Packaged Air-Cooled Water Chiller

Transcription

1 Installation, Operation and Maintenance Manual IOMM ALR-3 Group: Chiller Part Number: Effective: September 2001 Supersedes: IM ALR-2 Packaged Air-Cooled Water Chiller ALR 110F - ALR 150F Refrigerant R-22, 60 Hertz

2 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 Variable Water Flow 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 Preventive Maintenance Schedule...32 Refrigerant Charging...33 ALR Troubleshooting Chart...35 "McQuay" is a registered trademark of McQuay International 2001 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-3

3 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 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. The electrical control center includes all detection 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 nameplate 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-3 ALR110F through 150F 3

4 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-3

5 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 can 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, 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, detection 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-3 ALR110F through 150F 5

6 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 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 can 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-3

7 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 Lifting and Mounting Locations L2 L4 36 (914) CONTROL BOX R2 46 (1168) R1 102 (2591) R4 161 (4089) R3 192 (4877) R6 R (2118) L1 L3 2 (51) Typical Spacing for Isolator 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. ALR Model Lifting Weight for Each Point lb (kg) Mounting Loads for Each Point lb. (kg) L1 & L2 L3 & L4 R1 & R2 R3 & R4 R5 & R6 Operating Wt lb. (kg) Shipping Wt. lb. (kg) Copper Fin Add (1171) 2125 (963) 1835 (831) 1785 (809) 1230 (557) 9700 (4394) 9420 (4267) 1370 (620) (1164) 2205 (999) 1830 (829) 1805 (818) 1305 (591) 9880 (4476) 9550 (4326) 1370 (620) (1164) 2205 (999) 1830 (829) 1805 (818) 1305 (591) 9880 (4476) 9550 (4326) 1370 (620) (1164) 2205 (999) 1830 (829) 1805 (818) 1305 (591) 9880 (4476) 9550 (4326) 1370 (620) (1166) 2210 (1001) 1830 (829) 1805 (818) 1310 (593) 9890 (4478) 9560 (4340) 1370 (620) (1166) 2210 (1001) 1830 (829) 1805 (818) 1310 (593) 9890 (4480) 9560 (4330) 1370 (620) (1178) 2280 (1032) 1860 (842) 1840 (833) 1345 (609) (4571) 9760 (4421) 1370 (620) IOMM ALR-3 ALR110F through 150F 7

8 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-3

9 Figure 6, Typical Evaporator Water Piping Vent Outlet Drain Vibration Eliminator Valved pressure gauge Water strainer Vibration Eliminator Gate valve Flow Balancing Switch valve Gate valve Protect all field piping against freezing 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 ). 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-3 ALR110F through 150F 9

10 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 can 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 can be calculated using the following formulas and Table 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: Glycol GPM 24 capacity( glycol) = Flow Factor (from table 2,3) Delta T For Metric Applications -- To determine evaporator L/s (or Delta-T) knowing Delta-T (or L/s) and kw: kw Glycol L/s = Flow Factor(from table 2,3) 4.18 Delta T 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. 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 Table 3, Propylene Glycol % Freeze Point P.G. F C Cap. kw Flow PD ALR 110F through 150F IOMM ALR-3

11 Table 4, Capacity and Power Derates Chilled Water Fouling Factor ALTITUDE Delta-T (0.0176) (0.044) (0.132) (0.308) F C Cap. Power Cap. Power Cap. Power Cap. Power SEA LEVEL feet (610 m) feet (1220 m) feet (1830 m) 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-3 ALR110F through 150F 11

12 Figure 8, Evaporator Water Pressure Drops ALR 110 ALR ALR Table 5, Minimum/Maximum Flow Rates ALR Unit Size Minimum Flow gpm (l/s) Pressure Drop ft. (kpa) Maximum Flow gpm (l/s) Pressure Drop ft. (kpa) (10.4) 6.0 (17.9) 435 (27.4) 39.0 (116.0) (11.4) 4.3 (12.8) 480 (30.3) 30.5 (90.0) (12.3) 5.1 (15.2) 520 (32.8) 37.5 (111.8) (12.6) 5.3 (15.8) 535 (33.8) 40.0 (119.2) (13.0) 5.8 (17.3) 550 (34.7) 42.0 (125.2) (13.6) 4.3 (12.8) 570 (36.0) 29.5 (87.9) (13.9) 4.5 (13.4) 590 (37.2) 31.0 (92.4) 12 ALR 110F through 150F IOMM ALR-3

13 Physical Data Table 6, Physical Data ALR 110F through 135F PHYSICAL DATA ALR MODEL NUMBER 110F 120F 130F 135F BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Unit ARI Conditions, Tons (kw) (1) (388.1) (427.7) (453.6) (468.0) Number Of Refrigerant Circuits Unit Operating Charge, R-22, lbs Unit Operating Charge, R-22, (kg) (52.1) (52.1) (54.4) (54.4) (54.4) (54.4) (54.4) (54.4) Cabinet Dimensions, LxWxH, in. 229 x 83 x x 83 x x 83 x x 83 x 89 Cabinet Dimensions, LxWxH, (mm) (5809 x 2118 x (5809 x 2118 x (5809 x 2118 x (5817 x 2118 x 2210) 2210) 2210) 2210) Unit Operating Weight, lbs. (kg) 9700 (4394) 9880 (4476) 9880 (4476) 9880 (4476) Unit Shipping Weight, lbs. (kg) 9420 (4267) 9550 (4326) 9550 (4326) 9550 (4326) Add'l Weight If Copper Finned Coils, lbs. (kg) 1370 (620) 1370 (620) 1370 (620) 1370 (620) COMPRESSORS Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Semi-Hermetic Nominal Horsepower Number Of Cylinders Per Compressor Oil Charge Per Compressor, oz Oil Charge Per Compressor, (l) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT Staging - Circuit #1 in Lead Staging - Circuit #2 in Lead CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING Coil Face Area, sq. ft Coil Face Area, (m 2 ) (10.3) (10.3) (10.3) (10.3) (10.3) (10.3) (10.3) (10.3) Finned Height x Finned Length, in. 80 x x x x x x x x 208 Finned Height x Finned Length, (mm) (2032 x (2032 x (2032 x (2032 x (2032 x (2032 x (2032 x (2032 x 5283) 5283) 5283) 5283) 5283) 5283) 5283) 5283) Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 Maximum Relief Valve Pressure Setting, psig (kpa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE Number Of Fans - Fan Diameter, In. (mm) (711) (711) (711) (711) Number Of Motors - HP (kw) (1.1) (1.1) (1.1) (1.1) Fan And Motor RPM, 60 Hz Hz Fan Tip Speed, fpm Hz Total Unit Airflow, cfm DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE Diameter, in. - Length, in x x x x 95.5 Diameter, (mm) - Length, (mm) 325 x x x x 2426 Water Volume, Gallons, (L) 34 (127) 40 (150) 40 (150) 40 (150) Maximum Water Pressure, psig (kpa) 152 (1047) 152 (1047) 152 (1047) 152 (1047) Maximum Refrigerant Working Pressure, psig (kpa) 300 (2066) 300 (2066) 300 (2066) 300 (2066) Water Inlet / Outlet Victaulic Connections, in. (mm) 5 (127) 8 (203) 8 (203) 8 (203) Drain - NPT int, in. (mm).5 (12.7).5 (12.7).5 (12.7).5 (12.7) Vent - NPT int, in. (mm).5 (12.7).5 (12.7).5 (12.7).5 (12.7) NOTE: 1. Nominal capacity based on 95 F ambient air and 54 F/44 F water range. IOMM ALR-3 ALR110F through 150F 13

14 Table 7, Physical Data ALR 140F through 150F PHYSICAL DATA ALR MODEL 140F 145F 150F BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Unit ARI Conditions (1), Tons (kw) (489.0) (501.2) (523.3) Number Of Refrigerant Circuits Unit Operating Charge, R-22, lbs Unit Operating Charge, R-22, (kg) (56.6) (56.6) (58.9) (58.9) (58.9) (58.9) Cabinet Dimensions, LxWxH, in. 229 x 83 x x 83 x x 83 x 89 Cabinet Dimensions, LxWxH, (mm) (5817 x 2118 x 2210) (5817 x 2118 x 2210) (5817 x 2118 x 2210) Unit Operating Weight, Lbs. (kg) 9885 (4478) 9890 (4480) (4571) Unit Shipping Weight, Lbs. (kg) 9555 (4328) 9560 (4330) 9760 (4421) Add'l Weight If Copper Finned Coils, lbs. (kg) 1370 (620) 1370 (621) 1370 (621) COMPRESSORS Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Nominal Horsepower Number Of Cylinders Per Compressor Oil Charge Per Compressor, oz Oil Charge Per Compressor, (l) ( ) ( ) ( ) ( ) ( ) ( ) CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT Staging - Circuit #1 in Lead Staging - Circuit #2 in Lead CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING Coil Face Area,Sq. Ft Coil Face Area, (m 2 ) (10.3) (10.3) (10.3) (10.3) (10.3) (10.3) Finned Height x Finned Length, in. 80 x x x x x x 208 Finned Height x Finned Length, (mm) (2032 x (2032 x (2032 x (2032 x (2032 x (2032 x 5283) 5283) 5283) 5283) 5283) 5283) Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 Maximum Relief Valve Pressure Setting, psig (kpa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE Number Of Fans - Fan Diameter, In. (mm) (711) (711) (711) Number Of Motors - HP (kw) (1.1) (1.1) (1.1) Fan And Motor RPM, 60 HZ Hz Fan Tip Speed, fpm Hz Total Unit Airflow, cfm DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE Diameter, in. - Length, in x x x 96.8 Diameter, (mm) - Length, (mm) 356 x x x 2459 Water Volume, Gallons, (L) 40 (150) 55 (208) 55 (208) Maximum Water Pressure, psig (kpa) 152 (1047) 152 (1047) 152 (1047) Maximum Refrigerant Working Pressure, psig (kpa) 300 (2066) 300 (2066) 300 (2066) Water Inlet / Outlet Victaulic Connections, in. (mm) 8 (203) 8 (203) 8 (203) Drain - NPT int, in. (mm).5 (12.7).5 (12.7).5 (12.7) Vent - NPT int, in. (mm).5 (12.7).5 (12.7).5 (12.7) NOTE: 1. Nominal capacity based on 95 F ambient air and 54 F/44 F water range. 14 ALR 110F through 150F IOMM ALR-3

15 Electrical Data Field Wiring CAUTION Internal power wiring to the compressors for single and multiple point option are different. Field wiring must be installed according to unit wiring diagram. Wiring must comply with all applicable codes and ordinances. Warranty is void if wiring is not in accordance with specifications. Copper wire is required for all power lead terminations at the unit. Aluminum or copper can be used for all other wiring. ALR units can be ordered with internal power wiring for either single or multiple point power connection. If single point power connection is ordered, a single large power terminal block is provided and wiring within the unit is sized in accordance with the National Electrical Code. A single field supplied fused disconnect is required. If multiple point power wiring is ordered, three power connections, one per compressor circuit, one for condenser fans, and control circuit, are required. Separate field supplied fused disconnects are required for each of the three circuits. A single power block is provided for all of the condenser fans and the 115V control transformer. If the evaporator heater is on a separate disconnect switch from the main unit power supply, the unit can be shut down without defeating the freeze protection provided by the cooler heater. Table 8, ALR 110F 150F Electrical Data, Single Point ALR Min. Circuit Field Wire Hub (Conduit Connection) Fuse or HACR Breaker Size Unit Volts Hz Ampacity Size (MCA) Quantity Wire Gauge Quantity Size Recommended Maximum (102) F (102) / (51) (102) F (102) / (51) (102) F (102) / (51) F / (51) (76) F (76) (76) F (76) (76) F (76) (76) See page 21 for all Electrical Data notes. 2. A HACR breaker is designed for use on equipment with multiple motors. It stands for Heating, Air Conditioning, Refrigeration IOMM ALR-3 ALR 110F through 150F 15

16 Table 9, ALR 110F 150F Electrical Data, Multiple Point ALR Unit Size 110F 120F 130F 135F 140F 145F 150F Volts Min. Ckt. Amp MCA Qty. Power Supply Field Power Supply Field Power Supply Fans and Controls Fusing(1) Min. Circuit #1 Fusing (1) Min. Circuit #2 Ckt Ckt Field Wire Hub Rec. Max. Field Wire Hub Rec. Max. Field Wire Hub Amp Amp Wire Size Qty. Hub Fuse Fuse MCA Wire Qty. Size Size Size Size Qty Hub Fuse Fuse MCA Wire Qty. Size Size Size Size Qty. Hub Size (38) 1.50 (38) 1.00 (25) 1.00 (25) 1.50 (38) 1.50 (38) 1.00 (25) 1.00 (25) 2.00 (51) 2.00 (51) 1.00 (25) 2.00 (51) 2.00 (51) 1.00 (25) 2.00 (51) 2.00 (51) 1.00 (25) 2.00 (51) 2.00 (51) 1.00 (25) 2.00 (51) 2.00 (51) 1.00 (25) / / / / / / / (51) 2.00 (51) 1.00 (25) 1.50 (38) 1.50 (38) 1.50 (38) 1.50 (38) 1.50 (38) / / / / / / / (38) 1.50 (38) 1.50 (38) 3.00 (76) 1.50 (38) 3.00 (76) 1.50 (38) 3.00 (76) 3.00 (76) 2.00 (51) 1.50 (38) Field Fusing (1) Rec. Max. Fuse Fuse Size Size ALR 110F through 150F IOMM ALR-3

17 Table 10, ALR 110F 150F Compressor and Condenser Fan Motor Amp Draw ALR Unit Size 110F 120F 130F 135F 140F 145F 150F Volts No. 1 Rated Load Amps Compressors No. 2 No. 3 No. 4 Fan Motors (Each) No. Of Fan Motor Fan Motors (Each) Across-The-Line Locked Rotor Amps Compressors Reduced Inrush No. 1 No. 2 No. 3 No. 4 No. 1 No. 2 No. 3 No See page 21 for all Electrical Data notes. IOMM ALR-3 ALR 110F through 150F 17

18 Table 11, ALR 110F 150F Field Wiring Data, Single Point Power Wiring to Wiring to Optional Factory Mounted ALR Standard Power Block Disconnect Switch Unit Volts Terminal Connector Wire Range/Phase Terminal Connector Wire Range/Phase Size Amps (Copper Wire Only) Amps (Copper Wire Only) (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM 110F (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM (1 qty.) #4-400 MCM 400 (1 qty.) MCM (1 qty.) #4-400 MCM 250 (1qty.) #4-350 MCM (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM 120F (2 qty.) 1/0-600 MCM 600 (2 qty.) MCM (1 qty.) #4-400 MCM 400 (1 qty.) MCM (1 qty.) #4-400 MCM 250 (1qty.) #4-350 MCM (2 qty.) 1/0-600 MCM 800 (2 qty.) MCM 130F (2 qty.) 1/0-600 MCM 800 (2 qty.) MCM (1 qty.) #4-400 MCM 400 (1 qty.) MCM (1 qty.) #4-400 MCM 250 (1qty.) #4-350 MCM (2 qty.) 1/0-600 MCM 800 (2 qty.) MCM 135F (2 qty.) 1/0-600 MCM 800 (3 qty.) 3/0-400 MCM (1 qty.) #4-400 MCM 400 (1 qty.) MCM (1 qty.) #4-400 MCM 250 (1qty.) #4-350 MCM (2 qty.) 1/0-600 MCM 800 (2 qty.) MCM 140F (2 qty.) 1/0-600 MCM 800 (2 qty.) MCM (1 qty.) #4-400 MCM 400 (1 qty.) MCM (1 qty.) #4-400 MCM 400 (1 qty.) MCM (2 qty.) 1/0-600 MCM 800 (2 qty.) MCM 145F (2 qty.) 1/0-600 MCM 800 (2 qty.) MCM (1 qty.) #4-400 MCM 400 (1 qty.) MCM (1 qty.) #4-400 MCM 400 (1 qty.) MCM (4 qty.) 1/0-600 MCM 800 (2 qty.) MCM 150F (4 qty.) 1/0-600 MCM 800 (2 qty.) MCM (2 qty.) 1/0-600 MCM 400 (1 qty.) MCM (2 qty.) 1/0-600 MCM 400 (1 qty.) MCM See page 21 for all other Electrical Data notes. 18 ALR 110F through 150F IOMM ALR-3

19 Table 12, ALR 110F 150F, Field Wiring Data, Multiple Point Power with Power Blocks ALR Wiring to Standard Power Block Unit Volts Terminal Amps Connector Wire Range Per Phase (Copper Wire Only) Size Circuit 1 Circuit 2 Circuit 3 Circuit 1 (Fans) Circuit 2 Circuit (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM 110F (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM (1 qty.) #12-2/0 (1 qty.) #12-2/0 (1 qty.) #12-2/ (1 qty.) #12-2/0 (1 qty.) #12-2/0 (1 qty.) #12-2/ (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM 120F (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM (1 qty.) #12-2/0 (1 qty.) #12-2/0 (1 qty.) #12-2/ (1 qty.) #12-2/0 (1 qty.) #12-2/0 (1 qty.) #12-2/ (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM 130F (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM (1 qty.) #12-2/0 (1 qty.) #12-2/0 (1 qty.) #12-2/ (1 qty.) #12-2/0 (1 qty.) #12-2/0 (1 qty.) #12-2/ (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM 135F (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM (1 qty.) #12-2/0 (1 qty.) #12-2/0 (1 qty.) #12-2/ (1 qty.) #12-2/0 (1 qty.) #12-2/0 (1 qty.) #12-2/ (1 qty.) #12-2/0 (2 qty.) 1/0-600 MCM (2 qty.) 1/0-600 MCM 140F (1 qty.) #12-2/0 (2 qty.) 1/0-600 MCM (2 qty.) 1/0-600 MCM (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM (1 qty.) #12-2/0 (2 qty.) 1/0-600 MCM (2 qty.) 1/0-600 MCM 145F (1 qty.) #12-2/0 (2 qty.) 1/0-600 MCM (2 qty.) 1/0-600 MCM (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM (1 qty.) #12-2/0 (2 qty.) 1/0-600 MCM (2 qty.) 1/0-600 MCM 150F (1 qty.) #12-2/0 (2 qty.) 1/0-600 MCM (2 qty.) 1/0-600 MCM (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM (1 qty.) #12-2/0 (1 qty.) #4-400 MCM (1 qty.) #4-400 MCM See page 21 for all Electrical Data notes. IOMM ALR-3 ALR 110F through 150F 19

20 Table 13, ALR 110F 150F, Field Wiring Data, Multiple Point Power with Non-fused Disconnect ALR Wiring to Optional Non-Fused Disconnect Unit Volts Terminal Amps Connector Wire Range Per Phase (Copper Wire Only) Size Circuit 1 Circuit 2 Circuit 3 Circuit 1 (Fans) Circuit 2 Circuit (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/0 110F (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4-350 MCM (1 qty.) #4-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) MCM (1 qty.) MCM 120F (1 qty.) #14-1/0 (1 qty.) #4-350 MCM (1 qty.) MCM (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) MCM (1 qty.) MCM 130F (1 qty.) #14-1/0 (1 qty.) MCM (1 qty.) MCM (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) MCM (1 qty.) MCM 135F (1 qty.) #14-1/0 (1 qty.) MCM (1 qty.) MCM (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) MCM (1 qty.) MCM 140F (1 qty.) #14-1/0 (1 qty.) MCM (1 qty.) MCM (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) MCM (1 qty.) MCM 145F (1 qty.) #14-1/0 (1 qty.) MCM (1 qty.) MCM (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) MCM (1 qty.) MCM 150F (1 qty.) #14-1/0 (1 qty.) MCM (1 qty.) MCM (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/ (1 qty.) #14-1/0 (1 qty.) #4 4/0 (1 qty.) #4 4/0 See page 21 for all Electrical Data notes. 20 ALR 110F through 150F IOMM ALR-3

21 Notes for Electrical Data Single Point and Electrical Data Multiple Point Power: 1. Unit wire size ampacity (MCA) is equal to 125% of the largest compressor-motor RLA plus 100% of RLA of all other loads in the circuit including the control transformer. 2. If the control transformer option is furnished, no separate 115V power is required. 3. If a separate 115V power supply is used for the control circuit, then the wire sizing is 12 amps. 4. Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductor ampacity in accordance with NEC. Wire sizes for 6 conductors per conduit are based on 80% 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 (type THW) wire. 5. The unit power terminal block can have 2 lugs per phase. Single or parallel conductors should be used for power connections as listed under Recommended Power Lead Wire Size. 6. Recommended Fuse Sizes are selected at approximately 150% of the largest compressor RLA, plus 100% of all other loads in the circuit. 7. Maximum Fuse Sizes are selected at approximately 225% of the largest compressor RLA, plus 100% of all other loads in the circuit. 8. The recommended power lead wire sizes are based on an ambient temperature of 86 F. Ampacity correction factors must be applied for other ambient temperatures. Refer to the National Electrical Code Handbook. Voltage Limitations: Unit Nameplate - 208V/60Hz/3Ph: 187V to 220V Unit Nameplate - 230V/60Hz/3Ph: 207V to 253V Unit Nameplate - 460V/60Hz/3Ph: 414V to 506V Unit Nameplate - 575V/60Hz/3Ph: 517V to 633V Notes for Compressor and Condenser Fan Amp Draw : 1. Compressor RLA values are for wiring sizing purposes only but do not reflect normal operating current draw at rated capacity. If unit is equipped with SpeedTrol condenser fan motors, the first motor on each refrigerant circuit is a single phase, 1hp motor, with a FLA of 2.8 amps at 460 volts, 5.6 amps at 208, 230, and 575 volts. 2. Compressor LRA for reduced inrush start are for the first winding only. If the unit is equipped with SpeedTrol motors, the first motor is a single phase, 1 hp motor, with a LRA of 7.3 amps at 460 volts, 14.5 amps at 208, 230 and 575 volts. Notes for Field Wiring Data - Both Single and Multiple Point Power: 1. Single point power supply requires a single disconnect to supply electrical power to the unit. This power must be fused. 2. Multiple point power supply requires two independent power circuits each with separate disconnects and a separate control circuit. 3. All field wiring to unit power block or optional non-fused disconnect switch must be copper. 4. All field wire size values apply to 75 C rated wire per NEC. IOMM ALR-3 ALR 110F through 150F 21

22 Figure 9, ALR 110F through 150F, Typical Field Wiring Diagram, Single Source Power 22 ALR 110F through 150F IOMM ALR-3

23 Dimensional Data Figure 10, ALR 110F through ALR 150F Dimensions ALR SIZE "A" LENGTH CONN. SIZE (1) WATER CONNECTIONS CENTER OF GRAVITY ISOLATOR LOCATION B C E F X Y R S T 110F 229 (5809) 5 (127.0) 95.8 (2433) 17.1 (434) 16.3 (414) 31.4 (798) 120F 229 (5809) 8 (203.2) 94.7 (2405) 17.5 (445) 16.3 (414) 30.7 (780) 130F 229 (5809) 8 (203.2) 94.7 (2405) 17.5 (445) 16.3 (414) 30.7 (780) 135F 229 (5809) 8 (203.2) 94.7 (2405) 17.5 (445) 16.3 (414) 30.7 (780) 140F 229 (5809) 8 (203.2) 94.7 (2405) 17.5 (445) 16.3 (414) 30.7 (780) 145F 229 (5809) 8 (203.2) 94.8 (2408) 17.2 (437) 18.3 (465) 29.8 (757) 150F 229 (5809) 8 (203.2) 94.8 (2408) 17.2 (437) 18.3 (465) 29.8 (757) NOTE: Only left hand evaporator connections (as shown) are available (2426) 97.0 (2464) 97.0 (2464) 97.0 (2464) 97.0 (2464) 99.0 (2515) 99.0 (2515) 41.7 (1059) 41.7 (1059) 41.7 (1059) 41.7 (1059) 41.7 (1059) 41.7 (1059) 41.7 (1059) 36.0 (914) 36.0 (914) 36.0 (914) 36.0 (914) 36.0 (914) 36.0 (914) 36.0 (914) 102 (2591) 102 (2591) 102 (2591) 102 (2591) 102 (2591) 102 (2591) 102 (2591) 192 (4877) 192 (4877) 192 (4877) 192 (4877) 192 (4877) 192 (4877) 192 (4877) NO. OF FANS Air Discharge NOTE: Add 22 in. (559 mm) to each side for hail guards. IOMM ALR-3 ALR 110F through 150F 23

24 Wind Baffles and Hail Guards Wind Baffles/Hail Guards are a field installed option that is used to stabilize unit operation in high wind areas and to assist in operation at low ambient temperatures. Figure 11 is a sketch of a typical panel assembly on an ALR unit. The parts are shown in the table to the right and referenced by balloon numbers. Installation Instructions 1. The assembly consists of channel supports that are fastened to the coil frame, wind baffles that are parallel to the coil, end panels and horizontal hail guard panels located at the top of the coil. 2. Prepare pilot holes for mounting channel supports to the coil frame. Use the prepunched holes in the channel supports to locate the holes. Drill (#2 drill) holes in the frame at the top and bottom of the condenser coil, exercising care not to damage the coil itself. 3. Starting at the control box end, install the supports using (4) ¼-20 x ¼ self-threading screws. These ¼ inch screws are required for adequate strength. 4. The horizontal hail guards are installed next. Starting at the control box end, install the hail guard panels on top of the supports using (4) ¼-20 x ¾ self-threading screws, lock washers, and hex nuts. 5. Starting at the control box end, install the wind baffle panels on the front of the supports using (4) ¼-20 x ¾ self-threading screws, lock washers, and hex nuts. Each panel overlaps the adjacent one. 6. Install the end panels by drilling three holes in the coil end frame and securing the end panel with ¼ inch screws. Use the holes at the top, bottom and front of the end panel as a template and drill (#19 drill) holes into the flange of the supports. Install the #10-24 self-threading screws. Figure 11, Panel Layout Balloon Part Description Number 1 Channel/Support 2 Panel/Wind Baffle 3 Screw, ¼-20 x ¾ 4 Hex Nut, ¼-20 5 Lock Washer, ¼ 6 Panel/End (L.H.) 7 Panel/End (R.H.) 8 Panel/Hail Guard 9 Screw, x ½ 10 Panel/Wind Baffle 11 Panel/Hail Guard 24 ALR 110F through 150F IOMM ALR-3

25 Remote Evaporator General NOTE: Remote evaporator arrangements are not included in the ARI Certification Program and capacities are therefore not ARI certified. The ALR air-cooled chillers are available with remote evaporator on R-22 service only. This allows the main unit to be installed outdoors to save interior room and eliminates the need for anti-freeze solutions and heat tracing of chilled water lines since the chilled water system is indoors. There are some general guidelines to review before proceeding: 1. R-22 only. 2. Maximum line length of 100 ft (30 m) and Total Equivalent Length (TEL) of 200 ft (61 m). 3. No underground piping. 4. Careful attention should be given to piping layout and employment of insulation and check valves when using hot gas bypass. 5. Units with remote evaporator are not included in the ARI Certification Program. The remote evaporator is shipped separately, ready for quick and easy installation at the job site. Refrigerant accessories such as liquid line shut-off valves, replaceable core filter-driers, liquid line solenoid valves, expansion valves, and sightglasses are shipped in a kit for field installation and wiring. The evaporator is equipped with entering and leaving chilled water temperature sensor wells. The sensors leads are pre-wired to the ALR unit and must be field connected to the evaporator thermowells. Units with Microtech Control will have 100-foot cables. Units with UNT Control will require field splicing the cables. ALR units are shipped with an operating charge of refrigerant. Field piping must be leak tested, evacuated and charged during installation. Do not exceed 150 psig test pressure unless the unit is blanked off from the piping. Standard insulation is ¾ inch Armaflex or equal UL approved insulation. Double insulation is available as an option and is recommended in high humidity locations or for ice-making duty. Performance Derate Factors All performance tables and adjustment factors found in this catalog are applicable for remote evaporator installations, however, a performance derate must be applied to the R-22 performance data due to additional pressure drops in the suction and liquid lines which cause a loss of compressor performance. These derates are based on a suction line pressure drop equivalent of approximately 2 F (1 C) change in saturation temperature. For R-22 applications: Capacity = Tons (kw) x 0.97 Power = Compressor kw x 0.99 IOMM ALR-3 ALR 110F through 150F 25

26 Line Sizing Line sizing and layout should follow procedures found in the ASHRAE Handbooks or other recognized design manuals. Nominal circuit capacities are listed in Table 14. Unloading steps are found in the Physical Data tables. Table 14, Nominal Circuit Capacities ALR Model Circuit 1 Circuit 2 Tons (kw) Tons (kw) 110F 53 (185) 57 (200) 120F 60 (210) 60 (210) 130F 65 (227) 65 (227) 135F 68 (238) 68 (238) 140F 70 (245) 70 (245) 145F 73 (255) 73 (255) 150F 70 (245) 80 (280) Dimensions Use the ALR dimension drawing for the condensing unit section (no evaporator) and Figure 12 for the remote evaporator. The refrigerant connections are located approximately where the refrigerant connections to the unit mounted evaporator are on a packaged chiller. The remote evaporator dimensions are on Figure 12. Weights Weights for the remote evaporators are listed on the following dimension page. Weights for the outdoor unit can be calculated by subtracting the evaporator weight from the total unit weight found in the Physical Data section. Connection Sizes Table 15, Connection Sizes Unit Size ALR Unit Remote Evaporator Suction (IDS) Liquid (IDS) Suction (IDS) Liquid (IDS) Water (in.) /8 1 1/8 3 1/8 1 5/ /8 1 1/8 3 1/8 1 5/ /8 1 1/8 3 1/8 1 5/ /8 1 1/8 3 1/8 1 5/ /8 1 1/8 3 1/8 1 5/ /8 1 1/8 3 1/8 1 5/ /8 1 1/8 3 1/8 1 5/8 8 Refrigerant Piping Field installed refrigerant piping should be leak checked and evacuated in accordance with good practice. The refrigerant specialties (solenoid valve, expansion valve, filter-drier, and sight glass) are shipped in a kit with the evaporator. All other valves and fittings are supplied by the contractor. 26 ALR 110F through 150F IOMM ALR-3