McQuay ALR 035D Installation Manual

Page 1
Installation and
Maintenance Data
Bulletin No. IM 268-6
March 1995
Part No.
585558Y
Packaged Air Cooled Water Chiller
Models ALR 035D
Thru
185D
01995 McQuay International
Page 2

Table of Contents

Introduction
General Description
.......................................................
Nomenclature................................................................
Inspection......................................................................
Installation
Handling.........................................................................
Location.........................................................................
Service Access..............................................................
Vibration Isolators..
....................................................
Water Piping..................................................................
.
Flow
Switch
Water Connections
Refrigerant Charge
Glycol
Solutions
Evaporator Water Flow and Pressure Drop
Physical Data
Major Components
Dimensional Data
...........................................................
.......
........................................................
........................................................
.........................................................
...............
..............................................................
......................................................
.....................................................
Field Wiring
ElectricalData Single Point Electrical Data Multiple Point
VoltageLimitations
............................................
Compressor and Condenser Fan Motors Customer Wiring
TypicalField Wiring
Information................................
Diagram.......................................
...................................
................................
.............
Unit Layout and Principles of Operation
Major Component
Locations.......................................
ControlCenter.......................................................
DisconnectLocation
Electrical
Legend
Sequence of Operation
....................................................
.........................................................
...............................................
Start-up and Shutdown
Pre Start-up.................................................................
Start-up........................................................................
Temporary Shutdown
Start-up After Temporary Shutdown..
Extended Shutdown
..................................................
.........................
....................................................
9-12
14-16
17-l 8 19-21
. ......
22-23 24-26
28-29
4, 5
7-8
8
13
21
27
28 29
30 31
32 32 32 32
33
3
System Maintenance
3 3
3 4 4
General.........................................................................
Fan
Motor Bearings ElectricalTerminals.. Compressor Oil Oil
Equalization Condensers.. Refrigerant
Sightglass.................................................
.....................................................
....................................................
Level
............................................................
................................................................
Lead-Lag......................................................................
6
7
Service
7
7
Filter-Driers LiquidLine Solenoid Valve Thermostatic Evaporator
..................................................................
Expansion Valve
...................................................................
In Warranty Return Material Procedure
Compressor Components
.................................................................
Other Than
Appendix
Standard Controls
Thermostat Control Oil
Pressure Safety Control High Low
Compressor
..............................................................
Band
...........................................................
Pressure Control
Pressure Control
Lockout..............................................
Compressor Motor Protector
Pressure Control
FanTroll
Head
Optional Controls
Pressure Control
SpeedTroll
Head High Ambient Control High Return Water Control Low Ambient Start Freeze
Control PartWinding Phase/Voltage Hot Gas Bypass
........................................................
Start...................................................
Monitor.....................................
......................................................
Controls,Settings and Troubleshooting Chart
..................................................
..........................................
....................................
Compressors
......................
..............................37-38
............................................
.............................................
.................................
..............................
.........................
.............................................
.....................................
..................................................
41-42
Functions
.............................................
...........................43-44
45-46
33 33 33 33 33 34 34 34
34 34 35 35
36 36
37 37
38 38 38 38 39
40 40
41 41 41 41
42
Page 2 / IM 268
Product Warranty
...........................................................
See freeze protection references under the heading “Water Piping” on pages 6 and 13.
“FanTrol,” “McQuay.”
of McQuay International, Minneapolis, Minnesota, USA.
“Bulletin Illustrations cover the general appearance of McQuay International products at the time of
publication and we reserve the right to make changes in design and construction at anytime without notice.”
SeasonPak” and “SpeedTrol” are registered trademarks
46
Page 3

Introduction

General Description

McQuay type SeasonPak air cooled water chillers are com­plete, self-contained automatic refrigerating units that in­clude the latest in engineered components arranged to provide a compact and efficient unit. 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 compres-
sors, replaceable tube dual circuit shell-and-tube evapora­tor, and complete refrigerant piping. Liquid line components that are included are manual liquid line shutoff valves, sight­glass/moisture indicators, and double diaphragm hydraulic element thermal expansion valves. Other features include

Nomenclature

Reciprocating Compressors
compressor crankcase heaters, an evaporator heater for chilled water freeze protection, limited pumpdown during “on” or “off” seasons, compressor lead-lag switch to alter­nate the compressor starting sequence, and sequenced starting of compressors.
The electrical control center includes all safety and oper­ating controls necessary for dependable automatic opera­tion. Condenser fan motors are fused in all three conductor legs and started by their own three-pole contactors. Com­pressors are not fused but may be protected by optional circuit breakers, or
bythe
field installed fused disconnect for
protection.

Inspection

When the equipment is received all items should be carefully checked against the bill of lading to insure a complete
shipment. All units should be carefully inspected for damage
upon arrival. All shipping damage must be reported to the carrier and a claim must be filed with the carrier. The unit serial plate should 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 areavailable in
the Physical Data tables on pages 9 through 12.

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.
.
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 moving as this may result in serious damage. to dropping the unit. Do not push or pull the unit from any- To lift the unit, thing other than the base, and block the pushing vehicle
provided in the base of the unit. Spreader bars and cables away from the unit to prevent damage to the sheet metal should be arranged to prevent damage to the condenser cabinet and end frame (see Figure 1).
coils or unit cabinet (see Figure 2).
Never allow any part of the unit to fall during unloading or
Figure
1.
Suggested pushing arrangement
Blocklng Required
/-Across
Full Width
Figure 2. Suggested lifting arrangement
Spreader Bars
Recommended
(Use
CautIonI
2-1/2”
(64mm) diameter lifting holes are
Note: Number of fans can vary from this diagram. but
lifting
method remains the
same.
(Note Control Box
LocatIon)
IM 268 / Page 3
Page 4

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 ALR 110 through 185 chillers, it is recommended that the unit is oriented to that prevailing winds blow parallel to the unit
lenght, 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.
Minimizing clearances as shown in Figure 3 will prevent most discharge air recirculation to the condenserwhich will have a significant effect on unit performance.
Table 7. Clearances
Au? WJIT SIZE
035D -
070D
085D - 185D 10 ft. (3048mm) Min.
Notes:
1.
Minimum clearance between units is 1’2 ft.
2.
Units must not be installed in a pit that
3.
Minimum clearance on each side is 12 ft. (3658mm) when installed w a pit.
“X”
DHWENION
8
ft. (2438mm) Min.
(3658mm).
IS
deeper than the height of the
unit.
Service Access
Figure 3. Clearance requirements
;I-~-:_1
Each end of the unit must beaccessible after installation for assembly should be removed for service. periodic service work. Compressors, filter-driers, and manual liquid line shutoff valves are accessible on each side of the
to the
unit adjacent
control box. High pressure, low pressure,
The fan blade and fan motor rain shield must be removed
for access to wirinq terminals at the top of the motor.
and motor protector controls are on the compressor. Freezestats and cooler barrel thermostats are nearthecooler. Most other operational, safety and starting controls are located in the unit control box.
On all ALR units the condenser fans and motors can be
removed from the top of the unit. A complete fan/motor
Disconnect all power to the unit while servicing con-
denser fan motors. Failure to do so may cause bodily injury or death.

Vibration Isolators

Vibration isolators are recommended for all roof mounted installations or wherever vibration transmission is a consid­eration. Table 2 lists spring isolators for all ALR unit sizes. Figure4 shows isolator locations in relation to the unit control center. Figure 5 gives dimensions that are required to secure
Table 2. Vibration isolators (spring) Table 3. Spring flex isolators
ICPl-31 (CPl-31 (CPl-31 /CPl-31 (CPi-31 (CPl-31
10
ID
1
CPl-321CPl-32
1
CPl-321CPl-321CPl -321CPI
-32
each McQuay isolator selection to the mounting surface. Table 4 shows the isolator loads at each location in Figure 4, and the maximum loads for each McQuay selection are shown in Table 3.
L
Page 4
I IM
1300 135D
14!H3 ?soD
1650
17Cm
1950
268
CPZ-28 CP2-28 CP2-31 CP2-31 CP2-31
CP2-32 CP2-32
CP2-31
CP2-32 CP2-32 CP2-32
CP2-31
CP2-32 CP4-27 CP2-32
CP2-32 CP2-32 CP4-27 CP2-32 CP4-27 CP2-32 CP2-32 CP4-27 CP2-32 CP2-32 CP4-27 CP2-32 CP2-32 CP4-27 CP2-32 CP2-32 CP4-27 CP2-32 CP2-32 CP4-27 CP2-32 CP2-32
CP2-31
CP2-32
CP2-28 CP2-28
CP2-31 CPZ-31 CP2-32
CP2-31
CP2-32 CP2-32
CP2-31 CP2-31 CPZ-32
CP2-31
J
Page 5
Page 6

Water Piping

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 re-
quired for a safe and proper installation.
Basically, the piping should be designed with a minimum number of bends and changes in elevation to keep system cost down and performance up. It should contain:
1.
Vibration eliminatorstoreducevibrationand noisetrans-
mission to the building.
2.
Shutoff valves to isolate the unit from the piping system during unit servicing.
3.
Manual or automatic air vent valves at the high points of
the system. Drains should be placed at the lowest points
in the system. Some means of maintaining adequate system water
4. pressure (e.g., expansion tank or regulating valve).
Temperature and pressure indicators located at the unit
5.
to aid in unit servicing. A strainer or some means of removing foreign matter
6. from the water before it enters the pump. It should be placed far enough upstream to prevent cavitation at the pump inlet (consult pump manufacturer for recommen­dations). The use of a strainer will prolong pump life and
thus keep system performance up. A strainer should also be placed in the water lines just
7. prior to
the inlets of the evaporator and condenser. This will aid in preventing foreign material from entering and decreasing the performance of the evaporator.
8.
The shell-and-tube cooler has a thermostat and heating
cable to prevent feeze-up, due to low ambient, down to
-20°F (-29°C). It is suggested that the heating cable be wired to a separate 11 OV supply circuit. As shipped from the factory, it is factory wired to the control circuit. Any water piping to the unit must also be protected to prevent feezing.
9.
If the unit is used as a replacement chiller on a previously
existing piping system, the system should bethoroughly flushed prior to unit installation and then regular water analysis and chemical water treatment on the evapora­tor and condenser is recommended immediately at
equipment start-up.
10. The total quantity of water in the system should be
11. In the event glycol is added to the water system, as an
If a separate disconect is the cooler heating cable, it should be clearly marked so that it is not accidentally shut off during cold seasons.
preliminary leak check should be made. moisture condensationand possible damage to the building
structure. It is important to have the vapor barrier on the outside of the insulation to prevent condensation within the insulation on the cold surface of the pipe.
Figure 6. ALR evaporator
J
sufficient to prevent frequent “on-off” cycling. The total quantity of water, in the system, turnover rate should not be less than 15 minutes.
afterthought for freeze protection, recognize that the refrigerant suction pressure will be lower, cooling per­formance less, and water side pressure drop is greater. If the percentage of glycol is large, or if propylene is employed instead of ethylene glycol, the added pres­sure drop and loss of performance could be substantial. Reset the freezestat and low leaving water alarm tem­peratures. The freezestat is factory set to default at 36°F (2.2%). Reset the freezestat setting to approximately to 5°F (2.3” to 2.8%) below the leaving chilled water setpoint temperature. See the section titled
“Glycol
Solutions” for additional information concerning glycol.
used for the
110V supply to
Prior to insulating the piping and filling the system, a Piping insulation should include a vapor barrierto prevent
1
1L
T-
4”
III
Figure 7. Typical field evaporator water piping
Page 6 / IM 268
Pressure Gauge
Vibration
Eliminator
Lf
Water
Strainer
Gate
Valve
awitch
Note: Chilled water piping should be insulated.
Balancing
Valve
Gate
Valve
Page 7
Flow
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 compres-
sors 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 00175033-00. It is a “paddle” type switch and
Switch
adaptable to any pipe size from 1” (25mm) to 6” (152mm) nominal. Certain minimum flow rates are required to close the switch and are listed in Table 6. Installation should be as shown in Figure 8. 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 for an indicator
light or an alarm to indicate when a “no flow” condition exists.
Table 6. Flow switch minimum flow rates
2% ( 63.5) 3( 76.2) 30.00 4
(101.6)
5
(127.0)
6
(152.4)
Note: Water pressure differential switches are not recommended for outdoor applications.
24.30 (1.50) (1.90)
39.70
(2.50)
58.70
(3.70)
79.20
k5.00)

Water Connections

Water piping to thecooler can be brought up from the bottom of the unit or through the side between the vertical supports.
The dimensional data on pages 14 through 16 give the
necessary dimensions and locations for all piping connec­tions.

Refrigerant Charge

All units are designed for use with Refrigerant 22 and are shipped with an operating charge. The operating charge for
Figure 8.
L5’
(127mm)
Min.
After Switch
Note: On units sizes
Dia.
150D
through
L
5’ (127mm) Pipe Dia.
Min. Before Switch
185D
there is a
dia­gonal bracket off of a vertical support which will interfere with the water connection if brought in from the side. This brace
can be removed, but only after the unit is in place.
each unit is shown in the Physical Data tables on pages 9
through 12.

Glycol Solutions

The system glycol capacity, glycol solution flow rate in gpm,
and pressure drop through the cooler may be calculated using the following formulas and table.
Note: The procedure below does not specify the type of glycol. Use thederatefactors found in Table 7 for corrections when using ethylene glycol and those in Table 8 for propy­lene glycol.
1.
Capacity -Cooling capacity is reduced from that with
plain water. To find the reduced value multiply the chiller’s
water system tonnage by the capacity correction factor C
to find the chiller’s capacity in the glycol system.
2.
Flow -To determine evaporator gpm (or AT) knowing AT
(or gpm) and capacity:
Glycol
gpm =
24
x
capacity
For Metric Applications
(or AT) knowing AT (or Ips) and
Glycol Ips =
kW
4.18 x
(glycol)
AT
x G (from table)
-To determine evaporator Ips kW:
x Flow (from table)
AT
Pressure drop
-To determine pressure drop through
the cooler, when using glycol, enter the water pressure
drop curve on page8 at the actual glycol gpm. Multiply the water pressure drop found there by P to obtain corrected glycol pressure drop.
To determine glycol system
kW
by factor K.
multiply the
water system
kW,
Test coolant with a clean, accurate glycol solution hy-
drometer (similar to that found in service stations) to deter-
mine the freezing point. Obtain percent glycol from the
freezing point table below. On glycol applications it is nor-
mally recommended by the supplier that a minimum of 25% solution by weight be used for protection against corrosion.
Do not use an automative grade antifreeze. Industrial grade glycols must be used. Automotive antifreeze contains inhibitors which will cause plating on the copper tubes within the chiller evaporator. The type and handling of glycol used must be consistent with local codes.
IM 268 / Page 7
Page 8
Page 9
Page 10
Page 11
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Page 14
Page 15
Page 16
Page 17
Field
Wiring 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.
ALR 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 large power terminal block is provided and wiring within the unit is sized in accordance with the National Electrical Code. supplied disconnect is required. An optional transformer may be performed.
If multiple point power wiring is ordered, three power
connections, one per compressor circuit plus one for con-
denser
fans and control circuit, are required and wiring within the unit is sized in accordance with the National Electrical Code. Separate field supplied disconnects 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.
It may be desirable to have the unit cooler heater on a separate disconnect switch from the main unit power supply so that the unit may be shut down without defeating the freeze protection provided by the cooler heater.
A single
field
factory mounted
Wiring
Internal power wiring to the compressors for the single point versus the multiple point option are differ­ent. It is imperative that the proper field wiring be installed according to the way the unit is built.
Canadian c-ETL listing
Canadian units which are c-ETL listed and are equipped for multiple point power connections have a sticker (see figure below) 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.
Although be prowded with
optlons requiring more
than one source of electrical supply. some electrical authorities may require this unit to be connected to a external electrical
supply.
this umt
inspectlon
wngle
may
Table 14. Electrical data single point
03fiD
CWD
MOD
OS00
07QQ
085R
continued on next page
IM 268 / Page
17
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Page 31

Sequence of Operation

The following sequence of operation is typical for ALR Season Pak air cooled water chiIler. Models ALR035D through ALR 185D (items in italics apply only to Models ALR 0850
through
upon options.
185D).
The sequence vanes somewhat depending
Start-up
With the control circuit power on and the control stop switch S1
closed,
fuse
HTR2
MP1 control circuit transformer. The 24V transformer provides power to the contacts of the low pressure controls LP1 and
LP2 and the compressor lockout time delays
When the remote time clock or manual shutdown switch
turns on the chilled water pump, the flow switch closes and
115V water control
response to the LWC1 provided the manual pumpdown
switches PS1 and PS2 are closed (in the “auto” position); the
compressor lockout time relays R5 and R6 (R7 and thefreezestats FS1 and FS2, high pressurecontrols HP1 and
HP2, and the compressor motor protectors
(MP3 and MP4) do not sense failure conditions.
On a call for cooling, the leaving water control LCW1 energizes the liquid line solenoid valve SV1 for refrigerant circuit
through the expansion valve and into the evaporator. As the
evaporator refrigerant pressure increases, the low pressure
115V
power is applied through the control circuit
F1
to the compressor crankcase heaters (HTR1 and
(HTR3
and
HTR4),
the compressor motor protections
and MP2
power is applied to the relay contacts on the leaving
#1,
(MP3
and
MP4
and the primary of the 24V
TD1
and TD2.
LWC1
The unit will automatically operate in
R8);
and
MP1
and MP2
opening the valve and allowing refrigerant to flow
control PL1 closes. This energizes the compressor starting relay
R9,
starting the compressor via the compressor con­tactors Ml and thecondenserfan motorcontacts starting the fan motors.
As additional stages of cooling capacity are required, the leaving water control LCW1 energizes the liquid line solenoid valve SV2 of the refrigerant circuit sequencing time delay sequence is initiated in refrigerant circuit
If still more cooling is required, the leaving water control will start unloader solenoids until the capacity requirement is met.
M5.
Closing the R9 contacts also energizes
M11,
M12, Ml3 and M14,
#2.
TD11
has closed, the same starting
the
remaining compressors and then de-energize
After the compressor
#2.
Pumpdown
As the leaving water control is satisfied, it will unload the compressor(s) and then de-energize the liquid line solenoid valve(s) compressor has pumped most of the refrigerant out of the evaporator and into the condenser, the low pressure control(s)
PL1 and LP2 will open. If the refrigerant leaks into the low
side causing the pressure to close the low pressure controls
LP1 and LP2, the compressor will start after a two-hour time delay to pump the refrigerant into the condenser coil. If there is a call for cooling during the two-hour time delay, the timer is bypassed and the compressor will start.
pumpdown cycle. Flow switch, time clock and ambient lockout thermostat must be wired to allow pumpdown when unit is turned off.
SV1
and SV2, causing
Note:
Do not shut the unit down without going through the
the valve(s)
to close. When the
IM 268 / Page 31
Page 32

Start-up and Shutdown

1.
With all electric disconnects open, check all screw or lug
type electric connections to be sure they are tight for
good electrical contact. Check all compressor valve connections for tightness to avoid refrigerant loss at start-up. Although all factory connections are tight be­fore shipment, some loosening may have resulted from shipping vibration.
2.
Inspect all water piping for flow direction and correct connections at the evaporator.
Check to see that the thermostat water temperature
3. sensor is installed in the leaving water line (supply to building). On all ALR factory mounted.
4.
Check the compressor oil level. Prior to start-up, the oil level should cover at least one-third of the oil sightglass.
5.
Check the voltage of the unit power supply and see that it is within the
voltage unbalance must be within
Check the unit power supply wiring for adequate am-
6. pacity
and a minimum insulation temperature of 75°C.
Verifythat all mechanical and electrical inspections have
7. been completed per local codes.
units the
*lo%
tolerance that is allowed. Phase
sensor well and sensor are
*2%.

Pre Start-up

See that all auxiliary control equipment is operatrve and
8. that an adequate cooling load is available for initial start-
up.
Open the compressor suction and discharge shutoff
9. valves until backseated. Always replace valve seal caps.
Making sure control stop switch
10. pumpdown switches
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.
11.
Open all water flow valves and start the chilled water pump. Check all piping for leaks and vent theairfrom the evaporator as well as from the system piping. Flush the evaporator and system piping to obtain clean, noncor­rosive water in the evaporator.
Most relays andterminals in the unit control center are
hot with Sl and the control circuit disconnect on. Do
not close
S1
until start-up.
S1
is open (off) and
PS1
and PS2 are on “manual

Start-up

1.
Double check that the compressor suction and dis­charge shutoff valves are backseated. Always replace valve seal caps.
Open the oil equalization line valve
2. 185D
only).
3.
Open the manual liquid line shutoff valve at the outlet of the subcooler.
4.
Adjust the dial on temperature controller LCW1 to the desired chilled water temperature and set the control band (see “Thermostat” on page 37).
Start the auxiliary equipment for the installation by
5. turning on the time clock, ambient thermostat and/or remote on/off switch, and chilled water pump.
Check to
6.
in the “manual pumpdown” (open) position. If pressures on the low side of the system are above 60 psig (414 kPa),
Move pumpdown switches PSI and PS2 to the “manual pumpdown” position. After the compressors have pumped down, turn off the chilled water pump.
see that
the unit will start and pump down.
pumpdown switches PS1 and PS2 are
(ALR 085D
through
Temporary
10.
Shutdown
the water flow to the unit is interrupted to avoid freeze-up in the evaporator.
7.
After the compressor lockout timer
start the system by moving the pumpdown switches PS1 and PS2 to the “auto pumpdown” position.
8.
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” on page 34).
Superheat is factory adjusted to maintain between 8°F
9. and 12°F between 8°F and 12°F
After system performance has stabilized, it is necessary that the “Compressorized Equipment Warranty Form” (Form No.
ranty benefits. This form is shipped with the unit, and after completion should be returned to McQuay Service through your sales representative.
It is important that the compressors pumpd down before
(4.4”C
415415Y)
and
6.7”C).
Verify that the superheat is
(4.4X
be completed to obtain full war-
and
TD1
has timed out,
6.7X).
1.
Start the chilled water pump.
2. With emergency stop switch pumpdown switches PS1 and PS2 to the “auto pump­down” position.
3.
Observe the unit operation for a short time to be sure that the compressors do not cut out on low oil pressure.
/
Page 32
IM 268

Start-up After Temporary Shutdown

S1
in the “on” position, move
If shutdown occurs or will continue through periods below freezing ambient temperatures, make sions to insure against chiller vessel freeze-up.
provi-
Page 33

Extended Shutdown

1.
Close the manual liquid line shutoff valves.
2. After the compressors have pumped down, turn off the chilled water pump.
3.
Turn off all
4. Move the emergency stop switch
5. Close the compressor suction and discharge valves and the oil equalization line valve.
power to
the unit and to the chilled water pump.
S1
to the “off” position.

System Maintenance

General

6. Tag all opened disconnect switches to warn against start­up before the compressor suction and discharge valves.
7.
If glycol is not used in the system, drain all water from the unit evaporator and chilled water piping if the unit is to be shut down during winter. Do not leave the vessels or
piping open to the atmosphere over the shutdown period.
On initial start-up and periodically during operation, it will be
necessary to perform certain routine service checks. Among
these are checking the compressor oil level and taking
condensing, suction and oil pressure readings. During the operation, the oil level should be visible in the oil sightglass with the compressor running. On units ordered with gauges, condensing, suction and oil pressures can be read from the vertical supports on each side of the unit adjacent to the compressors.

Fan Motor Bearings

The fan shaft bearings are of the permanently lubricated type. No lubrication is required.
Excessive fan motor bearing noise is an indication of a potential bearing failure.

Electrical Terminals

Electric shock hazard. Turn off all power before con-
tinuing with following service.

Compressor Oil Level

The oil level should be watched carefully upon initial start-up and for some time thereafter.
At the present time, Suniso No. Texaco WF32 oils are approved by compressors. The oil level should be maintained at about
one-third of the sightglass on the compressor body. Oil levels may fluctuate between compressors in the same refrigerant circuit on four-compressor units (ALR 085Dthrough 185D).
Oil may be added to the Copeland compressor through the oil fill hole in the crankcase. To add oil, isolate the crank-
case and pour or pump in the necessary oil. If the system contains no refrigerant, no special precautions are neces-
3GS,
Calumet R015, and
Copeland
for use in these
The gauges are factory installed with a manual shutoff valve on each gauge line. The valves should be closed at all times except when gauge readings are being taken. On units ordered without gauges, Shrader fittings should be installed
in the plugged ports provided on the suction and discharge King valves on each compressor circuit,
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.
sary other than keeping the oil clean and dry.
If the system contains a refrigerant charge, close the suction valve and reduce crankcase pressure to (6.9 to 13.8 charge valve.
Add the required amount of oil. During the period the compressor 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 seconds. Close the oil port, open the compressor valves and
restore the system to operation.
kPa).
Stop the compressor and close the dis-
1
to 2 psig
1
or 2

Oil Equalization

Units with four compressors (ALR 085D through 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 wills till
185D)
come
exist during 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 Open For Normal Operation.” When valves are closed for compressor service, make sure they are opened again for unit operation.
IM 268
/
Page 33
Page 34

Condensers

Condensers are air cooled and constructed with 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
7~”
(9.5mm)

Refrigerant Sightglass

The refrigerant sightglasses should be observed periodi­cally.
(A monthly observation should be adequate.) A clear glass of liquid indicates that there is adequate refrigerant charge in the system to insure proper feed through the expansion valve. Bubbling refrigerant in the sightglass indi­cates that the system is short of refrigerant charge. Refriger­ant gas flashing in the sightglass could also indicate an

Lead-Lag

An optional feature on all McQuay ALR air cooled chillers is a system for reversing the sequence in which the compres­sors start. (Chillers with the hot gas bypass option on only one circuit do not have lead-lag.) For example, on a unit with the lead-lag switches in the “circuit 1 leads” position, the
normal starting sequence is compressor
#1
then compres-
supply outlets. Use caution when applying such cleaners as they may contain potentially harmful chemicals. Care should
be taken not to damage of the purge valve on the condenser will prevent the buildup of nonconcondensables. The purge valve is located under the
#1
fan deck of each compressor circuit.
excessive pressure drop in the line, possibly due to a clogged filter-drier or a restriction elsewhere in the system. An ele-
ment insidethe sightglass indicates what moisture condition corresponds to a given element color. If the sightglass does
not indicate a dry condition after the unit should be pumped down and the filter-driers changed.
#2.
With the lead-lag switches in the “circuit 2 leads”
sor
position, the reversed starting sequence is compressor then compressor #1 . It is achieved electrically by a multipole
switching arrangement. It is suggested that the lead-lag
switches in the unit control center be switched annually to
provide even compressor life.
the
fins during cleaning. Periodic use
about
12 hours of operation,
#2,

Service

Service on this equipment is to be performed by qualified refrigeration personnel familiar with equip- the unit. ment operation, maintenance, correct servicing pro­cedures, and the safety hazards inherent to this work. Causes for repeated tripping of safety controls must be investigated and corrected.
I

Filter-Driers

To change the filter-drier, pump the unit down by moving
pumpdown switches position.
Move the control switch
all power to the unit and install jumpers across the terminals
shown in the table. This will jump out the low pressure
PS1
and PS2 to
the“manual
S1
to the “off” position. Turn off
pumpdown”
Disconnect all power before doing any service inside
I
I
requirements set forth by the EPA in regards to refrig-
controls. 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 pressures reaches 0 to 5 psig (0 to 34.5
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 liauid line manual shutoff that may have entered during filter replacement. Aleakcheck is recommended before returning the unit to operation.
valve(s)
1
kPa),
to remove noncondensables

Liquid Line Solenoid Valve

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 Ps1 and PS2 to the “manual pumpdown” position.
Page 34
/
IM 268
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 pumpdown” position.
To replace the entire solenoid valve, follow the steps
involved when changing a filter-drier.
Ps1
and PS2 to the “auto
Page 35
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.) All ALR chillers are factory set for between 8°F and 12°F
(4.4%
to 6.7%) superheat. If it is necessary to increase the super­heat setting of the valve, remove the cap at the bottom of the valve to expose the adjustment screw. Turn the screw clockwise (when viewed from the adjustment screw end) to increase superheat 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.

Evaporator

The evaporator is of the direct expansion, shell-and-tube type with refrigerant flowing through the tubes and water flowing through the shell overthetubes. The tubes are inter­nally finned to provide extended surface as well as turbulent flow of refrigerant through the tubes. Normally no service work is required on the evaporator. There may be instances where a tube will leak refrigerant into the water side of the system. In the cases where only one or two tubes leak, the problem can best be solved by plugging the tube at both ends. When the tube must be replaced, the old tube can be removed and replaced.
To remove a tube, the unit should be temporarily pumped down. Follow the steps involved when changing a filter-drier. The tubes are mechanically expanded into the tube sheets (see Figure 20) at each end of the cooler. In order to remove the tubes, it is necessary to break this bond by collapsing the tube. After doing this at both ends of the shell, the tube can be removed for replacement. The new tube can then be inserted and re-expanded into the tube sheet.
of typical dual circuit shell-and-tube evaporator
view
Liquid Connections
Expansion Valve
Figure 19. Thermostatic expansion valve
Power Element (Contains Diaphragm)
-
Spring
Adjustment Screw
The bond produced by expansion must be refrigerant tight. This bond must be
(red) to the tube and rolling it into the tube sheet.
After re-assembling the evaporator, a small amount of refrigerant should be introduced by momentarily opening the manual liquid line valve. A leak check should then be per­formed on the evaporator.
Tube removal can only take place after the leaking tube is located. One method would be to subject each tube to air pressure by plugging each end and, with a pressure gauge attached to one of the end plugs, observing if there is a loss of air pressure over a period of a minute or two.
Another method is to place a cork plug in each tube on both ends of the cooler and applying pressure to the shell of
the cooler. After a period of time, the pressure will leak from the shell into the leaking tube or tubes and pop out the cork
plug.
produced
by applying Locktite
Re
rlgerant lubes
Water Nozzles
IM 268 / Page 35
Page 36

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 service personnel.
When a compressor fails in warranty, contact your local sales representative, or Warranty Claims Department 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. Provide full details;
Components Other Than Compressors
Material may not be returned except by permission of autho­rized factory service personnel 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
i.e,
unit
model and unit serial numbers. Include the invoice and the salvage value credit memo copies and we will reimburse the difference. In thistransaction, be certain 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 offers 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 the particular unit.
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 factory,
transportation charges prepaid.
that the
compressor
Page 36
/
IM 268
Page 37

Appendix

Standard Controls

Perform an operation check on all unit safety controls once per year.

Thermostat

The AS-UNT33n-1 microprocessor-based leaving water control is designed to control multiple capacity steps of cooling from a single sensor.
The device is provided with up to eight steps of capacity.
The
AS-UNT33n-1
setpoint and control band as shown in “Control Band” below.
If the Leaving Chilled Water Temperature begins to rise to the desired setpoint plus control band /2 (upper limit), cooling stage 1 makes bringing on the first stage of cooling. Addi­tional stages of cooling will follow as long as the leaving water temperature remains above the upper limit of the control
band. As the leaving water temperature begins to drop to setpoint will begin to de-energize.
stages as long as the leaving water temperature is between the upper and lower limits of the control band.
the upper limit of the control band, stages will be energized, and anytime the leaving water temperature falls below the lower
is a 60 second interstage On Delay between stages. Each stage incorporates minimum on and off timers with a maxi­mum cycle rate of six cycles per hour.
scription of the control’s application, settings, adjustments, and checkout procedures.
minus control band /2 (lower limit), cooling stages
There will be no energizing or de-energizing of cooling
As a rule, any time the leaving water temperature is above
limit of
At the initial start of the unit a time delay will occur. There
Note: Refer to bulletin IM 552 for a more complete de-
operation is based on an adjustable
the control band, stages will be de-energized.

Control band

Leaving Water Temperature will be controlled to the Actual Leaving Water Setpoint. The Actual Leaving Water Setpoint will be a function of what mode of operation the controller is in and if a reset option is used. The Control Band potentiom­eter located on the front of the controller is used to determine the Actual Leaving Dead Band and Prop Band.
Actual Leaving Dead Band: Control band Actual Leaving Prop Band: Dead band * number of stages.
Example: Control band = 4°F (2.2%)
=
2*6 =
12°F (6.7%)
6
Number of stages Dead band = 4/2 =2”F (1 .1 “C) Prop band =
As the Leaving Water Temperature rises above the Actual Leaving Water Setpoint, but within the Leaving Dead Band, there will be no Compressor Command (Staging). As the Leaving Water Temperature continues to rise above the Dead Band and into the Prop Band, the Compressor Com­mand will be increased. When Leaving Integration Gain is used, a Proportional Plus Integral command will be calcu­lated. As the Compressor Command increases, stages of cooling capacitywill be energized. Minimum on, off, interstage timers, and cycles per hour attributes will control the stages.
As the Leaving Water Temperature decreases towards
(A16)/2.
Figure 27. AS-UNT33n-1 leaving water control algorithm
the Actual Leaving Water Setpoint, the Compressor Com-
mand will be decreased. Upon re-entering the Dead Band,
the current Compressor Command will be maintained. If the
Leaving Water Temperature falls below the Actual Leaving
Water
Command will again start to decrease.
The “Control Band” is the non-stage area Anytime the Leaving Water Temperature is outside of the Control Band limits, staging will occur. Anytime the Leaving Water Temperature is within the Control Band limits, no staging occurs. As shown in the figure below, with a 45°F (7.2%) stages of cooling energize when the Leaving Water is 47°F (8.3%) or higher. Stages de-energize when the Leaving Water is 43°F (6.1%) or lower
stages
and 47°F (8.3%).
Operation limits
Do not operate unit at a thermostat setting below 42°F (6°C) or above 50°F (10%) as serious problems may result such as cooler freeze-up or compressor overheating.
operation
Setpoint
will
(using the same Dead Band),
setpoint and a 4°F (2.2%) Control Band setting,
[4”F
remain in
their
current state between 43°F (6.1 “C)
(2.2%) difference]. All
the Compressor
of the
controller.

Oil pressure safety control

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 psig (103
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 psig
kPa)
above the
IM 268
/
Page 37
Page 38
(69
kPa),
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, all a few minutes for the heater elements and bime-
tallic contacts to cool and reset the control again.
To
check the
the unit. Open thecircuit breakers
control, pumpdown and shut off all
or the
fused disconnect for
power to
that compressor and install a voltmeter between terminals 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 the “on” position. The control circuit should not 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 happens, the safety relay is de-energized, the voltmeter reading will rise to
115V, 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.
Figure 22. Oil pressure safety control
Pressure Actuator
contact
T2
Line
Note
2
Bimetallic Contacts
Notes: 1. Hot only when unit thermostat calls for compressor to run.
2. Hot only when other safety control contacts are closed.
L M
Heater Element
I
Safety
Neutral
Relay

High pressure control

The high pressure control is a single pole pressure activated
switch that closes on a pressure rise. When the switch closes, R1 is energized which in turn de-energizes the control circuit, shutting down thecompressor circuit.
R1
also
locks itself in a manually resettable holding circuit through
RS1
. The switch is factory set to close at 400 psig (2759
and open at 300 psig (2069
kPa).
kPa)
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
The control is attached to a Shrader fitting and is located
on a cylinder head near the discharge King valve.
Aftertesting the high pressure control, check the pressure
relief device (on the condenser header) for leaks.
Although there is an additional pressure relief device in the system set at 450 psig (3104 recommended that the “control stop” switch
kPa),
it is highly
S1
be close at hand in case the high pressure control should malfunction.

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 (414 open at 35 psig (241 running),
move the pumpdown switch(es)
kPa).
To check the control (unit must be
“manual pumpdown” position. As the compressor pumps down, the evaporator pressure will drop. The lowest evapo-
kPa)
and automatically
PSI and PS2 to the
rator pressure reached before cutout is the cutout setting of the control. Wait for the compressor lockout time delay(s) TD1
and TD2 to timeout. By moving the
PS1 and
PS2
to the “auto pumpdown” position, evaporator
pumpdown
switch(es)
pressure will rise. The highest evaporator pressure reached
before compressor restart is the cutin setting of the control.
The control is attached to a Shrader fitting and is located
below the suction King valve body.

Compressor lockout

Compressor lockout consists of a fixed 5-minute time delay. It is wired in series with the
R5
relay starting the compressor.
Its purpose is to prevent rapid compressor cycling when cooling demands are erratic. The circuit illustrated in Figure 23 is for the compressor circuit circuit
for
compressor circuit #2 is wired the same way. When
#1
control circuit. The control
the unit thermostat no longer calls for cooling and the compressor contactor have opened, the lockout time delay breaks open the circuit, preventing compressor re­start.
The circuit remains open for a period of five minutes so that, if the unit thermostat should call for cooling before the delay period has expired, the compressor will not restart. After five minutes the time delay will close its contacts to complete the circuit to compressor. When will shunt around
R5,
energizing R9 and starting the
R9
is energized, another set of contacts
TD1
to reset open for timing out the next
compressor cycle.
To check the control, the compressor must be running initially. Move the pumpdown switch
PS1
or PS2 to the “manual pumpdown” position. The compressor should not restartforfive minutes. Each refrigerant circuit can bechecked the same way.
Figure 23. Compressor lockout
L1lle
Linee
Neutral
Line
i
“i”l
FE
I
I I
I I
I
F
I39
i
1 o
@
Ml
T
Neutral
_ Neutral

Compressor motor protector

The solid-state compressor motor protector module incor-
porates atwo-minute “time off” relay utilizing the bleed down
capacitor principle. Any time the protection system opens or
power to 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.
period is passed, the pilot circuit will reset without delay when power is reapplied.
Figure 24. Compressor motor protector
24V
1
1 SV Line
the module is interrupted, the two-minute “time off”
Note: If the power circuit is broken once the two-minute
Line
-----‘I
rl
2
Control
Relay
I
Neutral
‘age 38 / IM 268
Page 39

Fan Trol head pressure control

FanTrol is a method of head pressurecontrol which cally
cycles the condenser fans in response to condenser pressure and ambient air temperature. This maintains head pressureand allows the unit to run at low ambient atures.
All ALR units have dual independent circuits with the fans
for circuit 1 and circuit 2 being controlled independently by
Table 19. Factory FanTrol settings
automati-
air temper-
the condensing pressure and ambient air of each circuit.
Fans 11 and 21 start with each compressor and fans 12 and 22 cycle on and off in response to condenser pressure. The cutout and cutin pressures are given in Table 19. 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 the table. Note that the number of fans on each unit varies. FanTrol sensor locations are shown in Figures 25 through 28.
Notes:
0
With SpeedTrol all unit minimum ambient operating temperature drops to 0°F (18°C)
0
Minimum head pressure on partly loaded compressor is 110 psig (759
kPa);
on full load it is 170 psig (1172
kPa).
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.
IM 268
/
Page 39
Page 40

Optional Controls

SpeedTrol head pressure control (optional)
The SpeedTrol system of head pressure control operates in
conjunction with FanTrol by modulating the motor speed on fans 11 and 21 in response to condensing temperature. By reducing the speed of the last fan as the condensing pres­sure falls, the unit can operate at lower ambient tempera-
tures.
The SpeedTrol fan motor is a single phase, thermally protected motor specially designed for variable speed application. The solid-state speed controls SC1 1 and SC21 are mounted inside condenser fan 11 and 31 fan compartment. Units with 460 volt power have a transformer mounted inside the condenser fan 21 fan compartment to step the voltage down to 230 volts for the SpeedTrol motor, shown in Figures 26 and 28.
The SpeedTrol control at approximately 230 psig (1586
starts to
modulatethe
kPa)
and maintains a mini-
Figure 25.
208/240
volt,
motor speed
mum condensing pressure of 170 to 180 psig (1172 to 1241
kPa).
The SpeedTroI sensors are clipped to a return bend on the
bottom row of the condenser coil.
High ambient control (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 (2586 reset at 300 psig (2069 block off condenser surface or start the unit with condenser fan motor fuses in only fan fuse block (FB6) and observe the cutin 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 temperatures of unit. High ambient sensor loca­tions are shown in Figures 25 and 27.
Figure 26.
SpeedTw
Controls
kPa)
and will automatically
kPa).
To check the control either
High Ambient
%?llSCVS
PC6 a
Figure 27.
PCS
FanTrol Sensors
PC22 a PC12
Figure 28.
FanTrol
TC13. TC14.
Sens ors
TC23,
SpeedTrol Controls
TC24
Page 40 I IM 268
Page 41
High return water control (optional)
The high return water control senses the temperature of return water and partially unloads one or both compressor circuits. The control has an adjustable 0 to 100°F (17.8 to
37.8%) temperature range with 3°F (1.7%) switch differen-
tial.
The purpose of the control is to prevent high superheated suction temperatures entering the compressor should the return water temperature become too high. High suction
temperature with the compressor at full load could result in
serious damage to the compressor. A 70°F (21
.l”C) setpoint
is recommended for the high return water thermostat.
The unit is shipped from the factory with the control sensor taped to the bottom of the control box and must be field installed. It is recommended that the sensor be clamped
to the side of the return water line
near the cooler connection
and insulated (see Figure 6).
To check the control, the system should be operating at
full load conditions. By slowly turning the dial setting down, the control should partially unload one compressor circuit.
By continuing to dial the setting down, the second compres­sor circuit should unload depending on what the interstage differential is set at.
Low ambient start (optional)
Low ambient start is available on all units as an option with FanTrol
and included automatically with optional 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 con-
tacts that essentially short circuit the low pressure control and freezestat and allow the compressorto start with the low
pressure control open.
After about 2-3/4 minutes, the time delay will open and de-
energize 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 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
start-up. If the system has built up enough evaporator
pressure, the compressor will continue to run.
To check the control, turn off all power to the unit and remove the wire(s) leading to the terminals of the low pres­sure control(s)
LP1
and LP2 and the freezestat FS1 and
FS2. 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) PS1 and PS2 to the “auto pumpdown” position. Energize the control circuit by turning
on the control circuit disconnect or main power disconnect
(depending on the installation) and the control stop switch S1
The compressor contactors should pull in instantly and
trip back out after the 2%minute time delay.
Figure 29. Low ambient start
Low Ambient
Start Time Delay
Line
Note: Line is only hot when the unit thermostat calls for compressor to run.
TD9
Low Ambient
start Relay
SpeedTrol.
Neutral
T
Freeze control (optional)
The freeze control is a single pole pressure switch that closes on a pressure fall. It contains a pressure actuated contact that, upon a fall in evaporator pressure, energizes a
60-
second time delay. Aftertiming out, R1 is energized which in
turn de-energizes the 24V control circuit, shutting down the
compressor circuit. R1 also locks itself into a manually reset­table holding circuit through to close at 54 psig (372 The
60-second
time delay prevents nuisance cutouts due to
RS1
The control is factory set
kPa)
and open at 57 psig (393
kPa).
momentary drops in suction pressure.
To check the setpoint of the freezestat, attach one lead of the voltmeter to terminal 46 in the control box and the other lead to ground to check circuit a suction
pressure above 57 (393 kPa), there should
#1.
With the unit running and
be 0 VAC to ground. To check the cutin point of the freezestat, slowly close off the manual liquid line shutoff valve bringing the suction pressure down. When the freezestat switch closes, slowly close off the manual liquid line shutoff valve bringing
the suction pressure down. When the freezestat switch
closes, the voltmeter will read 24V to ground. The corre­sponding pressure will be the cutin point of the control. Slowly open the manual liquid line valve to check the cutout point pressure of the control. To check the calibration of the freezestat for compressor circuit
#2,
attach the voltmeter
between terminal 76 and ground and repeat the same steps.
To adjust the control if necessary, remove the setpoint locking bracket from the top of the control. Unscrew the pressure connection off the Shrader fitting on the suction line. Attach the pressure connection to a refrigerant tank
through a set of compound gauges and slowly pressurize the
switch while listening for the cutin and cutout points of control.
Turn theadjusting stem clockwise in%-turn increments to decrease the cutin pressure of the control and counterclock­wise to increase the cutin pressure of the control. After the control is calibrated, reconnect the pressure connection to
the Shraderfitting on the suction line and reattach the locking
bracket to the top of the control.
Part winding start (optional)
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 inrush to the compressors upon start-up. 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.
Figure 30. Part winding start
Compr. Contactor
#1
Motor
Winding)
Line
I
TD1
A
Part Winding
Time Delay
Compr. Contactor
(#2
Motor
Windlng)
Phase/voltage monitor (optional)
The phase/voltage monitor is a device which provides pro­tection against three-phase electrical motor loss due to power failure conditions, phase loss, and phase reversal. Whenever any of these conditions occur, an output relay is deactivated, disconnecting power to the thermostatic con-
IM 268 / Page 41
Page 42
trol circuit, automatically pumping down the unit.
The output relay remains deactivated until power line conditions return to an acceptable level. Trip and reset delays have 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
output does not close, perform the following tests:
Check the voltages between
L1-L2, L1
-L3
and
L2-L3.
These voltages should be approximately equal and within
+lO%
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 not close after the appropriate delay.
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 condi­tions.
The system consists of a solenoid valve piped in series with a pressure regulating valve as shown in Figure 31. The solenoid valve is factory wired to open whenever the unit
thermostat calls for the first stage of cooling. The pressure
regulating valve is factory set to begin opening at 58 psig
(400
kPa) 132°F
(0°C) for R-221 when the air charged bulb is in an 80°F (26°C) ambient temperature. Since the bulb is factory mounted on the suction line, and suction line tem­peratures are usually in the 50°F to 60°F (10°C to 60°C) range, Figure 32 indicates that for ALR chillers, the valve is factory set to begin opening at 54 to 56 psig (372 to 386
kPa).
This setting can be changed by changing the pressure of the
air charge in the adjustable bulb. To raise the pressure setting, remove the cap on the bulb and turn the adjustment screw clockwise. To lower the setting, turn the screw coun-
Do
terclockwise.
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.
The gas line may become hot enough to cause injury in a very short time; care should be taken during
valve checkout.
Figure 31. Hot gas bypass diagram
Figure 32. Hot gas bypass adjustment range
Solenoid Valve
Bypas Valve
stable Remote Bulb
External Equalizer Connection
To Suction Side of Evaporator
To Evaporator Inlet
After
Expansion
Valve
Page 42
I
IM 268
Page 43

Controls, Settings and Functions

(Texas
Instruments)
Oil Pressure
High Ambient Unloader Pressure Control
FanTrol Condenser Pressure Control
Pumpdown
Control
Switch
Phase/Voltage Monitor Reset Switches Control Stop Switch
Lead-Lag Switches
I
1
Protects the evaporator from water freeze-up.
Time delay prevents nuisance trips. TD15, 16 Stops compressor when discharge pressure is too
high. (Used for pumpdown) Stops compressor when suction LPI, 2
pressure is too low. Protects motor from high temperature by sensing
winding temperature.
Stops compressor if oil pressure drops below setpolnt for 120 seconds.
Unloads compressor circuits if condenser pressure is too high.
Maintains condenser pressure by cycling the con­denser fans in response to ambient air temperature (TC) and condenser pressure (PC). TC23, 24, 25
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
pressure or freezestat. Shuts down entire control circuit. Reverses sequence that compressors start in.
FUNCTION
high
1 SYMBOL ]
1
FS1,
2
HP1,
2
MP1-4
OP1-4
PC5. 6
PC1 2,22
TC13,14,15
PSI. 2 PVM
RS1 -4
S1
S2-4
!!
Closes
Opens at 57 psig (393
60 second
Closes at 400 psig (2759 Opens at 300 psig (2069
Closes at 60 psig (414 Opens at 35 psig (241
500 ohms cold to 20,000 ohms hot
Pressure sensor opens at 15 psig (103 drops below 10 psig (69 the sensor closes, energizing a
120 second delay before stop-
ping the compressor. Closes at 375 psig (2586
Opens at 300 psig (2069 See table with
Auto/manual
-
N/A
N/A
On/off
-
1
Circuit1 leads Circuit
SETTING
at 54 psig (372
kPa)
oil pressure
FanTrol
2 or
kPa) kPa)
kPa)
kPa)
kPa)
kPa)
kPa)
kPa)
kPa)
settings.
Manual thru
N/A Manual thru
Auto
Auto from 2700-4500 ohms Compressor junction box
Manual
Auto
Auto
N/A When conditions return to
an acceptable level. Manual
N/A N/A
N/A
RS1,
2
RS1,
2
RESET’
LOCATION
Suction line near cooler
Control box On compressor
On compressor
On condenser coil header 75 psig (517
PC1 2-22 on coil header See table with TC13-25 in control box settings Sensors mounted in back of control box
Control box Control box
Control box
Control box Control box
Back of control box or on N/A bulkhead
DIFFERENTIAL
3 psig (21
N/A 100 psig (690
30 psig (207
15,000 ohms
N/A N/A
N/A
N/A N/A
kPa),
fixed.
kPa),
kPa),
kPa)
FanTrol
fixed
fixed
N/A
N/A
N/A
N/A
Condenser section on liquid N/A line after filter-drier and be-
fore TEV. Condenser section
Control box. Sensor in supply water line to buildingfrom 0°F to 10°F from chiller.
Control box
On cooler
Control box
N/A
Adjustable control band (-12.2%)
Adjustable thru LWC1
N/A
3°F
(1.7”C),
fixed
I
Continued on next page
(-17.8”C
Page 44
The McQuay ALR SeasonPak air cooled water chiller provides not only lower operating costs, but lower installation costs, low maintenance costs and greater design flexibility, in both comfort and
process cooling applications.
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.
Page 45

Troubleshooting Chart

Compressor will 1
1. Main switch
2. Fuse blown. Circuit breakers open.
3. Thermal overloads tripped.
4. Defective contactor or
5. System shut down 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 support on suction or liquid line.
3. Worn compressor.
1. Noncondensables in system.
2. System overcharged with refrigerant.
3. Discharge shutoff valve partially closed.
4.
FanTrol
5. Fan not running.
6. Dirty condenser coil.
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 line or compressor suction gas strainers.
5. Expansion valve malfunctioning.
6. Condensing temperature too low.
7. Compressor will not unload.
8. Insufficient water flow.
9. Evaporator head ring gasket slippage.
3.
out of adjustment.
Faulty thermostat stage or broken wire.
coil.
1.
Close switch
2 Checkelectricalcircurtsand motorwtndingforshortsorgrounds
Investigate for possible overloading. Replace fuse or reset breakers after fault is corrected. Check for loose or corroded connections.
3 Overloads are auto reset. Check unit closely when unit comes
back on line.
4. Repair or replace.
5. Determine type and cause of shutdown and correct it before resetting safety switch.
6. None. Wait until unit calls for cooling.
7. Repair or replace coil.
8. Check motor for opens, short
9 Check all wire
1.
Check setting of expansion valve. 2 Relocate, add or remove hangers. 3 Replace.
1 Purgee the noncondensables.
2. Remove excess.
3. Open valve.
4. Adjust
5.
Check electrical circuit.
6 Clean coil. 1 Check condenser control operation.
2. Open valve.
3. Check for leaks. Repair and add charge.
4. See
corrective steps for low suction pressure below.
5. See corrective steps for failure of compressor to load.
1. Reduce load or add additional equipment.
2. Check remote bulb. Regulate superheat.
3. See corrective steps for failure of compressor to load 1 Check for leaks. Repair and add charge.
2 Clean chemically. 3 Replace. 4 Clean 5 Check and reset for proper superheat. 6 Check means for regulating condensing temperature. 7 See corrective steps for failure of compressor to unload. 8 Adjust flow 9 To troubleshoot take pressure drop across vessel and consult
factory to obtain design pressure drop for that vessel.
1 Replace. 2 Replace. 3 Replace. 4
Reset thermostat setting to fit application.
1.
Replace 2 Adjust flow.
FanTrol
strainers.
junctions.
settings.
circuit
Tighten all terminal screws.
or burnout.
1.
Clogged suction oil strainer.
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.
into crankcase.
2. Excessive compression ring blow-by
3. Suction superheat too high.
4. Crankcase heater burnout.
1.
Clean.
2. Check crankcase heater. Reset expansion valve tor
superheat. Check liquid line solenoid valve operation.
3. Repair or replace. Keep valve closed except when taking
ing.
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 Adjust flow.
13 Open valve.
1.
Check for leaks and repair. Add refrigerant
2 Replace compressor.
3. Adjust superheat.
4. Replace crankcase heater.
continued on next page
Page 45 / IM 268
higher
read-
Page 46
Thermal Protector Switch Open
6. High ambient temperature around the overload relay.
7. Failure of second starter to pull in on part winding start system.
1.
Operating beyond design conditions
2. Discharge valve partially shut.
3. Blown valve plate gasket.

Product Warranty

1.
Check supply voltage for excessive line drop.
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 start until fault is corrected.
6.
Provide ventilation to reduce heat.
7.
Repair or replace starter or time delay mechanism.
1. Add facilities so that conditions are within allowable limits
2. Open valve.
3. Replace gasket.
McQuay International, hereinafter referred to as the “Com­pany,” warrants that it will provide, at the Company’s op-
tion, either free replacement parts or free repair of compo-
nent 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 ini­tial start-up or eighteen (18) months from the date shipped by the Company, whichever comes first. For additional con­sideration, McQuay 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 motor­compressor which proves defective in material or workman­ship. For an additional consideration, McQuay 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, or ex­tended motor-compressor warranty, simply contact the sell­ing agency. For McQuay, BarryBlower and
JennFan
brand names, contact McQuay International, Warranty Claims De­partment, PO. 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 war-
ranty of merchantability or fitness for a particular 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, negli-
gence or strict tort.
This parts warranty and the optional .extended warran­ties extend only to the original user. Of course, abuse, mis­use, or alteration of the product in any manner voids the Company’s warranty obligation. Neitherthe 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 con­trols, 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 the Com­pany within ten (10) days of original equipment start-up. If that is not done, the date of shipment shall be presumed to
be 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.
Page 46
/
IM 268
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