McQuay ALR-060A Installation Manual

BULLETIN NO. IM 172

JULY 1978

INSTALLATION AND

MAINTENANCE DATA

PACKAGED AIR COOLED WATER CHILLER

TYPE ALR-060 THRU 130A

GROUP

McQuay-PERFEX

Inc. 13600 Industrial Park Blvd., P.O. Box 1551, Minneapolis, Mn. 55440

INTRODUCTION

NOMENCLATURE

PRE-INSTALLATION

INSTALLATION

HANDLING LOCATION

ACCESS FOR SERVICING

VIBRATION ISOLATORS

WATER PIPING

PIPING PRACTICES CHILLED WATER THERMOSTAT FLOW SWITCH

PIPING CONNECTIONS FIELD WIRING START-UP AND SHUT-DOWN ELECTRICAL

CONTROL CENTER

CONTROL PANEL LAYOUTS

ELECTRICAL LEGEND

SEQUENCE OF OPERATION

PUMPDOWN

MAJOR COMPONENT LOCATIONS

WIRING SCHEMATICS

DESCRIPTION OF UNIT CONTROLS UNIT MAINTENANCE

GENERAL

REFRIGERANT SIGHT GLASS

FILTER-DRIERS

LIQUID LINE SOLENOID VALVE THERMOSTATIC EXPANSION VALVE EVAPORATOR CONDENSERS COMPRESSOR WEAR AND LEAD-LAG COMPRESSOR OIL LEVEL FAN BELT TENSION FAN SHAFT BEARINGS FAN MOTOR BEARINGS ELECTRICAL TERMINALS

IN WARRANTY RETURN MATERIAL PROCEDURE

TROUBLE SHOOTING CHART

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CYCLE

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.-.8-l

..11-13 ..13-16 ..16-4 7

.-.16-l

..18-19

..21-3 9

..40-4 7 ..47-5 1

..48-4 9 ..49-5 0

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. . .

..4- 7

. .

..5- 6 ..6- 7

..8- 9

..10

7 ..17 ..18

..19

..2 0

..4 7 ..4 7 ..4 7 ..4 8

..5 0 ..5 0 ..5 0

..5 1

..5 1 ..5 1 ..5 1 ..5 1 ..5 2

Page 2

INTRODUCTION

McQuay type ALR 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.

evacuation,

installation. with integral subcooler sections, pressors,

and complete refrigerant piping.

included are:

filter driers, dicators, valves.

evaporator heater for chilled water freeze protection, recycling

pumpdown during "on" or "off" seasons,

alternate the compressor starting sequence, of compressors.

The electrical control center includes all safety and operating con-

trols necessary for dependable automatic operation.

and fan motor is fused in all three conductor legs and started by its own three pole contactor.

Each unit is completely assembled and factory wired before

charging and testing,

Each unit consists of: twin air cooled condensers

replaceable tube dual circuit shell and tube evaporator,

manual liquid line

liquid line solenoid valves, sight glass/moisture in-

and double diaphragm hydraulic element thermal expansion

Other features include:

and comes complete and ready for

multiple accessible hermetic com-

Liquid line components that are

shutoff

compressor crankcase heaters, an

compressor lead lag switch to

valves,

and sequenced starting

replaceable core

Each compressor

NOMENCLATURE

RECIPROCATING COMPRESSORS LOW POWER CONSUMING AIR COOLED CONDENSER

-It

ALR- 085AD

DUAL REFRIGERANT CIRCUITS DESIGN VINTAGE

NOMINAL CAPACITY (TONS)

PRE-INSTALLATION

Inspection

When the equipment is received,

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

damage should be reported to the carrier and a claim should be filed.

The unit serial plate should be checked before unloading the unit to

be sure that it agrees with the power supply available.

all items should be carefully checked

All units

All shipping

Page 3

Handling

INSTALLATION

Care should betaken to avoid rough handling or shock due to ping the unit.

Do not push or pull the unit from anything other

drop-

than the base,and block the pushing vehicle away from the unit to prevent damageto the sheet metal cabinet.

FIGURE 1

SUGGESTED PUSHING ARRANGEMENT

GOOD PUSHING ARRANGEMENT

CABINET DAMAGE UNLIKELY

(See Figure 1).

BLOCKING

POOR PUSHING ARRANGEMENT

CABINET DAMAGE LIKELY

Never allow any part of the unit to fall during unloading or moving as this may result in serious damage.

To lift the unit,

2%"

diameter lifting holes are

provided in the base of the unit. Spreader bars and cables should bearranged to prevent damage to the condenser coils or unit cabinet.

FIGURE 2

SPRE

SUGGESTED LIFTING ARRANGEMENT

:ADER

(See Figure 2).

Page 4

‘LMUST

(NOTE CONTROL

USE THESE RIGGING HOLES

Box

LOCATION)

Location

Due to the vertical condenser design, it is recommended that certain precautions be taken before installation to orient the unit so that prevailing winds blow parallel to the unit length thus minimizinq effects on condensing pressure. the unit in this manner, a wind

If it is not practical to orient

deflecting fence should be

consi-

dered.

It is also necessary to provide the unit for service access and 60 in.

fan diameter) should be allowed on each side of the unit

for condenser air inlet and compressor removal on units 060

adequate clearance on all sides of

satisfactory performance.

At least

065.

If parallel units are installed side by side, 120 in. should be allowed between units.

This will prevent excessive condensing temperatures and enhance system performance and operating economy. Clearance for service access should be at least 78 in. at the control center end for compressor removal on units 075 thru 130 and sufficient at the end opposite the control center for evaporator tube replacement.

FIGURE 3

60” MINIMUM-CLEARANCE

These clearances are illustrated in Figure 3.

CLEARANCE AROUND UNIT

FOR AIR INLET

60” MINIMUM CLEARANCE

FOR AIR INLET AND COMPRESSOR

REMOVAL ON ALR-060,065

NOTE: Minimum vertical clearance above unit should be

10 feet

I I

Access for Servicing

Each end of the unit must be accessible after installation for peri-

odic service work.

Compressors,

filter driers,

and manual liquid

line shutoff valves are accessible from the control center end of the

unit through removable access panels on unit sizes 075 thru 130 and

hinged side access doors on unit sizes 060 and 065. safety, They are protected by a keylocked,

tains internal "dead front" nel from high operational controls.

located just below the main control center.

and starting controls are located in the unit control center.

weatherproof enclosure which con-

doors for protection of service person-

voltage starting controls while servicing low voltage

All resettable or adjustable controls are

There is one resettable

All operational,

control enclosure on each side of the unit and each encl.osure contains

controls for compressors on that side of the unit.

Capped connections

for field service gauges are also located inside these enclosures. In addition,

each of these enclosures are removable to improve access to

compressors for field replacement.

Page 5

The condenser fans, motors,

and drives are accessible through a walk-

in, keylocked access door on units ALR-075 thru 130 or a removable access panel on units ALR-060 and located at the end of the unit opposite the control center.

065.

The access door or panel is

Expan-

sion valves are accessible from the same access door on unit sizes 075 thru 130 and from side access doors at the control center end

on unit sizes 060 and 065.

An internal fan guard is located below the condenser fans and drives on units 075 thru 130.

This guard must be removed to service the

fan drives but must always be re-installed when service work is com-

plete.

On unit sizes 060 and 065,

an interlock switch kills power

to condenser fans whenever the access panel is removed for service

work on fans or drives.

CAUTION:

Disconnect all power to the unit while

servicing condenser fan drives.

Vibration Isolators Vibration isolators are recommended for all roof mounted installa-

tions or wherever vibration transmission is a consideration.

lists spring isolators for all ALR unit sizes.

tor locations in relation to the unit control center.

Figure 4 shows isola-

Figure 5 gives

Table 1

dimensions that are required to secure each McQuay isolator selection to the mounting surface.

For applications which require a higher degree of isolation efficiency, Table 2 shows the isolator loads at each location shown in Figure 4, and the maximum loads for each McQuay selection.

TABLE 1

ALR LOCATIONS LOCATIONS UNIT SIZE

060A 065A 075A 2 164048-28 085A 2 16404B-28 105A

IIOA

120A 130A

l&4

ORDERING

NUMBER NUMBER

(877-j

216404B-27 216404B-27 216404B-27

2164048.31

216404B.31 216404B.32 216404B-32 216404B.32 216404B

VIBRATION ISOLATORS

SPRING ISOLATORS

Z&5

ORDERING

(877-j

216404B~27

216404B-28 216404B-28 216404B-31

2164048-31

__-

LOCATIONS

3&6

ORDERING

NUMBER

(877-i

216404B-28 216404B-28 216404B-27

216404B-27

216404B-31

216404B.31 216404B-32 216404B-32

TABLE 2

Page 6

ISOLATOR LOADS

WATER PIPING

Piping Practices Due to the variety of piping practices, it is advisable to follow

the recommendations of local authorities.

They can supply the in-

staller with the proper building and safety codes required 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 perfor-

mance up.

Vibration eliminators to reduce vibration and noise transmission

It should contain:

to the building.

Shutoff valves to isolate the unit from the piping system dur-

2. ing unit servicing.

Manual or automatic air vent valves at the high points of the

system.

Some means of maintaining adequate system water pressure (e.g.; expansion tank or regulating valve).

Temperature and pressure indicators located at the unit to aid in unit servicing.

A strainer or some means of removing foreign matter 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.

Prior to insulating the piping and filling the system, a preliminary leak check should be made. Piping insulation should include a vapor barrier to prevent moisture condensation and 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.

Chilled Water Thermostat

The chilled water thermostat is mounted inside the unit control center.

On models ALR-075A through

130A,

the thermostat sensor is fac-

tory mounted in the return water connection of the evaporator. On models

water line as shown in Figure 6.

ALR-060A

and

065A,,

the sensor must be installed in the return

The thermostat sensor should be in-

sulated after installation.

FIGURE 6

THERMOSTAT SENSOR

REDUCING BUSHING

THERMOSTAT SENSOR INSTALLATION

RETURN WATER CONNECTION OF EVAPORATOR

LRETURN WATER LINE

Page 8

CAUTION:

Flow Switch

Thermostats have maximum operating temperature limits of:

ALR-060 and 065

140F on return water for standard ca-

pacity reduction.

125F on return water for optional capacity reduction. ALR-075 throuqh 130

125F on return water for standard capacity reduction.

250F on return water for optional ca-

pacity reduction.

Temperatures exceeding these limits may damage the controls.

WATER FLOW SWITCH

A ing water line to insure that there will be adequate water cooling load to the evaporator before the unit can start. safeguard against slugging the compressors on start up.

MUST

BE MOUNTED in either the entering

leav-

flow and

This will

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-

175033x-00.

size from to close the switch and are listed in Table 3.

It is a "paddle"

to 6" nominal.

type switch and adaptable to any pipe

Certain minimum flow rates are required

Installation

should be as shown in Figure 7.

TABLE

FLOW SWITCH MINIMUM FLOW RATES

NOMINAL

PIPE SIZE

(INCHES)

l/4

l/2

2112

5 6

MINIMUM REQUIRED

FLOW TO ACTIVATE

SWITCH

6.00

9.80

12.70

18.80

24.30

30.00

39.70

58.70

79.20

(GPM)

FIGURE 7

+ FLOW4

DIA.

5 PIPE

AFTER SWITCH

MINIMUM 5 PIPE DIA.-MINIMUM

FLOW DIRECTION

J’

MARKED ON SWITCH

1.00

NPT FLOW SWITCH

CONNECTION

BEFORE SWITCH

Electrical connections in the unit control center should be made at terminals 11 and 12. should be wired between these two terminals.

normally closed contacts on the switch that could be used for an in-

The normally open contacts of the flow switch

There is also a set of

dicator light or an alarm to indicate when a "no flow" condition

exists.

Page 9

Piping Connections Water piping connections at the unit vary in size and style depen-

ding on the baffle option ordered.

These connection variations are

shown in the table with Figure 8.

Piping through the unit cabinet can be through the end or bottom of

the unit as the application dictates.

hole centers for piping through the end of the unit.

Pilot holes locate

Figure 8 gives

the proper

the necessary dimensions for either piping method.

FIGURE 8

ALR

r\,

060AD 192 80.0 73.8 36.1 16.3 33.7 24.0 065AD 192 80.0 73.8 36.1 16.3 33.7 24.0 075AD 228 98.8 92.5 47.0 8.0 76.0 30.0 91.4

*COOLER CONNECTIONS

Ail

connections

couplings by others.

DIMENSIONS (INCHES)

are NPS steel

Page 10

tib.1

pipe.

thru

6-inch

pipe

connections are

furnished

COOLER

with grooves for

victaulic

Field Wirinq

FIELD WIRING

Wiring should be done in accordance with

all applicable codes and

ordinances.

Warranty

-Warranty is voided if wiring is not in accordance with specifica-

tions.

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.

All unit sizes are set up as standard for separate 115 volt power

supply circuits for the control circuit and cooler heater.

The con-

trol circuit only or both the control circuit and cooler heater can

be powered off of the main unit power supply if the optional control

circuit transformer is ordered.

have the unit

the main unit

out defeating

cooler heater on a separate disconnect switch from

power supply so that the unit may be shut down with-

the freeze protection provided by the cooler heater.

It may be desirable, however, to

TABLE 4

Wire sizing ampacities and recommended power lead wire sizes

Notes: 1. Separate terminals provide for the field connection of a

separate

2. Wire sizing amps are equal to 125% of the Nameplate Amps of the largest motor plus 100% of the Nameplate Amps of all other loads in the circuit (the control circuit is not included). To include the control circuit, add 10 amps to 208 or 230 volt units and 5 amps to 460 volt units. Recommended power lead wire and maximum fuse sizes are not affected.

3. Recommended power lead wire sizes for three conductors per conduit are based on 100% conductor

115/60/1

power supply to the control circuit.

ampacity at 86 F ambient for no more than 3 conductors per conduit. Wire sizes for six conductors per conduit are based on 80% of the above mentioned conductor ampacity in accordance with NEC. Voltage drop has not been included, therefore, it is recommended that power

leads be kept short. All terminal block connections must

be made with copper wire.

The unit power terminal block has two lugs per phase. Single or parallel conductors per phase may be used for power hookup as listed under “Recommended Power

Lead Wire Size.” The cooler heater cable current draw is 3.5 amps.

Page 11

A standard feature on all ALR units is

COPSTM(Controlled

Override of

Pump Shutdown),a system for interlocking the field supplied chilled

water pump into the chiller control system.

A relay (R-19) is wired

into the unit control circuit so that a time clock and/or ambient thermostat can be connected to a pair of terminals (6 and 11) inside the unit control center. starter.

Once the pump starts,

The time clock can energize a pump

the flow switch and/or pump inter-

lock will close and energize that part of the control circuit that

will allow the unit to start.

This feature makes it possible to start the chilled water pump and the chiller simultaneously only when cooling is required.

For re-

cycling pumpdown without a demand for cooling, a pair of relays

(energized by low pressure controls) are also wired into this cir-

cuit to start the pump,

close the flow switch and pump down the

unit.

NOTE:

If a time clock,

ambient thermostat and/or re-

mote on-off switch are not used, terminals 6

and 11 must be jumpered together before the

unit will start.

Figure 9 shows typical field wiring that is required for unit installation.

FIGURE 9

TYPICAL FIELD WIRING DIAGRAM

Standard is separate power supply circuits for controls and cooler heater. These circuits may be combined by installing jumpers from terminals 1 NOTE C: Pump starter, contacts of R9, terminals 7 & 8 are limited to 250 volts maximum.

CUSTOMER CONNECTION FIELD WIRING FACTORY WIRING BLACK WIRING (LINE) WHITE WIRING (NEUTRAL)

flow switch and/or starter interlock.

9 & 10 - 20.

R10,

and

R19

between

START - UP AND SHUT DOWN

Pre Start-Up

With all electric disconnects open,

check all screw or lug type electrical connections to be sure they are tight for good electrical contact. fore shipment,

Although all factory connections are tight be-

some loosening may have resulted from shipping

vibration,

Inspect all water piping for flow direction and correct connections at the evaporator.

Page 13

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. system piping to obtain clean,

orator circuit.

Check to see that the thermostat water temperature sensor is installed in the return water line (return to chiller).

075A through ALR-060A tion, and the sensor should be secured in the well with the retaining

clip provided. On ALR-075A through 130A units with optional cap-

acity reduction,the sensor is installed directly into the return water line i.e.;

Check the compressor oil level. Prior to start-up, the oil level should cover at least

Remove the (8) compressor shipping blocks that are attached to the

compressor rails and the base of the unit. not have shipping blocks. Check the voltage of the unit power supply and see that it is within the balance must be with _+ 2%. Check the unit power supply wiring for adequate ampacity and a minimum insulation temperature rating of 75C. Verify that all mechanical and electrical inspections have been

completed per local codes.

See that all auxiliary control equipment is operative and that an adequate cooling load is available forinitial start up.

and 065A units with standard or optional capacity reduc-

the sensor well should be full of heat conducting

13OA

10%

units with standard capacity reduction, or

no well or heat conducting compound is required.

l/2

tolerance that is allowed.

non-corrosive water in the evap-

of the oil sight glass.

Flush the evaporator and

ALR-

compound

The ALR 060 and 065 do

Phase voltage un-

Start-Up

Open the compressor suction and discharge back seated.

Open the manual liquid line shutoff valve at the outlet of the subcooler.

Check to see that pumpdown switches

3. pumpdown"position and the control stop switch

"on

position.

Adjust the dial on temperature controller

chilled water temperature.

Throw the main power and control circuit disconnects to the "on"

5. position.

CAUTION:

Allow the crankcase heaters to operate for at least 8 hours prior to start-up.

Start the auxiliary equipment for the installation by turning

7. on the time clock,

if the unit and chilled water pump are electrically interlocked

by using the COPS

Start the system by moving pumpdown switches

"auto.

After system performance has stabilized, it

"Compressorized Equipment Warranty Form" (form no. 206036A) be

completed to obtain full warranty benefits.

with the unit and after completion should be returned to McQuay's

Service Department through your sales representative.

pumpdown" position.

Always replace valve seal caps.

(PSl &

Most relays and terminals in the unit control center are hot with control circuit

ambient thermostat and/or remote on/off switch

method discussed in "Field Wiring".

disconnect

shutoff valves until

PS2) are in the

(Sl)

is in the

TCl

to the desired

and the

on.

(PSl &

necessary that the

This form is shipped

PS2) to the

"man.

Page 14

Temporary Shut-Down

Move pumpdown switches

After

pump.

It is important that the compressors pump down before the water flow

to the unit is interrupted to avoid freeze up in the evaporator.

Start-Up After Temporary Shut-Down

Extended Shut-Down

the compressors have pumped down, turn off the chilled water

NOTE:

Start the chilled water pump.

With control stop switch

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

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

Turn off all power to the unit and to the chilled water pump. Move the control stop switch

Close the compressor suction and discharge valves.

Tag all opened disconnect switches to warn against start up be-

fore opening the compressor suction and discharge valves. Drain all water from the unit evaporator and chilled water pip-

ing if the unit is to be shut down during winter.

With the unit left in this condition, it is

capable of recycling pumpdown operation. To

defeat this mode of operation, simply move

control stop switch

(PSl &

(PSl

& PS2) to the "man. pumpdown" position.

(Sl)

to the "off" position.

(Sl)

in the

PS2) to the "auto. pumpdown" position.

(Sl)

to the "off" position.

"on"

position, move pump-

Start-Up After Extended Shut-Down

Inspect all auxiliary equipment to see that it is in satisfac-

tory operating condition.

Remove all debris that has collected on the surface of the condenser coils.

Open the compressor suction and discharge valves.

Open the manual liquid line shut off valves.

Check to see that pumpdown switches ual pumpdown position.

Turn on the electric power to the unit and other parts of the

system.

Allow the crankcase heaters to operate for at least 8 hours prior to start-up.

Start the chilled water pump and purge the water piping as well

as the evaporator in the unit.

Check to see that the control stop switch tion.

CAUTION:

Most relays and terminals in the unit

control center are hot with control circuit disconnect on.

(PSl

and PS2) are in the man-

(S1)is

in the

and the

"on"

posi-

Page 15

10.

Start the unit by moving

pumpdown

switches

(PSl

& PS2) to the

"auto.pumpdown" position.

11.

After running the unit for a short time check the oil level in

each compressor crankcase and check for flashing in the refrigerant sight glass (see "Maintenance" on Page 47).

ELECTRICAL

Control Center

All electrical controls are enclosed in a weatherproof control cen-

ter with keylocked, hinged access doors.

posed of three separate enclosures.

The upper enclosure is the largest and contains all of the 208, 230, fan motor starting controls.

Also included in this enclosure but

partitioned separately are the exposed terminal type

ational controls.

A "dead front"

cover over the high voltage sec-

The control center is com-

or 460 volt compressor and

115 volt oper-

tion protects service personnel from high voltage starting controls

while servicing low voltage operational controls.

Below the upper enclosure are two smaller, contain 115 volt adjustable or resettable controls.

separate enclosures that

There is one of

these enclosures on each side of the unit, and each contains controls

for the compressors on that side.

Power supply conduits are intended to come into the bottom of the upper enclosure and between the two lower enclosures.

mended that the unit disconnect switch be mounted away but

Figure 10 recommends unit mounting arrangements if the disconnect

it is recomfrom the unit

must be unit mounted.

Page 16

+ 36 hidden pages

McQuay ALR-060A Installation Manual

TABLE OF CONTENTS

INTRODUCTION

NOMENCLATURE

PRE-INSTALLATION

Handling

INSTALLATION

Location

Access for Servicing

VIBRATION ISOLATORS

WATER PIPING

Chilled Water Thermostat

Flow Switch

FIELD WIRING

START - UP AND SHUT DOWN

ELECTRICAL

Control Center