

NIA

Adjustable thru CPI

NIA

Continued on next paga

ALP CONTROLS, SETTINGS, AND FUNCTIONS (Continued)

LOW AMBlENT START TIME DELAY

COMPRESSOR

SEQUENCING TIME DELAYS

COMPRESSOR UNLOADERS CONTROLLED

REMOTELY (Thermostat)

SUCTION UNLOADER

PRESSURE CONTROL

Bypasses low pressure control and freezestat to

allow evaporator pressure to build up in low

ambient conditions.

Staggers compressor starting to reduce in amp draw

TD9—1 o

TDII—13

TDII: 20 seconds

TD12, 13:40 seconds

Auto Control box NIA

Solenoid valveaon compressor heads to load or unload compressors. Energize to unload; de-energize to load compressor.

Senses suction pressure to load or unload compressors. Cut-in (energize)to unload compressor; cut-out (de-energize) to load compressor.

Ul, 2

PC8, 9 Recommended cut-in: 84psig cut-out 72 psig

The McQuay ALP SEASONCON air cooled water condensing unit provides not only lower operating costs, but lower

installation costs, low maintenance costs and greater design flexibility,

In order for McQuay to better serve our customers, feedback of recurring service problems or complaints dealt with in the field would be appreciated. Problems or complaints can be reported to McQuay by filling out a Product Quality Report (Form No. 2S-636-784). These forms are available from McQuay service and sales representative organizations and should be routed back through these organizations to McQuay’s Engineering and Marketing departments.

NIA

Adjustable 20—1 00 psig

in both comfort and process cooling applications.

Auto

Control box Adjustable

TROUBLESHOOTING CHART

PRORLFM I POSSIBLE CAUSES

. ..--—...

COMPRESSOR WILL NOT RUN

COMPRESSOR NOISY OR VIBRATING

HIGH DISCHARGE PRESSURE

LOW DISCHARGE PRESSURE

HIGH SUCTION PRESSURE

LOW SUCTION

PRESSURE

COMPRESSOR WILL WILL NOT UNLOAD 2. Unloader mechanism defective. OR LOAD

COMPRESSOR LOADINGIUNLOADING INTERVALS TOO SHORT

LOSS OFOIL 1. Clogged suction oil strainer. PRESSUREOR NUISANCE OIL PRESSURE CONTROL TRIPS

COMPRESSOR LOSES OIL

1. Main switch open.

2. Fuse blown. Circuit breakers open.

3. Thermal overloads tripped.

4. Defective contactor or coil.

5. System shutdown by safety devices.

6. No cooling required.

7. Liquid line solenoid will not open.

8. Motor electrical trouble.

9. Loose wiring.

1. Flooding of refrigerant into’~crankcase

2, Improper piping supporl orisuction or liquid line.

3. Worn compressor.

1. Noncondensables in system.

2. System overcharged with refrigerant.

3. Discharge shutoff valve partially closed.

4. Fan not running.

5. Dirty condenser coil,

6. FANTROL outof adjustment.

1. Faulty condenser temperature regulation

2. Suction shutoff valve partially closed.’

3. Insufficient refrigerant in system. 4, Low suction pressure.

5. Compressor operating unloaded.

1. Excessive load.

2. Expansion valve overfeeding.

3. Compressor unloaders open.

1. Lack of refrigerant.

2. Evaporator dirty.

3. Clogged liquid line filter-drier.

4. Clogged suction Iineor compressor suction gas strainers.

5. Expansion valve malfunctioning.

6. Condensing temperature too low.

7. Compressor will not load.

8. Insufficient airor water flow.

1. Defective capacity control.

3. Faulty thermostat stage or broken capillary tube.

4. Stages not set for application.

1. Erratic water thermostat.

2. Insufficient water flow.

2. Excessive liquid in crankcase.

3. Oil pressure gauge defective.

4. Low oil pressure safety switch defective.

5.Worn oil pump.

6. Oil pump reversing gear stuck in wrong position.

7. Worn bearings.

8. Low oil level.

9. Loose fitting on oil lines.

10. Pump housing gasket leaks. 11, Flooding of refrigerant into crankcase.

12. Iced up evaporator coil.

13. insufficient air orwaterflow. 1, Lack of refrigerant.

2, Excessive compression ring blow-by.

3. Suction superheat too high.

4. Crankcase heater burned out.

5. Insufficient oilinaystem.

6. Suction risers too large.

7. Insufficient traps in suction risers.

1. Close switch. 2, Check electrical circuits andmotor w’ndngforshoflsor

grounds. Investigate for possible overloading. Replace

fuse orreset breakers aflerfault is corrected Check for loose or corroded connections.

3. Overloads areauto reset. Check unit closely wher unit comes back on line.

4. Repair or replace.

5. Determine type andcause of shutdown and correct it before resefiing safety switch.

6. None. Wait until unit calls for cooling

7. Repair or replace coil.

8. Check motor for opens, shorfcircuit, or burnout

9. Check all wire junctions. Tighten all terminal screws

1. Check setting of expansion valve.

2. Relocate. adder remove hangers

3. Replace.

1. Purge the noncondensables.

2. Remove excess.

3. Open valve

4. Check electrical circuit.

5. Clean coil.

6. Adjust FANTROL settings.

1. Check condenser control operation.

2. Open valve.

3. Check for leaks. Repair and add charge.

4. See Corrective Steps for low suction pressure be!ow

5. See Corrective Steps for failure of compressor to load below.

1, Reduce load oradd additional equipment.

2. Check remote bulb. Regulate superheat.

3. See Corrective Steps below for failure of compressor to load.

1. Check for leaks. Repair and add charge

2. Clean chemically.

3. Replace.

4. Clean strainers.

5. Check and reset for proper superheat.

6. Check means forregulafing condensing temperature.

7. See Corrective Steps below for failure of compressor to unload.

6. Adjust airflow orwatergpm.

1. Replace.

2. Replace.

3. Replace.

4. Reset thermostat setting to fit application.

1. Replace.

2. Adjust gpm.

l.Clean.

2. Check crankcase heater. Reset expansion valve for higher superheat. Check liquid line solenoid valve operation.

3. Repair or replace. Keep valve closed except when taki~g readings.

4. Replace.

5. Replace.

6. Reverse direction of compressor rotation.

7, Replace compressor.

8. Add oil.

9. Check and tighten system.

10, Replace gasket.

11. Adjust thermal expansion valve. 12, Clean coil.

13. Adjust air flow or water gpm.

1. Check for leaks and repair. Add refrigerant.

2. Replace compressor.

3. Adjust superheat.

4. Replace crankcase heater.

5. Add oil until sightglass is V, full.

6. Check line sizing atdesign conditions and change if incorrect.

7. Install suction P4rapsat each 20 foot vertical rise

POSSIBLE CORRECTIVE STSPS

Continued on Nexl P.?ge

Page 5811M 269

MOTOR OVERLOAD RELAYS OPENOR BLOWN FUSES

COMPRESSOR THERMAL

PROTECTOR SWITCH

OPEN

—

PROBLEM

TROUBLESHOOTING CHART (Continued)

‘ f?OSSIBLECiWSES

1. Low voltage during high load conditions.

2. Defective or grounded wiring in motor.

3. Loose power wiring.

4. High condensing temperature.

5. Power line fault causing unbalanced voltage

6. High ambient temperature around the overload relay.

7. Failure of second starter to pull in on part winding start svstems.

1. Operating beyond design conditions.

2. Oiacharge valve partially shut.

3. Blown valve plate gasket.

POSSIBLSCORRECTIVE S=PS

1. Check supply voltage for excessive line drip.

2. Replace compressor motor.

3. Check all connections and tighten.

4. See Corrective Steps for high discharge pressure.

5. Check supply voltage. Notify power company. Do not atarl until fault is corrected.

6. Provide ventilation to reduce heat.

7. Repair or replace atarter or time delay mechanism.

1. Add facilities ao conditions are within allowable Iimita.

2. Open valve.

3. Replace gasket

lM2691Page59

Product Warranty

McQuay International, hereinafter referred to as the “Company,” Warrants that it will provide, at the Company’s

option, either free replacement parts or free repair of component parts in the event any product manufactured by the Company and used in the United States proves defective in material or workmanship within twelve (12) months from ini-

tial start-up or eighteen (18) months from the date shipped

by the Company, whichever comes first. For additional consideration, McQuay International warrants that for four (4) years following the initial warranty period it will provide, at

the Company’s option, free replacement parts for the motor-

compressor, or, free replacement for any integral component of the motor-compressor which proves defective in material or workmanship. For an additional consideration, McQuay International warrants that for nine (9) years following the initial warranty period it will provide free replacement of the heat exchanger in gas-fired or oil-fired furnaces which proves defective in material and workmanship. (Extended warranties for motor-compressors and heat exchangers are not applicable unless separately purchased.)

To obtain assistance under this parts warranty, extended motor-compressor warranty, or extended heat exchanger warranty, simply contact the selling agency. To obtain information or to gain factory help, contact McQuay International, Warranty Claims Department, P.O. Box 1551, Minneapolis, MN 55440, telephone (612) 553-5330.

This warranty constitutes the buyer’s sole remedy. It is given in lieu of all other warranties. There is no implied warranty of merchantability or fitness for a par-

ticular purpose. In no event and under no circumstances

shall the Company be liable for incidental or consequential damages, whether the theory be breach of this or any other warranty, negligence or strict tort.

This parts warranty and the optional extended warranties extend only to me original user. Of course, abuse, misuse, or alteration of the product in any manner Company’s warranty obligation. Neither the parts or extended warranty obligates the Company to pay any labor or service costs for removing or replacing parts, or any shipping charges. Refrigerants, fluids, oils, and expendable items such as filters are not covered by this warranty.

The extended warranties apply only to integral components of the motor-compressor or heat exchanger, not to refrigerant controls, electrical controls, or mechanical con-

trols, or to failures caused by failure of those controls.

Attached to this warranty is a requirement for equipment containing motor-compressors and/or furnaces to report start-up information. The registration form accompanying

the product must be completed and returned to McQuay

International within ten (10) days of original equipment startup. If that is not done, the date of shipment shall be presumed to be the date of start-up and the warranty shall expire twelve (12) months from that date.

No person (including any agent, salesman, dealer or dis-

tributor) has authority to expand the Company’s obligation

beyond the terms of this express warranty, or to state that

the performance of the product is other than that published

by the Company.

voids the

McQuaY”

13600 Industrial Park Blvd., P.O. Box 1551, Minneapolis, MN 55440 USA (612) 553-5330

@ Printed onrecyclecl papercontaining at least 10% post-consumerrecycled material

McQuay ALP-045C Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual