McQuay ALR110E Installation Manual
Installation Manual
IM ALR
Packaged Air-Cooled Water Chiller
ALR 110E - ALR 185E
Refrigerant R-22, 60 Hertz
Group:
Part Number:
Effective:
Supersedes:
Chiller
November 1997
074653001
IM 676
© 1997 McQuay International
Table of Contents
Introduction...............................................................................................................3
General Description............................................................................................................................... 3
Inspection..............................................................................................................................................3
Installation............................................................................................................................................. 3
Handling................................................................................................................................................3
Location................................................................................................................................................. 4
Service Access.......................................................................................................................................5
Vibration Isolators.................................................................................................................................6
Water Piping..........................................................................................................................................7
Flow Switch...........................................................................................................................................8
Water Connections.................................................................................................................................8
Refrigerant Charge ................................................................................................................................9
Glycol Solutions....................................................................................................................................9
Evaporator Water Flow and Pressure Drop.........................................................................................11
Physical Data ...........................................................................................................12
Electrical Data......................................................................................................... 15
Field Wiring.........................................................................................................................................15
Dimensional Data.................................................................................................... 24
Unit Layout and Principles of Operation..............................................................25
Control Center.....................................................................................................................................25
Start-up and Shutdown .......................................................................................... 27
Pre Start-up.......................................................................................................................................... 27
Start-up................................................................................................................................................27
Sequence of Operation ........................................................................................................................ 28
"McQuay" is a registered trademarks of McQuay International
"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
2
1997 McQuay International
construction at anytime without notice"
ALR 110E through 185E IM ALR
Introduction
General Description
McQuay air-cooled water chillers are complete, self-contained automatic refrigerating units. Every
unit is completely assembled, factory wired, charged, and tested. Each unit consists of twin air-cooled
condensers with integral subcooler sections, multiple accessible hermetic compressors, replaceable
tube dual circuit shell-and-tube evaporator, and complete refrigerant piping. Liquid line components
include manual liquid line shutoff valves, sight-glass/moisture indicators, solenoid valves, and double
diaphragm hydraulic element thermal expansion valves. Other features include compressor crankcase
heaters, an evaporator heater for chilled water freeze protection, limited pumpdown during “on” or
“off” periods, compressor lead-lag switch to alternate the compressor starting sequence, and
sequenced starting of compressors.
automatic operation. Condenser fan motors are fused in all three phases and started by their own
three-pole contactors. Compressors are not fused but may be protected by optional circuit breakers,
or by a field installed fused disconnect.
Inspection
Check all items carefully against the bill of lading. Inspect all units for damage upon arrival. Report
shipping damage and file a claim with the carrier. Check the unit name plate before unloading,
making certain it agrees with the power supply available. McQuay is not responsible for physical
damage after unit leaves the factory.
The electrical control center includes all safety and operating controls necessary for dependable
Note:
Unit shipping and operating weights are available in the Physical Data tables
beginning on page 12.
Installation
Note:
Installation is to be performed by qualified personnel who are familiar with local codes
and regulations.
WARNING
Sharp edges and coil surfaces are a potential hazard. Avoid contact with them.
Handling
Be careful to avoi d rough handling of the unit. Do not push or pull the unit from anything other than
the base. Block the pushing vehicle away from the unit to prevent damage to the sheet metal cabinet
and end frame (see Figure 1).
To lift the unit, 2 1/2" (64mm) diameter lifting holes are provided in the base o f the unit.
Arrange spreader bars and cables to prevent damage to the condenser coils or cabinet (see Figure 2).
IM ALR ALR110E through 185E
3
Figure 1, Suggested pushing arrangement
co
ocation)
Figure 2, Suggested lifting arrangement
Spreader bars
recommended
(Use Caution)
Blocking required
across full width
NOTE: Number of fans can vary
from this diagram. Lifting method
remains the same.
Must use these rigging
holes. (Be aware of
ntrol box l
Location
Unit Placement
ALR units are for outdoor applications and can be mounted on a roof or ground level. Set units on a
solid and level foundation. For roof mounted applications, install the unit on a steel channel or Ibeam frame to support the unit above the roof. For ground level applications, install the unit on a
substantial base that will not settle. A one piece concrete slab with footings extended below the frost
line is recommended. Be sure the foundation is level (within 1/2” [13 mm] over its length and width).
The foundation must support the operating weights listed in the Physical Data tables beginning on
page 12.
On ground level app lications protect fins against vandalism using the optional coil guards or by
erecting a screen fence. The fence must allow free flow of air to the condenser coil for proper unit
operation.
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ALR 110E through 185E IM ALR
Clearances
The flow of air to and from the condenser coil must not be limited. Restricting air flow or allowing
air recirculation will result in a decrease in unit performance and efficiency. There must be no
obstruction above the unit that would deflect discharge air downward where it could be recirculated
back to the inlet of the condenser coil. The condenser fans are prope ller type and will not operate
with ductwork on the fan outlet.
Install the unit with enough side clearance for air entrance to the coil and for servicing. Provid e
service access to the evaporator, compressors, electrical control panel and piping components as
shown in Figure 3.
Do not allow debris to accumulate near the unit. Air movement may draw debris into the
condenser coil causing air starvation. Give special consideration to low ambient operation where
snow can accumulate. Keep condenser coils and fan discharge free of snow or other obstructions to
permit adequate airflow.
Figure 3, Clearance requirements
5 ft. (1524mm) Clearance for
air inlet
4 Ft.
(1220mm)
clearance for
5 Ft. (1524mm) clearance for
air inlet
"10 feet (3048)
for evaporator
tube removal
Sound Isolation
The ultra-low sound levels of the ALR reciprocating
chiller is suitable for most applications. When
additional sound reduction is necessary, locate the
unit away from sound sensitive areas. Avoid
locations beneath windows or between structures
where normal operating sounds may be
objectionable. Reduce structurally transmitted sound
by isolating water lines, electrical conduit and the
unit itself. Use wall sleeves and rubber isolated
piping hangers to reduce transmission of water or
pump noise into occupied spaces. Use flexible
electrical conduit to isolate sound thr ough electrical
conduit. Spring isolators are effective in reducing the
low amplitude sound generated by reciprocating
compressors and for unit isolation in sound sensitive
areas.
Service Access
Each end of the unit must be accessible after installation for periodic service. Compressors, filterdriers, and manual liquid line shutoff valves are accessible on each side of the unit adjacent to the
control box. High pressure, low pressure, and motor protector controls are on the compressor.
Freezestats and cooler barrel thermostats are near the cooler. Most other operational, safety and
starting controls are located in the unit control box.
The condenser fan and motors can be removed from the top of the unit.
IM ALR ALR110E through 185E
5
Vibration Isolators
Vibration isolators are recommended for all roof mounted installations or wherever vibration
transmission is a consideration. Table 1 lists isolator loads and type. Table 2 lists spring isolator part
numbers for all unit sizes. See Dimensional Data beginning on page 24 for dimensions required to
secure each isolator to the mounting surface.
Table 1, Isolator Loads and Type
ALR ISOLATOR LOADS AND TYPE FOR EACH MOUNTING LOCATION
UNIT R S T
SIZE TYPE LB KG TYPE LB KG TYPE LB KG
110E CP-2-28 1339 607 CP-2-28 1364 619 CP-2-31 1697 770
120E CP-2-31 1362 618 CP-2-31 1490 676 CP-2-32 1748 793
130E CP-2-31 1492 677 CP-2-32 1570 712 CP-2-32 1838 834
135E CP-2-31 1506 683 CP-2-32 1670 758 CP-2-32 1904 864
140E CP-2-31 1556 706 CP-2-32 1752 795 CP-2-32 1912 867
145E CP-2-31 1572 713 CP-2-32 1680 762 CP-4-27 2093 949
150E CP-2-32 1601 726 CP-2-32 1704 773 CP-4-27 2120 962
160E CP-4-27 1948 884 CP-2-32 1962 890 CP-2-32 1848 838
170E CP-4-27 2052 931 CP-2-32 2002 908 CP-2-32 1849 839
180E CP-4-27 2052 931 CP-2-32 2002 908 CP-2-32 1849 839
185E CP-4-27 2052 931 CP-2-32 2002 908 CP-2-32 1849 839
Two of each isolator type is required for a total of six per unit.
NOTE:
Table 2, Spring Flex Isolator Part Numbers
TYPE COLOR McQuay Each
Part No. Lb. KG
CP1-25 Red 477927A-25 450 204
CP1-26 Purple 477927A-26 600 272
CP1-27 Orange 477927A-27 750 340
CP1-28 Green 477927A-28 900 408
CP1-31 Gray 477927A-31 1100 499
CP1-32 White 477927A-32 1300 590
CP2-25 Red 477929A-25 900 408
CP2-26 Purple 477929A-26 1200 544
CP2-27 Orange 477929A-27 1500 681
CP2-28 Green 477929A-28 1800 817
CP2-31 Gray 477929A-31 2200 998
CP2-32 White 477929A-32 2600 1180
CP4-26 Purple 580513A-26 2400 1089
CP4-27 Orange 580513A-27 3000 1361
CP4-28 Green 580513A-28 3600 1633
CP4-31 Gray 580513A-31 4400 1996
CP4-32 White 580513A-32 5200 2359
Max. Load
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ALR 110E through 185E IM ALR
Water Piping
Local authorities can supply the installer with the proper building and safety codes required for safe
and proper installation.
Install piping with minimum bends and changes in elevation to minimize pressure drop. Consider
the following when installing water piping:
1. Vibration eliminators to reduce vibration and noise transmission 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. Install drains at the lowest
points in the system.
4. A means of maintaining adequate system water pressure (expansion tank or regulating valve).
5. Temperature and pressure indicators located at the unit to aid in unit servicing.
6. A strainer or other means of removing foreign matter from the water before it enters the pump.
Place the strainer 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 keep
system performance up.
7. Place a strainer in the water line just before the inlet of the evaporator. This will help prevent
foreign material from entering and decreasing the performance of the evaporator.
CAUTION
If separate disconnect is us ed for the 110V supply to the evaporator heating cable, m ark the
disconnect clearly to ensure disconnect is not accidentally shut off during cold seasons.
8. The shell-and-tube evaporator has a thermostat and heating cable to prevent freeze-up down to 20°F (-29°C). It is suggested that the he a ting cable be wired to a separate 110V supply circuit.
As shipped from the factory, the heating cable is wired to the control circuit. All water piping to
the unit must also be protected to prevent freezing.
9. If the unit is used as a replacement chiller on a previously existing piping system, flush the
system thoroughly before unit installation. Regular water anal ysis and che mical water tre atment
on the evaporator is recommended immediately at equipment start-up.
10. The total water volume in the system should be sufficient to prevent frequent “on-off” cycling.
Turnover rate should not be less than 15 minutes for normal variable cooling loads. Turnover
rate for process cooling or a constant load, should not be less than 6 minutes.
11. When glycol is added to the water system for freeze protection, the refrigerant suction pressure
will be lower, cooling performance less, and water side pressure drop greater. If the percentage
of glycol is high, or if propylene is used 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°C). Reset the freezestat setting
to approximately 4 to 5 degrees F (2.3 to 2.8 degrees C) belo w the leaving chilled water setpoint
temperature. See the section titled “Glycol Solutions” for additional information concerning
glycol.
12. Perform a preliminary leak check before insulating the piping and filling the system.
13. Piping insulation should include a vapor barrier to prevent condensation and possible damage to
the building structure.
IM ALR ALR110E through 185E
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Figure 4, Typical field evaporator water piping
Vent
Outlet
Valved
pressure
gauge
Vibration
Eliminator
Flow
Switch
Balancing
valve
Gate valve
Protect all field piping
against freezing
Drain
Vibration
Eliminator
Water
strainer
Gate valve
Flow Switch
Mount a water flow switch in either the entering or leaving water line to shut down the unit when
water flow is interrupted.
A flow switch is available from McQuay (part number 00175033-00). It is a “paddle” type
switch and adaptable to any pipe size from 3” (76mm) to 8” (203mm) nominal. Certain minimum
flow rates are required to close the switch and are listed in Table 3. Installation should be as shown in
Figure 5. Connect the normally open contacts of the flow switch in the unit control center at terminals
5 and 6. There is also a set of normally closed contacts on the switch that can be used for an indicator
light or an alarm to indicate when a “no flow” condition exists. Freeze protect any flow switch that is
installed outdoors.
NOTE:
Differential pressure switches are not recommended for outdoor installation.
Table 3, Flow switch minimum flow rates
NOMINAL PIPE SIZE MINIMUM REQUIRED FLOW TO
INCHES (MM) ACTIVATE SWITCH - GPM (L/s)
1 (25.4) 6.00 (0.38)
11/4 (31.8) 9.80 (0.62)
11/2 (38.1) 12.70 (0.80)
2 (50.8) 18.80 (1.20)
21/2 (63.50) 24.30 (1.50)
3 (76.20) 30.00 (1.90)
4 (101.6) 39.70 (2.50)
5 (127.0) 58.70 (3.70)
6 (152.4) 79.20 (5.00)
Figure 5, Flow switch installation
Flow direction marked
on switch
1" (25mm) NPT flow
switch connection
Tee
5" (127mm) pipe dia.
Min. after switch
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ALR 110E through 185E IM ALR
5" (127mm) pipe dia.
Min. before switch
The procedure
Note:
does not specify the
type of glycol. Use
the derate factors
found in Table 4 for
corrections when
using ethylene glycol
and those in Table 5
for propylene glycol.
Water Connections
Bring water piping to the Evaporator from the bottom of the unit or through the side between the
vertical supports.
Note:
On units sizes 160E through 185E 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.
Refrigerant Charge
All units are designed for use with HCFC-22 are shipped with an operating charge. The operating
charge (using HCFC-22) for each unit is shown in the Physical Data tables beginning on page 12.
Glycol Solutions
The system glycol capacity, glycol solution flow rate in GPM, and pressure dr op through the cooler
may be calculated using the following formulas and table.
1.
Capacity --
capacity correction factor C.
2.
Flow
Glycol GPM (from table)
For Metric Applications
and kW:
Glycol L / s (from table)
3.
Pressure drop
the water pressure drop curve on page 11 at the actual glycol GPM. Multiply the water pressure
drop by PD correction factor from Table 4 or Table 5 to obtain corrected glycol pressure drop.
4. To determine the unit's power consumption when using glycol, multiply the water system kW by
factor kW.
Test coolant with a clean, accurate glycol solution hydrometer (similar to that found in service
stations) to determine the freezing point. Obtain percent glycol from the freezing point table below.
On glycol applications it is normally recommended by the supplier that a minimum of 25% solution
by weight be used for protection against corrosion.
Find the reduced capacity by multiplying the chiller capacity with water by the
-- To determine evaporator gpm (or Delta-T) knowing Delta-T (or gpm) and capacity:
×
24 capacity glycol
=
()
−
Delta T
×
G
-- To determine evaporator L/s (or Delta-T) knowing Delta-T (or L/s)
=
kW
×−
Delta T
4.18
×
Flow
-- To determine pressure drop through the evaporator, when using glycol, enter
IM ALR ALR110E through 185E
9
CAUTION
Do not use an automotive 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.
Table 4, Ethylene glycol
% Freeze Point
E.G. °F °C Cap. kW GPM PD
10 26 -3 0.991 0.996 1.013 1.070
20 18 -8 0.982 0.992 1.040 1.129
30 7 -14 0.972 0.986 1.074 1.181
40 -7 -22 0.961 0.976 1.121 1.263
50 -28 -33 0.946 0.966 1.178 1.308
Table 5, Propylene glycol
% Freeze Point
P.G. °F °C Cap. kW GPM PD
10 26 -3 0.987 0.992 1.010 1.068
20 19 -7 0.975 0.985 1.028 1.147
30 9 -13 0.962 0.978 1.050 1.248
40 -5 -21 0.946 0.971 1.078 1.366
50 -27 -33 0.929 0.965 1.116 1.481
Table 6, Capacity and power derates
Chilled Water Fouling Factor
ALTITUDE °F °C Cap. kW Cap. kW Cap. kW
SEA 10 5.6 1.000 1.000 0.975 0.986 0.919 0.939
LEVEL 12 6.7 1.005 1.002 0.980 0.989 0.923 0.941
2000 feet 12 6.7 0.992 1.011 0.970 0.998 0.914 0.949
4000 feet 12 6.7 0.978 1.025 0.956 1.008 0.904 0.958
6000 feet 12 6.7 0.963 1.034 0.942 1.017 0.895 0.966
Delta-T 0.00025 (0.044) 0.00075 (0.132) 0.00175 (0.308)
6 3.3 0.992 0.995 0.996 0.982 0.911 0.935
8 4.4 0.995 0.997 0.969 0.984 0.914 0.937
14 6.8 1.010 1.005 0.985 0.991 0.928 0.943
16 8.9 1.014 1.007 0.989 0.993 0.930 0.944
6 3.3 0.978 1.005 0.957 0.990 0.903 0.943
8 4.4 0.982 1.007 0.961 0.993 0.905 0.945
10 5.6 0.986 1.009 0.965 0.995 0.909 0.947
14 6.8 0.997 1.014 0.973 1.001 0.919 0.952
16 8.9 1.000 1.016 0.975 1.002 0.921 0.953
6 3.3 0.966 1.016 0.944 0.999 0.894 0.951
8 4.4 0.969 1.018 0.947 1.001 0.896 0.953
10 5.6 0.973 1.021 0.952 1.005 0.900 0.956
14 6.8 0.982 1.027 0.959 1.011 0.909 0.960
16 8.9 0.986 1.028 0.961 1.015 0.911 0.961
6 3.3 0.953 1.025 0.930 1.009 0.884 0.961
8 4.4 0.955 1.028 0.934 1.011 0.887 0.962
10 5.6 0.959 1.031 0.939 1.013 0.890 0.964
14 6.8 0.968 1.036 0.946 1.020 0.899 0.968
16 8.9 0.972 1.037 0.949 1.024 0.902 0.969
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ALR 110E through 185E IM ALR
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