McQuay ALR110F Installation Manual

Installation, Operation and Maintenance Manual IOMM ALR-2

Packaged Air-Cooled Water Chiller

ALR 110F - ALR 150F Refrigerant R-22, 60 Hertz

Group: Chiller Part Number: 330145705 Effective: December 2000 Supersedes: IM ALR-1

Table of Contents

Introduction.................................................................................................................3

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

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

Installation.................................................................................................................................................................3

Handling....................................................................................................................................................................4

Installation and Application........................................................................................5

Location.....................................................................................................................................................................5

Vibration Isolators.....................................................................................................................................................7

Lifting and Mounting Weights...................................................................................................................................7

Water Piping..............................................................................................................................................................8

Refrigerant Charge...................................................................................................................................................10

Glycol Solutions......................................................................................................................................................10

Evaporator Water Flow and Pressure Drop............................................................................................................11

Variable Water Flow................................................................................................................................................11

Physical Data.............................................................................................................13

Electrical Data...........................................................................................................15

Field Wiring.............................................................................................................................................................15

Dimensional Data......................................................................................................23

Wind Baffles and Hail Guards..................................................................................24

Remote Evaporator...................................................................................................25

General....................................................................................................................................................................25

Dimensions, Remote Evaporator............................................................................................................................27

Unit Layout and Principles of Operation..................................................................28

Control Center.........................................................................................................................................................28

Start-up and Shutdown..............................................................................................29

Pre Start-up.............................................................................................................................................................29

Start-up ...................................................................................................................................................................29

Sequence of Operation............................................................................................................................................30

Unit Maintenance......................................................................................................31

Preventative Maintenance Schedule........................................................................................................................32

Refrigerant Charging................................................................................................................................................33

ALR Troubleshooting Chart ...................................................................................................................................34

"McQuay" is a registered trademarks of McQuay International

"Illustrations and data cover the McQuay International products at the time of publication and we reserve the right

to make changes in design and construction at anytime without notice"

2 ALR 110F through 150F IOMM ALR-2



1997 McQuay International

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, two accessible hermetic compressors per circuit, replaceable tube, dual circuit shelland-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.

The electrical control center includes all safety and operating controls necessary for dependable automatic operation. Condenser fan motors are fused in all three phases and started by their own three-pole contactors. Compressors are protected by circuit breakers. Optional factory installed or field installed fused disconnect switches are available.

Operator information on the standard UNT controller can be found in IOM UNT33n. Information on the optional MicroTech control can be found in the latest version of OM-RCPMICRO.

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.

Note: Unit shipping and operating weights are available in the Physical Data tables beginning on page 13.

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.

IOMM ALR-2 ALR110F through 150F 3

Handling

Be careful to avoid 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.

To lift the unit, 2 1/2" (64mm) diameter lifting holes are provided in the base of the unit. Arrange spreader bars and cables to prevent damage to the condenser coils or cabinet (see Figure 2).

Figure 1, Suggested Pushing Arrangement

Figure 2, Required Lifting Arrangement

NOTES:

1. All four rigging points on a unit must be used. See Figure 5 for location, and weight at lifting points for a specific size unit.

2. Crosswise and lengthwise spreader bars must be used to avoid damage to unit. Lifting cables from the unit mounting holes up must be vertical.

3. The number of condenser fans can vary from this diagram.

4 ALR 110F through 150F IOMM ALR-2

Installation and Application

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 I-beam 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 13.

On ground level applications protect the unit against vandalism by using the optional lower wire mesh guards or by erecting a screen fence. The fence must allow free flow of air to the condenser coil for proper unit operation.

Clearances

The flow of air to and from the condenser coils 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 propeller 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. Provide 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.

Service Access

Each end of the unit must be accessible after installation for periodic service. Compressors, filter-driers, and manual liquid line shutoff valves are accessible on each side of the unit adjacent to the control box. High pressure, low pressure, and motor protector controls are on 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.

IOMM ALR-2 ALR110F through 150F 5

Figure 3, Clearance Requirements

Notes:

1. Minimum side clearance between two units is 12 feet.

2. Unit must not be installed in a pit or enclosure that is deeper or taller than the height of the unit unless extra

clearance is provided per note 4.

3. Minimum clearance on each side is 8 feet when installed in a pit no deeper than the unit height.

4. Minimum side clearance to a side wall or building taller than the unit height is 8 feet provided no solid wall

above 6 feet is closer than 12 feet to the opposite side of the unit.

5. The evaporator can be removed from the side of the unit.

6. Do not mount electrical conduits, etc, above the side rail on either side if the unit.

7. There must be no obstruction of the fan discharge.

Sound Isolation

The low sound level 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 through electrical conduit. Spring isolators are effective in reducing the low amplitude sound generated by reciprocating compressors and for unit isolation in sound sensitive areas.

6 ALR 110F through 150F IOMM ALR-2

Vibration Isolators

Vibration isolators are recommended for all roof mounted installations or wherever vibration transmission is a consideration.

Figure 4, Spring Flex Isolators

Lifting and Mounting Weights

Figure 5, ALR 110-150 Lifting and Mounting Locations

ALR

Model

36 (914)

BOX

CONTROL

46 (1168)

NOTES: 2 ½ in. (63.5 mm) lifting holes at location "L" on sides of base rails. 1 in. (25.4 mm) mounting holes at location "M" on bottom of base rails.

Lifting Weight for Each Point

102 (2591)

Mounting Loads for Each Point

lb (kg)

L1 & L2 L3 & L4 R1 & R2 R3 & R4 R5 & R6

192 (4877)

161 (4089)

lb. (kg)

110 2585 (1171) 2125 (963) 1835 (831) 1785 (809) 1230 (557) 9700 (4394) 9420 (4267) 1370 (620) 120 2570 (1164) 2205 (999) 1830 (829) 1805 (818) 1305 (591) 9880 (4476) 9550 (4326) 1370 (620) 130 2570 (1164) 2205 (999) 1830 (829) 1805 (818) 1305 (591) 9880 (4476) 9550 (4326) 1370 (620) 135 2570 (1164) 2205 (999) 1830 (829) 1805 (818) 1305 (591) 9880 (4476) 9550 (4326) 1370 (620) 140 2570 (1166) 2210 (1001) 1830 (829) 1805 (818) 1310 (593) 9890 (4478) 9560 (4340) 1370 (620) 145 2570 (1166) 2210 (1001) 1830 (829) 1805 (818) 1310 (593) 9890 (4480) 9560 (4330) 1370 (620) 150 2600 (1178) 2280 (1032) 1860 (842) 1840 (833) 1345 (609) 10090 (4571) 9760 (4421) 1370 (620)

83.4

(2118)

Operating Wt

lb. (kg)

2 (51) Typical Spacing for Isolator Mounting (6)

Shipping Wt.

lb. (kg)

Copper Fin

Add

IOMM ALR-2 ALR110F through 150F 7

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 used for the 110V supply to the evaporator heating cable, mark 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 heating 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 analysis and chemical water treatment on the evaporator is recommended immediately at equipment start-up.

10. The total water quantity in the system should be sufficient to prevent frequent "on-off" cycling. For air-

conditioning systems, system gallons equal to 7 time the flow rate is recommended..

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) below 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.

8 ALR 110F through 150F IOMM ALR-2

Figure 6, Typical 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 017503300). 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 1. Installation should be as shown in Figure 7. 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 1, Flow Switch Minimum Flow Rates

NOMINAL PIPE SIZE MINIMUM REQUIRED FLOW TO

INCHES (MM) ACTIVATE SWITCH - GPM (L/s)

3 (76.20) 30 (1.9) 4 (101.6) 39 (2.5) 5 (127.0) 59 (3.7) 6 (152.4) 79 (5.0) 8 (203.0) 140 (8.8)

Figure 7, Flow Switch Installation

Flow direction marked on switch

1" (25mm) NPT flow switch connection

Tee

1 1/4" (32mm) pipe dia. min. after switch

1 1/4" (32mm) pipe dia. min. before switch

Water Connections

Bring water piping to the evaporator from the bottom of the unit or through the side between the vertical supports.

IOMM ALR-2 ALR110F through 150F 9

Note: The procedure does not specify the type of glycol. Use the derate factors found in Table 2 for corrections when using ethylene glycol and those in Table 3 for propylene glycol.

Refrigerant Charge

All units designed for use with HCFC-22 are shipped with an operating charge (remote evaporator applications are shipped with a unit operating charge and may require additional charge for field piping). The operating charge (using HCFC-22) for each unit is shown in the Physical Data tables beginning on page 13.

Glycol Solutions

The system glycol capacity, glycol solution flow rate, and pressure drop through the cooler may be calculated using the following formulas and Table 4.

1. Capacity -- Find the reduced capacity by multiplying the chiller capacity with water by the capacity

correction factor "Cap".

2. Flow -- To determine evaporator flow (or Delta-T) knowing Delta-T (or GPM) and capacity:

)(24

GPM Glycol FactorFlow

For Metric Applications -- To determine evaporator L/s (or Delta-T) knowing Delta-T (or L/s) and kW:

L/s Glycol FactorFlow

18.4

3. Pressure drop -- To determine pressure drop through the evaporator, when using glycol, enter the water

pressure drop curve on page 12 at the water flow. Multiply the water pressure drop by "PD" correction factor from Table 2 or Table 3 to obtain corrected glycol pressure drop.

4. To determine the unit's power consumption when using glycol, multiply the water system kW by glycol

factor "kW".

Test coolant with a clean, accurate glycol solution hydrometer (similar to that found in service stations) to determine the freezing point. Obtain the percent glycol from the freezing point table below. It is normally recommended by the supplier that a minimum of 25% glycol solution by weight be used for protection against corrosion.

glycolcapacity

TDelta

−

TDelta

−×

2,3) table(from

CAUTION

Do not use automotive grade antifreeze. Industrial grade glycols must be used. Automotive

antifreeze contains inhibitors that 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 2, Ethylene Glycol

% Freeze Point

E.G. °F °C Cap. kW Flow 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 3, Propylene Glycol

% Freeze Point

P.G. °F °C Cap. kW Flow 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

10 ALR 110F through 150F IOMM ALR-2

Table 4, Capacity and Power Derates

SEA

LEVEL

2000 feet

(610 m)

4000 feet

(1220 m)

6000 feet

(1830 m)

Water

Delta-T

°F °C Cap. Power Cap. Power Cap. Power Cap. Power

6 3.3 0.992 0.995 0.985 0.993 0.962 0.986 0.919 0.972

8 4.4 0.995 0.997 0.988 0.995 0.965 0.988 0.922 0.974 10 5.6 1.000 1.000 0.993 0.998 0.970 0.991 0.927 0.977 12 6.7 1.005 1.002 0.998 1.000 0.975 0.993 0.932 0.979 14 6.8 1.010 1.005 1.003 1.003 0.980 0.996 0.936 0.982 16 8.9 1.014 1.007 1.007 1.005 0.984 0.998 0.940 0.984

6 3.3 0.978 1.005 0.971 1.003 0.949 0.996 0.906 0.982

8 4.4 0.982 1.007 0.975 1.005 0.953 0.998 0.910 0.984 10 5.6 0.986 1.009 0.979 1.007 0.956 1.000 0.914 0.986 12 6.7 0.992 1.011 0.985 1.009 0.962 1.002 0.919 0.988 14 6.8 0.997 1.014 0.990 1.012 0.967 1.005 0.924 0.991 16 8.9 1.000 1.016 0.993 1.014 0.970 1.007 0.927 0.993

6 3.3 0.966 1.016 0.959 1.014 0.937 1.007 0.895 0.993

8 4.4 0.969 1.018 0.962 1.016 0.940 1.009 0.898 0.995 10 5.6 0.973 1.021 0.966 1.019 0.944 1.012 0.902 0.998 12 6.7 0.978 1.025 0.971 1.023 0.949 1.016 0.906 1.002 14 6.8 0.982 1.027 0.975 1.025 0.953 1.018 0.910 1.004 16 8.9 0.986 1.028 0.979 1.026 0.956 1.019 0.914 1.005

6 3.3 0.953 1.025 0.946 1.023 0.924 1.016 0.883 1.002

8 4.4 0.955 1.028 0.948 1.026 0.926 1.019 0.885 1.005 10 5.6 0.959 1.031 0.952 1.029 0.930 1.022 0.889 1.008 12 6.7 0.963 1.034 0.956 1.032 0.934 1.024 0.893 1.011 14 6.8 0.968 1.036 0.961 1.034 0.939 1.026 0.897 1.013 16 8.9 0.972 1.037 0.965 1.035 0.943 1.027 0.901 1.014

0.0001 (0.0176) 0.00025 (0.044) 0.00075 (0.132) 0.00175 (0.308)ALTITUDE

Fouling FactorChilled

Evaporator Water Flow and Pressure Drop

Evaporator flow rate must fall between the minimum and maximum values shown in the evaporator pressure drop curve. Flow rates below the minimum values will result in laminar flow that will reduce efficiency, cause erratic operation of the expansion valve and could cause low temperature cutouts. Flow rates exceeding the maximum values can cause erosion on the evaporator water connections and tubes.

Measure the chilled water pressure drop through the evaporator at field installed pressure taps. It is important not to include the effect of valves or strainers in these readings.

Variable Water Flow

Variable water flow involves changing the water flow through the evaporator as the load changes. McQuay chillers are designed for this duty provided that the rate of change in water flow is slow and the minimum and maximum flow rates for the vessel are not exceeded.

Ten percent is the maximum allowable percent per minute change of flow. The ALR control logic has timers that limit the rate of unloading or loading allowed. Slow changes allow the chiller the opportunity to sense a change, react to the change and stabilize preventing operational problems.

IOMM ALR-2 ALR110F through 150F 11

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