McQuay RCS-15E Installation Manual

10 & 12.5 TON

15 & 20 TON

Installat

ion and Ma

intenance Manual

IM 910

roup: Applied Systems

Part Number: 92-102421-10

Air-Cooled Split-System Condensing Units for Rooftop Systems and Air Handlers

Models RCS 10E to 20E 10, 12.5, 15 & 20 Tons

Date: February 2008

Table of Contents

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

Checking Product Received . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standard Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Crankcase Heaters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Order Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Standard Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Corrosive Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rooftop Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Slab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation of Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Typical Piping Recommendations . . . . . . . . . . . . . . . 9

Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Wire Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Evacuation and Charging . . . . . . . . . . . . . . . . . . . . . 13

Final Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

re-Start Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

ccessories Installation . . . . . . . . . . . . . . . . . . . . . . 15

Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Louvers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Maintenance and Operation . . . . . . . . . . . . . . . . . . . 15

Crankcase Heaters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Charge Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . 23

Service and Warranty Procedure . . . . . . . . . . . . . . . 24

RCS Condensing Unit Equipment Warranty

Registration Form. . . . . . . . . . . . . . . . . . . . . . . 25-26

Quality Assurance Survey Report . . . . . . . . . . . . . . 27

Nomenclature

R C S — 15 –E

Design vintageRooftop Condensing Unit

Nominal capacity (tons) 10, 12, 15, 20

2 IM 910

Recognize this symbol as an indication of

Important Safety Information!

ANGER

▲▲

The use of unauthorized components, accessories or devices may adversely affect the operation of the condensing unit and may also endanger life and property.

The manufacturer disclaims any responsibility for such loss or injury and the manufacturer’s warranty does not cover any damage or defect to the air conditioner caused by the attachment or use of any components, accessories or devices (other than those authorized by the manufacturer) into, onto or in conjunction with the condensing unit.

Introduction

This manual contains the installation and operating instructions for your split condensing unit. There are a few precautions that should be taken to derive maximum satisfaction from it. Improper installation can result in unsatisfactory operation or dangerous conditions.

Read this manual and any instructions packaged with separate equipment required to make up the system prior to installation. Give this manual to the owner and explain its provisions. The owner should retain this manual for future reference.

Checking Product Received

Upon receiving the unit, inspect it for any damage from shipment. Claims for damage, either shipping or concealed, should be filed immediately with the shipping company. Check the unit model number, electrical characteristics, and accessories to determine if they are correct.

Standard Unit Features

CABINET — Galvanized steel with a durable powder paint finish. Stamped louvered panels offer 100% protection for the condenser coil.

COMPRESSOR — Tandem scrolls are utilized with compressors mounted and piped as a set. Replacement must be by complete set, not individual compressors. The compressor set is mounted on isolators, and features inherent protection with crankcase heaters as standard. By staging compressors, 50% and 100% loading is allowed.

CONDENSER COIL — Constructed with copper tubes and

luminum fins mechanically bonded to the tubes for maximum

a heat transfer capabilities. All coil assemblies are leak tested at 450 psig internal pressure.

REFRIGERANT CONNECTIONS — Field piping connections are made through a fixed panel. This allows complete access or removal of access panels after piping connections

ave been made.

CRANKCASE HEATER — Standard, all models.

LOW AMBIENT CONTROL — A pressure sensitive fan

cycling control to allow unit operation to 0°F is standard.

SERVICE VALVES — Standard on liquid lines, optional on vapor lines.

SERVICE ACCESS — The control box, as well as the compressor and other refrigerant controls, is accessible through access panels. It may be opened without affecting the normal operation of the unit.

Condenser fan motors are accessible by removing wire grilles.

FILTER DRIER — Field supplied.

SIGHT GLASS — Optional, field supplied.

TRANSFORMER — Step down type, line to 24 volts.

CONTACTOR — The contactor is an electrical switch which

operates the compressor and condenser fans.

HIGH PRESSURE CONTROL — Opens the contactor circuit on high refrigerant pressure; manual reset.

LOW PRESSURE CONTROL — Stops compressor operation in the event of loss of refrigerant.

CONDENSER FAN MOTOR (Direct Drive) — Ball bearing 1075 RPM motors are mounted to minimize vibration and noise problems.These are permanent split capacitor types and require the same capacitance for both run and start.

TESTING — All units are run tested at the factory prior to shipment. Units are shipped with a holding pressure of nitrogen.

IM 910

Figure 1: Dimensions – 10 Ton Units

ST-A0890-11

ST-A0890-12

ST-A0890-11

ST-A0890-12

ST-A0890-11

Figure 2 : Dimensions – 12.5 Ton Units

IM 910

Gauge (nominal)

Top (frame)

CONDENSER FANS:

Quantity

CONDENSER COIL:

Quantity

REFRIGERANT CONNECTION:

Vapor, O.D.F. (inches), Sweat Type (1 ea.)

CABINET:

Finish

Liquid O.D.F. (inches), Sweat Type (1ea.)

MODEL RCSNOMINAL CAPACITY (TONS)

Operating Weight (lbs.) Shipping Weight (approximate, lbs.)

Type RPM

CFM (total) Diameter (inches) Drive Motor Horsepower (ea.) Type RPM

Rows Fins per inch Square Feet Fins/Tubes Tube Size, O.D. (inches)

Sheet Metal

Sides (posts) Base rails (frame)

COMPRESSOR:

Quantity

10 12.5

569 640 609 680

Tandem Scroll Tandem Scroll

3500 3500

Capacity Steps

Percent from full load 50 50

6,800 6,800

24 24

Direct Direct

PSC PSC

1075

22 22

27.0 32.875

Al/Cu Al/Cu

Powder Paint Powder Paint

Galvanized Galvanized

20 20 20 20 14 14

945 985

Tandem Scroll

3500

10,200

Direct

PSC 1075

40.375 Al/Cu

Powder Paint

Galvanized

20 20 14

818 858

Tandem Scroll

3500

10,200

Direct

PSC 1075

40.375 Al/Cu

Powder Paint

Galvanized

20 20 14

10E

12E

15E

20E

1/3 1/3

1/3

3/8 3/8

3/8

1-3/8

1-5/8

5/8

7/8

Figure 3 : Dimensions – 15 to 20 Ton Units

ST-A0890-11

ST-A0890-12

ST-A0890-11

T-A0890-12

ST-A0890-13

Table 1 – Physical Data

IM 910

CONDENSING UNIT

Gauge (nominal)

Top (frame)

CONDENSER FANS:

Quantity

CONDENSER COIL:

Quantity

REFRIGERANT CONNECTION:

Vapor, O.D.F. (inches), Sweat Type (1 ea.)

CABINET:

Finish

Liquid O.D.F. (inches), Sweat Type (1ea.)

MODEL NO. NOMINAL CAPACITY (TONS)

Operating Weight (lbs.) Shipping Weight (approximate, lbs.)

ype

RPM

FM (total) Diameter (inches) Drive Motor Horsepower (ea.) Type RPM

Rows Fins per inch Square Feet Fins/Tubes Tube Size, O.D. (inches)

Sheet Metal

Sides (posts) Base rails (frame)

COMPRESSOR:

Quantity

10 12.5

569 640 609 680

andem Scroll Tandem Scroll

3500 3500

Capacity Steps

ercent from full load 50 50

,800 6,800

24 24

irect Direct

PSC PSC

1075

27.0 32.875

Al/Cu Al/Cu

13/8 13/8

Powder Paint Powder Paint

Galvanized Galvanized

20 20 20 20 14 14

945 985

Tandem Scroll

3500

10,200

Direct

/3 PSC 1075

2 3

40.375 Al/Cu

15/8

Powder Paint

alvanized

20 20 14

818 858

andem Scroll

3500

10,200

Direct

PSC

1075

40.375 Al/Cu

15/8

Powder Paint

Galvanized

0 20 14

A0890-14

Table 2: Electrical Data

lectrical

odel

umber

0ECAZ 3-60-208/230 17.3/17.3 137 4.8 44/44 50/50 60/60 27 [2.51] 1 6600 [3115] 309 [8760] 569 [258.1] 609 [276.2]

10EDAZ 3-60-460 9 62 2.8 24 30 30 27 [2.51] 1 6600 [3115] 309 [8760] 569 [258.1] 609 [276.2]

10EYAZ 3-60-575 7.1 50 2 18 20 25 27 [2.51] 1 6600 [3115] 309 [8760] 569 [258.1] 609 [276.2]

12ECAZ 3-60-208/230 18.6/18.6 156 4.8 47/47 60/60 60/60 32.88 [3.05] 2 6600 [3115] 413 [11709] 640 [290.3] 680 [308.4]

2EDAZ 3-60-460 9 75 2.8 24 30 35 32.88 [3.05] 2 6600 [3115] 413 [11709] 640 [290.3] 680 [308.4]

2EYAZ 3-60-575 7.4 54 2 19 25 25 32.88 [3.05] 2 6600 [3115] 413 [11709] 640 [290.3] 680 [308.4]

5ECAZ 3-60-208/230 28.8/28.8 195 7.2 72/72 80/80 100/100 40.38 [3.75] 2 9900 [4672] 573 [16245] 819 [371.5] 859 [389.6]

5EDAZ 3-60-460 14.7 95 4.2 38 40 50 40.38 [3.75] 2 9900 [4672] 573 [16245] 819 [371.5] 859 [389.6]

15EYAZ 3-60-575 10.8 80 3 28 30 35 40.38 [3.75] 2 9900 [4672] 573 [16245] 819 [371.5] 859 [389.6]

20ECAZ 3-60-208/230 37.2/37.2 239 7.2 91/91 110/110 125/125 40.38 [3.75] 3 9900 [4672] 778 [22056] 945 [428.7] 985 [446.8]

20EDAZ 3-60-460 17.2 125 3.3 42 50 50 40.38 [3.75] 3 9900 [4672] 778 [22056] 945 [428.7] 985 [446.8]

20EYAZ 3-60-575 12.4 80 2.4 31 35 40 40.38 [3.75] 3 9900 [4672] 778 [22056] 945 [428.7] 985 [446.8]

Figure 4: Control Box Configuration

hase

requency (Hz)

oltage (Volts)

Compressor

Rated Load

Amperes

(RLA)

Locked Rotor

Amperes

(LRA)

Fan Motor

ull Load

F A

mperes

FLA)

(

Minimum

ircuit

C mpacity

mperes

Fuse or HACR

Circuit Breaker

inimum

M A

mperes

aximum mperes

ace Area

q. Ft. [m2]

Outdoor Coil

ows

L/s]

[

Refrig.

P ircuit

z. [g]

bs. [kg]

Weight

hipping

bs. [kg]

Installation

Crankcase Heaters

These units are equipped with a crankcase heater that is facto-

The condensing unit consists of a completely assembled package which includes a compressor pack, condenser coils, fans, fan motors, outdoor control box, factory wiring, factory tubing

and fittings. ry wired to operate whenever the main power supply to the unit is “on” and compressors are “off.” Before starting the equipment after prolonged shut-down or at the time of initial spring start-up, be sure that the circuits to the condensing units are closed for at least 24 hours.

Order Parts

When reporting shortages or damaged parts, or when ordering repair parts, give the complete unit model and serial numbers which are stamped on the unit rating plate.

Standard Items

6 IM 910

Corrosive Environment

The metal parts of this unit may be subject to rust or deteriora-

tion if exposed to a corrosive environment. This oxidation

could shorten the equipment’s useful life. Corrosive elements

include salt spray, fog or mist in seacoast areas, sulphur or

chlorine from lawn watering systems, and various chemical

contaminants from industries such as paper mills and petrole-

um refineries.

If the unit is to be installed in an area where contaminants are

likely to be a problem, special attention should be given to the

equipment location and exposure.

• Avoid having lawn sprinkler heads spray directly on the unit

INSTALLATION GENERAL

The condensing unit should be installed outdoors. It should be located as near as possible to the evaporator section to keep connecting refrigerant tubing lengths to a minimum. The unit must be installed to allow a free air flow to the condenser coils.

If several units are installed adjacent to each other, care must be taken to avoid recirculation of air from one condenser to another. In all installations, adequate space must be provided for installation and servicing.

cabinet.

• In coastal areas, locate the unit on the side of the building away from the waterfront.

• Shielding provided by a fence or shrubs may give some protection, based on clearances recommended in this book.

Regular maintenance will reduce the build-up of contaminants and help to protect the unit’s finish.

DANGER

▲▲

isconnect all power to unit before starting maintenance.

D Failure to do so can cause electrical shock resulting in severe personal injury or death.

• Frequent washing of the cabinet, fan blade and coil with fresh water will remove most of the salt or other contaminants that build up on the unit.

• Regular cleaning and waxing of the cabinet with a good automobile polish will provide some protection.

• A good liquid cleaner may be used several times a year to remove matter that will not wash off with water.

Several different types of protective coatings are offered in some areas. These coatings may provide some benefit, but the effectiveness of such coating materials cannot be verified by the equipment manufacturer.

Installation General

If several units are installed adjacent to each other, take care to

void recirculation of air from one condenser to another. In all

a installations, adequate space must be provided for installation and servicing.

The unit must not be connected to any duct work. Do not locate unit under a roof drip; if necessary, install gutters, etc., to prevent water run-off onto the unit. To prevent air recircula-

ion, it is recommended that the unit not be installed under an

t overhang. However, if this is necessary, allow a minimum of 60 inches above the unit for air discharge.

Rooftop Installation

If rooftop installation is required, make certain that the building construction is adequate for the weight of the unit. (Refer to physical data chart.) Before placing the unit on the roof, make certain that the nylon rigging slings are of sufficient length to maintain equilibrium of the unit when lifting. Under no circumstances should the unit be lifted by only one corner for rooftop installation.

Slab Installation

Condensing units should be set on a solid level foundation. When installed at ground level, the unit should be placed on a 6 inch cement slab. If the pad is formed at the installation site, do not pour the pad tight against the structure, otherwise vibration will be transmitted from the unit through the pad.

Figure 5: Clearances

IM 910

DETAIL

CORNER WEIGHTS (Pounds)

MODEL

10 TON 140 150 135 144

12.5 TON 167 163 140 170

15 TON 211 198 211 198

20 TON 238 246 235 227

ABCD

15 & 20

TON

10 & 12.5

TON

ST-A0890-17

ST-A0890-18

Figure 6: Rigging

8 IM 910

Installation of Piping

INSTALLATION OF PIPING

IMPORTANT: CONDENSING UNITS ARE SHIPPED WITH A NITROGEN HOLDING CHARGE. EVACUATE CONDENSING UNIT BEFORE CHARGING WITH REFRIGERANT.

Once located, the condensing unit is ready to be interconnected with the evaporator using ONLY refrigeration grade dehydrated tubing. T

he following should be considered when connecting the tubing.

1. Pitch the vapor line toward the compressor approximately 1/2 inch every 10 feet to facilitate oil return.

2. It is recommended that the sight glass, filter drier and liquid line solenoid valve be installed in the liquid line just prior to the evaporator.

3. Silver solder (such as silfos, Easy Flow, etc.) should be used for all refrigerant joints.

4. Thoroughly clean all joints before fluxing. DO NOT USE ACID FLUX.

5. When fluxing, limit the application of paste to the minimum and always apply flux to the male portion of the connection.

6. vapor lines should be insulated to prevent condensate drip. Use insulation of at least 3/8 inch wall thickness. The insulation should be installed on the tubing prior to making the sweat connections.

7. Insulate the liquid line whenever the heat pick-up or transfer can affect the sub-cooling.

8. Care should be taken to avoid transmission of noise or vibration to building structure.

WARNING

DO NOT USE OXYGEN TO PURGE LINES OR PRESSURE SYSTEM FOR LEAK TEST. OXYGEN REACTS VIOLENTLY WITH OIL, WHICH CAN CAUSE AN EXPLOSION RESULTING I

N SEVERE PERSONAL INJURY OR DEATH.

TABLE 2 REFRIGERANT PIPING DATA

21/8

15/8

13/8

11/8

TUBE SIZE

(IN.) O.D.

SOLE-

NOID

VALVE

ANGLE

VALVE

SHORT

RADIUS

ELL

LONG

RADIUS

ELL

TEE LINE

FLOW

TEE

BRANCH

FLOW

102

115

141

4.7

5.7

6.5

7.8

2.7

3.2

3.8

5.2

3.2

3.9

4.5

5.3

1.9

2.2

2.6

3.4

1.7

2.3

2.9

3.7

5.2

6.9

8.7

12.0

6.6

8.2

9.7

12.0

8.0

10.0

12.0

16.0

FOR NON-FERROUS VALVES & FITTINGS (BRAZED)

EQUIVALENT LENGTH (FT.) [m] OF STRAIGHT TYPE "L" TUBING

pproximately 3 PSIG pressure drop.

approximately 3 PSIG pressure drop.

adjacent to evaporator. Filter drier should be between the condensing unit and sight glass.

. Pitch all horizontal vapor lines downward in the direction of flow

prevent dirt and moisture from entering the piping.

possible to minimize piping runs.

tubing noise transmission into the conditioned space, the suction clamp must be installed after tubing is brazed as illustrated in figure 7.

92-22205-38

. Size liquid line for no more than 10

loss which corresponds to

(

1/2" to 10 ft. run).

TYPICAL PIPING RECOMMENDATIONS

The following will be of help in accomplishing a successful i

nstallation.

approximately 3 PSIG pressure drop.

2. Size vapor lines for no more than 2F loss which corresponds to

approximately 3 PSIG pressure drop.

3. Install sight glass, filter drier and solenoid valve in liquid line

adjacent to evaporator. Filter drier should be between the condensing unit and sight glass.

4. Pitch all horizontal vapor lines downward in the direction of flow

5. When making up refrigerant piping, take every precaution to

prevent dirt and moisture from entering the piping.

6. Locate the condensing unit and evaporator(s) as close together as

possible to minimize piping runs.

7. Liquid or vapor lifts not to exceed 60 ft.

8. To prevent suction line breakage due to vibration and to prevent

tubing noise transmission into the conditioned space, the suction clamp must be installed after tubing is brazed as illustrated in figure 7.

92-22205-38

RECOMMENDED VAPOR AND LIQUID LINE

SIZES FOR VARIOUS LENGTHS OF RUN

200

EQUIVALENT

LENGTH TO

EVAPORATOR

(FEET)

200

LIQUID LINE O.D.

SIZES (INCHES)

VAPOR LINE O.D.

SIZES (INCHES)

150

15/8

21/8 21/8

21/8

15/8

NOTE: Line length between condenser and evaporator (suction and liquid) not to exceed 150’ equivalent length.

1. Size liquid line for no more than 10oF loss which corresponds to

(1/2" to 10 ft. run).

0” to 15”

16” to 50”

51” to 100”

101” to 150”

WARNING

▲▲

Do not use oxygen to purge lines or pressure system for leak test. Oxygen reacts violently with oil, which can cause

n explosion resulting in severe personal injury or death.

NOTE – The condensing unit is shipped with a holding charge of dry nitrogen which must be purged from the unit before evacuation.

Once located, the condensing unit is ready to be interconnected with the evaporator using ONLY refrigeration grade dehydrated tubing.The following should be considered when connecting the tubing.

1 Pitch the vapor line toward the compressor approximately

1/2 inch every 10 feet to facilitate oil return.

2 It is recommended that the sight glass, filter drier and liq-

uid line solenoid valve be installed in the liquid line just prior to the evaporator.

3 Silver solder (such as silfos, Easy Flow, etc.) should be

used for all refrigerant joints.

4 Thoroughly clean all joints before fluxing. DO NOT USE

ACID FLUX.

5 When fluxing, limit the application of paste to the mini-

mum and always apply flux to the male portion of the connection.

6 Vapor lines should be insulated to prevent condensate

drip. Use insulation of at least 3/8 inch wall thickness. The insulation should be installed on the tubing prior to making the sweat connections.

7 Insulate the liquid line whenever the heat pick-up or

transfer can affect the sub-cooling.

8 Care should be taken to avoid transmission of noise or

vibration to building structure.

Table 3: Refrigerant Piping Data

Typical Piping Recommendations

The following will be of help in accomplishing a successful installation.

1 Size liquid line for no more than 10°F loss which corre-

sponds to approximately 3 psig pressure drop.

2 Size vapor lines for no more than 2°F loss which corre-

sponds to approximately 3 psig pressure drop.

3 Install sight glass, filter drier and solenoid valve in liquid

line adjacent to evaporator. Filter drier should be between the condensing unit and sight glass.

4 Pitch all horizontal vapor lines downward in the direction

of flow (1/2” to 10 ft. run).

5 When making up refrigerant piping, take every precaution

to prevent dirt and moisture from entering the piping.

6 Locate the condensing unit and evaporator(s) as close

together as possible to minimize piping runs.

7 Liquid or vapor lifts not to exceed 60 ft.

8 To prevent suction line breakage due to vibration and to

prevent tubing noise transmission into the conditioned space, the suction clamp must be installed after tubing is brazed as illustrated in figure 7.

Figure 7: Suction Clamp

Table 4: Recommended Vapor and Liquid Line Sizes for Various Lengths of Run

IM 910

+ 19 hidden pages