Product Manual PM ALP2-2 Group: Chiller Date: February 2000 Supersedes: PM ALP2-1 Air-Cooled Condensing Units ALP 027C through ALP 041C, 25 to 40 Tons, 88 to 140 kw 50 and 60 Hertz Direct Expansion Evaporators CDE.10C - CDE.35C 10 to 35 Tons, 35 to 123 kw 1997 McQuay International
Table of Contents Introduction... 3 Design Features... 4 Selection Procedure... 7 ALP Capacity Table... 9 ALP Capacity Curves... 10 ALP Part Load Performance Data... 12 Capacity, CDE-.10C to CDE-.35C Evaporators, R-22... 13 Water Pressure Drops... 14 Electrical Data... 15 Physical Data... 17 Dimensional Data... 18 Sound Data... 20 Installation and Application Data... 22 Optional Equipment... 27 Guide Specifications... 28 Our Facility is "McQuay" is registered trademarks of McQuay International 1997 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 construction at anytime without notice" 2 Product Manual ALP2-2
Introduction McQuay International offers a complete range of condensing units from 12 to 120 tons (42 to 420 kw). This manual covers Model ALP 027C through ALP 041C condensing units with capacities from 25 to 40 tons (88 to 140 kw). See Product Manual ALP1-2 for information on Models ALP 012D through ALP 019D, 12 to 20 tons (42 to 70 kw) and Product Manuals PM ACZ and PM ACR for units with capacities to 120 tons (420 kw). The McQuay ALP air-cooled condensing units offer unsurpassed efficiency, flexibility, reliability, and serviceability in a total package concept. Improved to include the latest heat transfer surface design and the most advanced and efficient reciprocating compressors in the industry, ALP condensing units not only exceed efficiency requirements set forth by ASHRAE Standard 90.1, but the competition s full load efficiencies in an overall product line comparison. The McQuay air-cooled condensing units are completely factory assembled, piped, wired and shipped in one piece, ready for installation. Each unit consists of motor compressor, condenser coils with integral subcooler circuits, multiple propeller type direct drive condenser fans with independent fan motors, heavy-gauge weatherproof casing and weatherproof electrical control center containing all necessary safety and operating controls (excluding staging thermostats) and motor starting equipment. Lower Operating Costs The C vintage ALP air-cooled condensing units offer some of the highest operating efficiencies available today. These high operating efficiencies are made possible through use of the most efficient components available to the industry. The use of an integrated airside economizer whenever practical to maximize energy savings and minimize low load cycling is recommended. This will eliminate the need to operate mechanical cooling (compressor operation) at low ambient temperatures that could result in unstable operation. Greater Design Flexibility Available in 4 sizes between 25 and 40 nominal tons (88 to 140 kw), there is a selection that will closely match the required capacity. The unit is designed for use in ambient air temperatures up to 120 F (49 C) and optional low ambient controls are available to permit operation down to 0 F (-18 C). Many optional features have been added to fit your needs, SpeedTrol head pressure control for low ambient unit operation, copper fins, or coated aluminum fins are available. Optional factory mounted gauges for oil, suction, and discharge pressures are convenient for routine maintenance and service. Low Installation Costs Complete factory assembly ready for connection of power, refrigerant piping and staging thermostats eliminates on-site construction costs of built-up systems. A rigid steel channel base distributes unit weight for low roof loading on roof mounted applications. Lifting holes in the base channels permit quick unit rigging. Product Manual ALP2-2 3
Code and Agency Appliance All ALP units are constructed and/or rated with the latest ARI Standard 365, ANSI/ASHRAE 15 Safety Code, National Electrical Code, C ETL and ETL. Design Features Cabinet Construction Designed for easy handling and low installation costs, the air-cooled condensing units are factory assembled and mounted on a rugged steel channel base. The channel base distributes the unit weight for low roof loading. Lifting holes in the base simplify rigging for installation. The small footprint of these ALP models gives the designer great flexibility with equipment layout. Compressors McQuay ALP condensing units use the most advanced and efficient reciprocating compressors in the industry: the Copeland DISCUS valve compressors. These heavy-duty, industrial quality, semihermetic compressors are designed for Refrigerant 22 and high loading associated with air-cooled applications. Serviceable compressors offer reduced maintenance costs because if problems develop with components such as oil pumps, unloaders and pistons, they can be serviced in the field without replacing the compressor. Both suction and discharge service valves are provided to allow isolation of compressor from the refrigerant circuit. Hermetic, 1750/1460 RPM induction type motors are employed. The motors are refrigerant suction gas cooled. A finned motor housing helps dissipate motor heat. Solid-state modules in the motor terminal box respond to temperature sensors imbedded in all three motor windings to provide inherent thermal overload protection for all run and start conditions. The motor terminal box is located above the crankcase oil level. The compressor housing is constructed from close grained, high nickel content, alloy cast iron with no bolted joint between the motor and compressor. The housing includes a cast iron cylinder head and stator cover, and a crankcase oil sight glass. A suction strainer is built into the compressor in the gas stream between the suction service valve and the motor to filter out foreign and abrasive particles. An internal relief valve relieves discharge pressure to the suction side for safety protection at high compression ratios as required by ANSI/ASHRAE 15 Safety Code. Suction and discharge valves are made of Swedish steel with contoured valve retainers to relieve valve stress and reduce valve noise. Compressor design features low clearance volume for high volumetric efficiency. Main bearings are solid cast bronze insert type with oversized bearing area that result in ultra-low bearing loadings. The crankshaft is constructed from die-forged, high strength steel alloy with integral counterweights, statically and dynamically balanced for smooth operation. 4 Product Manual ALP2-2
Connecting rods are lightweight aluminum alloy with integral bearing surfaces on crankshaft and piston end. Pistons are close grain cast iron with oil and compression rings. Piston pins are full floating type for long life. Compressors have a force-feed lubrication system with positive oil displacement, a reversible oil pump, and an operating oil charge. The pump feeds oil through rifle drilled passages in the crankshaft to all bearing surfaces. Magnetic plugs trap magnetic particles that enter the crankcase. The oil supply is filtered through a large area oil strainer. A crankcase heater minimizes oil dilution by refrigerant. Condenser Coils The ALP unit condenser coils are constructed with internally enhanced seamless copper tubes arranged in a staggered row pattern and mechanically expanded into McQuay lanced and rippled aluminum fins with full fin collars. An integral subcooler circuit provides sufficient subcooling to effectively eliminate the possibility of liquid flashing and increase unit efficiency. A standard wire mesh screen protects the coil fin surface. Hot Gas Mufflers Hot gas discharge line mufflers are supplied on all units as standard. Reduced sound levels provide some of the quietest condensing units on the market, satisfying the most demanding customers. Condenser Fans and Motors Multiple direct drive propeller fans operate in formed bell-shaped orifices at low tip speeds for maximum static efficiency and minimum noise and vibration. A heavy-gauge close meshed fan guard protects each fan. A heavy-duty, 3-phase motor with permanently lubricated ball bearings and inherent overload protection drives each condenser fan. Factory fusing provides short circuit protection. Electrical Control Center The McQuay ALP air-cooled condensing unit is shipped with operating and safety controls including unit control stop switch, limited recycling pumpdown control, manual pumpdown switch, oil pressure control, high and low pressure controls, fan cycling control, 120V control transformer, and motor starting equipment factory wired, operationally tested, and ready for service. Cycling/ unloading control is field furnished and installed. Controls are centrally located in a weatherproof control center with keylocked doors to prevent unauthorized entry. Panel access doors include steel rod door retainers to prevent flapping while open. A fixed 5-minute solid-state timer is provided as standard to delay compressor restart after safety cutout or power interruption, or under irregular cooling load demands. Deadfront panels protect service personnel from accidental contact with line voltage components. Product Manual ALP2-2 5
Figure 1, Typical Control Panel NOTE: Components show with dotted lines are optional. Remote Evaporators To complement the air-cooled condensing units for applications requiring water chillers, the CDE direct expansion evaporator is offered for remote location. These high quality brazed plate-to-plate stainless steel heat exchangers are built to provide long life, dependable service and peak efficiency under demanding operating conditions and are available in capacities from 10 to 35 tons. CDE.10C through.35c evaporators are designed and constructed in accordance with Underwriters Laboratories, Inc. (UL) and Canadian Standard Association (CSA). 6 Product Manual ALP2-2
Selection Procedure The ratings in the Quick Selection Table and the Performance Curves are based on unit operation in a well designed, properly piped system. Selection Procedure 1. Condensing unit capacities are based on 12 degrees F (6.7 degrees C) of subcooling with normal operating refrigerant charge. Select the thermal expansion valves accordingly. Maximum liquid lift capability without additional subcooling is 65 feet (20 m). 2. Ratings are shown at saturated suction temperatures corresponding to pressures at the compressor. In actual practice, suction line pressure drop has the effect of reducing compressor capacity, forcing the compressor to operate at a lower suction pressure to maintain the desired evaporator temperature. 3. Ratings are in I-P units for 60 cycle operation. For 50 hertz operation, multiply unit capacity by 0.87 and kw input by 0.84 and convert for SI units using Table 1. 4. Ratings are for sea level operation. For operation at other elevations, multiply ratings by factors from Table 2. General Procedures It is important that the components of a direct expansion split system be properly matched. Failure to do so may result in inability to maintain desired conditions and premature equipment failure. The ALP condensing unit may be directly selected from the Quick Selection Table on page 9 or from the Capacity Curves beginning on page 10 if the ambient air temperature and saturated suction temperature at the compressor are known. The ambient air temperature is a known design parameter, but the suction temperature at the compressor is typically known only within certain allowable limits. The actual compressor operating suction temperature and the overall performance of the system will depend directly upon the choice of the remote DX evaporator. Direct Expansion Water Evaporator When using a McQuay brazed plate evaporator, start with a preliminary evaporator selection at a nominal evaporating temperature, using the evaporator capacity data beginning on page 13. Enter the Quick Selection Table and select a unit to meet the required cooling load at a saturated suction temperature (SST) at least 2 degrees F (1 degree C) below the evaporator temperature to allow for normal suction line loss. If a more accurate selection is required, the evaporator performance should be plotted against condensing unit performance to determine the balanced system performance. Again, take care to add suction line loss. After the balanced system operating point is determined, the unit power requirement may be interpolated from the Quick Selection Table at the actual suction temperature. Direct Expansion Cooling Coils (Air Handlers) As there is generally far more flexibility in the selection of a cooling coil, it is usually selected to match the condensing unit performance. The capacities of the condensing unit and the coil will be equal at some common suction temperature (allowing for line losses). This is called the balance point. The balance point should be in the range of 33 F to 50 F (1 C to 10 C) SST (Saturated Suction Temperature) for satisfactory operation at all load points, not just full load. Too low a suction temperature may cause coil frosting problems and too high a temperature can cause compressor motor overheating. Product Manual ALP2-2 7
A condensing unit s capacity and efficiency increases with increasing suction temperatures and the most economical selection would be made close to the 50 F (10 C) point. At the same time, higher temperatures mean larger coil surface requirements. A compromise must be made, and for most comfort air conditioning applications a temperature between 40 F and 50 F (4 C and 7 C) will provide good results. During part load operation, the compressor will unload and a new balance point will be established. A direct expansion system can usually handle capacity reduction to 50 percent without unloading a portion of the coil. The balance point will rise several degrees. Should a condensing unit unload below 50 percent, as do the ALP037C and 041C, the cooling coil must be split to match the steps of unloading as closely as possible. In this case, a 50/50 coil split will be satisfactory for these units unloading of 100-67-33-0. The split does not have to exactly match the unloading. In this case, full coil operation at the 100 and 67 percent points and 50 percent coil at the 33 percent step will be adequate. Each coil section must have its own expansion valve and solenoid valve. Sample Selection, 60 Hz, (CDE matched with a McQuay ALP air-cooled condensing unit) Given: 1. Total required cooling load: 30 tons (105 kw). 2. Required evaporator conditions: 55 to 45 F (12.8 to 7.2 C) leaving chilled water; 36 F (2.2 C) SST; 72 gpm (4.6 l/s). 3. Ambient air temperature: 95 F (35 C) 4. Maximum water pressure drop: 20 ft.(60 kpa) Find: A CDE/ALP balanced system that meets the capacity requirements. Solution: 1. From the Evaporator Capacity Tables on page 13, make a preliminary evaporator selection at two arbitrary evaporator temperatures. A CDE-.30C-1 at 45 F leaving water temperature and 36 F SST delivers 32.8 tons. The same evaporator with 45 F leaving water temperature and 37 F refrigerant temperature delivers 29.5 tons. 2. From the Quick Selection Table, page 9, an ALP-037C has the required capacity to meet the cooling load requirement at 95 F ambient when operating at about 35 F SST at the compressor (37 F at the evaporator). 3. Plot the above evaporator capacities on the ALP-037C condensing unit curve at the two arbitrary refrigerant temperature in the sample above. By joining the two points, the Evaporator Capacity Line is established. 4. To take suction line loss into consideration, move horizontally to the left 2 degrees and draw a line parallel to the Evaporator Capacity Line. This establishes the System Capacity Line. 5. From the System Capacity Line determine the balanced conditions as follows: 6. From the intersection of the System Capacity Line and the 95 F ambient line read left to find the matched capacity. 7. From the same intersection, read downward to find a Saturated Suction Temperature. 8 Product Manual ALP2-2
Capacity Conversion Factors Table 1, I-P to SI Conversion Factors Inch - Pound Multiply By To Obtain SI Btu/Hr 0.000293 kw Ft. of Water 2.99 Kpa CFM 0.000472 m3/s GPM 0.0632 L/sec. HP 0.746 KW Inches 25.4 mm Pounds 0.4537 kg PSI 6.897 Kpa Ton Refrig. 3.516 KW Table 2, Altitude Correction ELEVATION, ft (m) ABOVE SEA LEVEL) BAROMETRIC PRESSURE CAPACITY MULTIPLIER Sea Level 29.92 1.000 1000 (305) 28.86 0.991 2000 (610) 27.82 0.981 3000 (915) 26.81 0.972 4000 (1220) 25.84 0.962 5000 (1525) 24.89 0.943 6000 (1830) 23.98 0.943 Table 3a, Fouling Correction EVAPORATOR FOULING FACTOR COOLING CAPACITY MULTIPLIER Clean 1.02 0.0005 (0.088) 1.00 0.001 (0.176) 0.98.0.002 (0.352) 0.94 ALP Capacity Table Table 4, Capacity Table, 60 Hz, I-P Units ALP UNIT SIZE 027C 032C 037C 041C SAT. SUCT. TEMP ( F) 35 40 45 50 35 40 45 50 35 40 45 50 35 40 45 50 AMBIENT AIR TEMPERATURE 90 F 95 F 100 F 105 F 110 F 120 F Tons kw EER Tons kw EER Tons kw EER Tons kw EER Tons kw EER Tons kw EER 22.3 24.6 27.0 29.5 25.2 27.6 30.1 32.7 31.4 34.4 37.6 41.0 36.5 39.7 43.1 46.7 23.2 23.9 24.7 25.5 27.5 28.5 29.5 30.5 35.0 36.3 37.6 39.0 42.0 43.9 45.9 48.1 11.5 12.3 13.1 13.8 11.0 11.6 12.2 12.8 10.7 11.3 11.9 12.6 10.4 10.8 11.2 11.6 21.6 23.8 26.1 28.7 24.5 26.8 29.2 31.8 30.5 33.5 36.6 39.9 35.4 38.5 41.8 45.2 23.9 24.7 25.6 26.4 28.3 29.3 30.4 31.4 36.0 37.3 38.7 40.1 43.2 45.2 47.4 50.0 10.8 11.5 12.2 13.0 10.3 10.9 11.5 12.1 10.1 10.7 11.3 11.9 9.8 10.2 10.5 10.9 20.9 23.1 25.3 27.8 23.7 26.0 28.3 30.9 29.6 32.5 35.5 38.7 34.2 37.2 40.4 43.7 1. ARI rating point at 45 F suction temperature and 95 F ambient. 2. Tons, kw, and EER are for the entire unit including fan motors and control power. Fan motor kw is 1.1 kw each, control power is 0.4 kw per unit. 3. EER = BTU/Watt = 12 x Tons/kW, Tons = GPM x delta T/24 4. Rating shown are for 60 Hz operation. For 50 Hz, multiply Tons by 0.87 and kw by 0.84 5. Ratings in accordance with ARI Standard 365 24.6 25.5 26.4 27.4 29.0 30.1 31.3 32.4 36.8 38.3 39.7 41.2 44.4 46.6 48.9 51.4 10.2 10.8 11.5 12.1 9.8 10.3 10.8 11.4 9.6 10.1 10.7 11.2 9.2 9.6 9.9 10.2 20.2 22.3 24.5 26.8 22.9 25.1 27.5 30.0 28.7 31.5 34.4 37.6 33.0 35.9 38.9 42.2 25.3 26.3 27.3 28.3 29.7 30.9 32.1 33.3 37.7 39.2 40.7 42.2 45.6 47.9 50.5 53.1 9.6 10.1 10.7 11.3 9.3 9.8 10.2 10.7 9.1 9.6 10.1 10.6 8.7 9.0 9.3 9.5 19.5 21.5 23.6 25.9 22.1 24.3 26.6 28.9 27.8 30.5 33.3 37.4 31.9 34.6 37.5 40.6 26.0 27.0 28.1 29.2 30.4 31.6 32.9 34.1 38.5 40.1 41.6 43.2 46.7 49.3 52.2 55.0 9.0 9.5 10.0 10.6 8.7 9.2 9.7 10.1 8.7 9.1 9.6 10.1 8.2 8.4 8.6 8.9 18.7 20.7 22.7 24.9 21.4 23.4 25.7 28.0 26.9 29.5 32.3 35.2 30.6 33.3 36.0 38.9 26.6 27.8 28.9 30.1 31.0 32.3 33.6 34.9 39.2 40.9 42.4 44.0 47.9 50.8 53.9 56.9 8.4 8.9 9.4 9.9 8.3 8.7 9.2 9.6 8.2 8.7 9.1 9.6 7.7 7.9 8.0 8.2 Product Manual ALP2-2 9
ALP Capacity Curves Figure 2, ALP 027C Figure 3, ALP 032C 10 Product Manual ALP2-2
Figure 4, ALP 037C Figure 5, ALP 041C Product Manual ALP2-2 11
ALP Part Load Performance Data Most HVAC systems operate at part load most of the time and it is important that part load efficiency be maximized. The McQuay ALP Condensing Unit optimizes part load efficiency by using efficient compressor cylinder unloading. Standard capacity reduction steps are accomplished by the most efficient method of cylinder unloading in the industry today. A signal from the temperature or pressure controller positions the solenoid valve to put high side pressure against an unloader plunger. The plunger closes the suction port on the valve plate, preventing the suction gas from entering the cylinder and reducing the work required to stroke the piston. Less work consumes less energy for more efficient cylinder unloading than by conventional bypass methods. Figure 6, ALP Unit Part Load Performance 027C 032C 037C 041C ALP UNIT SIZE % Full Load Capacity % Full Load kw % Full Load Capacity % Full Load kw % Full Load Capacity % Full Load kw % Full Load Capacity % Full Load kw UNIT PERFORMANCE (1) STANDARD CAPACITY REDUCTION 100 100 100 100 1. Unit performance including compressors and fans. 2. Part load EER can be calculated by dividing % Full Load Capacity by Full Load kw (this table), then multiplying the result by the full load EER (Capacity Data Table). 100 100 100 100 81 62 81 62 65 48 65 48 47 32 47 32 12 Product Manual ALP2-2
Capacity, CDE-.10C to CDE-.35C Evaporators, R-22 Table 5, 42 F (5.6 C) LWT Refrigerant Temperature, F ( C) Model Number 32 (0) 33 (0.6) 34 (1.1) 35 (1.7) 36 (2.2) 37 (2.8) Capacity, tons (kw) CDE-.10C-1 10.4 (36.6) 9.6 (33.8) 8.7 (30.6) 7.7 (27.1) 6.7 (23.6) 5.4 (19.0) CDE.15C-1 16.0 (56.3) 14.8 (52.1) 13.0 (45.8) 11.3 (39.8) 9.6 (33.8) 7.8 (27.5) CDE.18C-1 20.8 (73.2) 19.6 (69.0) 17.5 (61.6) 15.2 (53.5) 13.0 (45.8) 10.7 (37.7) CDE-.22C-1 26.7 (94.0) 24.2 (85.2) 21.7 (76.4) 19.0 (66.9) 16.2 (57.0) 13.3 (46.8) CDE-.25C-1 31.7 (111.6) 28.7 (101.0) 25.7 (90.5) 22.7 (79.9) 19.3 (67.9) 16.0 (56.3) CDE-.30C-1 36.2 (127.4) 32.8 (115.5) 29.5 (103.8) 26.0 (91.5) 22.3 (78.5) 18.5 (65.1) CDE-.35C-1 38.6 (135.9) 36.0 (126.7) 33.0 (116.2) 29.2 (102.8) 25.2 (88.7) 21.0 (73.9) Table 6, 44 F (6.7 C) LWT Refrigerant Temperature, F ( C) Model Number 34 (1.1) 35 (1.7) 36 (2.2) 37 (2.8) 38 (3.3) 39 (3.9) Capacity, tons (kw) CDE-.10C-1 10.4 (36.6) 9.6 (33.8) 8.7 (30.6) 7.7 (27.1) 6.7 (23.6) 5.4 (19.0) CDE.15C-1 16.0 (56.3) 14.8 (52.1) 13.0 (45.8) 11.3 (39.8) 9.6 (33.8) 7.8 (27.5) CDE.18C-1 20.8 (73.2) 19.6 (69.0) 17.5 (61.6) 15.2 (53.5) 13.0 (45.8) 10.7 (37.7) CDE-.22C-1 26.7 (94.0) 24.2 (85.2) 21.7 (76.4) 19.0 (66.9) 16.2 (57.0) 13.3 (46.8) CDE-.25C-1 31.7 (111.6) 28.7 (101.0) 25.7 (90.5) 22.7 (79.9) 19.3 (67.9) 16.0 (56.3) CDE-.30C-1 36.2 (127.4) 32.8 (115.5) 29.5 (103.8) 26.0 (91.5) 22.3 (78.5) 18.5 (65.1) CDE-.35C-1 38.6 (135.9) 36.0 (126.7) 33.0 (116.2) 29.2 (102.8) 25.2 (88.7) 21.0 (73.9) Table 7, 45 F (7.2 C) LWT Refrigerant Temperature, F ( C) Model Number 35 (1.7) 36 (2.2) 37 (2.8) 38 (3.3) 39 (3.9) 40 (4.4) Capacity, tons (kw) CDE-.10C-1 10.4 (36.6) 9.6 (33.8) 8.7 (30.6) 7.7 (27.1) 6.7 (23.6) 5.4 (19.0) CDE.15C-1 16.0 (56.3) 14.8 (52.1) 13.0 (45.8) 11.3 (39.8) 9.6 (33.8) 7.8 (27.5) CDE.18C-1 20.8 (73.2) 19.6 (69.0) 17.5 (61.6) 15.2 (53.5) 13.0 (45.8) 10.7 (37.7) CDE-.22C-1 26.7 (94.0) 24.2 (85.2) 21.7 (76.4) 19.0 (66.9) 16.2 (57.0) 13.3 (46.8) CDE-.25C-1 31.7 (111.6) 28.7 (101.0) 25.7 (90.5) 22.7 (79.9) 19.3 (67.9) 16.0 (56.3) CDE-.30C-1 36.2 (127.4) 32.8 (115.5) 29.5 (103.8) 26.0 (91.5) 22.3 (78.5) 18.5 (65.1) CDE-.35C-1 38.6 (135.9) 36.0 (126.7) 33.0 (116.2) 29.2 (102.8) 25.2 (88.7) 21.0 (73.9) Table 8, 48 F (8.9 C) LWT Refrigerant Temperature, F ( C) Model Number 38 (3.3) 39 (3.9) 40 (4.4) 41 (5.0) 42 (5.6) 43 (6.1) Capacity, tons (kw) CDE-.10C-1 10.4 (36.6) 9.6 (33.8) 8.7 (30.6) 7.7 (27.1) 6.7 (23.6) 5.4 (19.0) CDE.15C-1 16.0 (56.3) 14.8 (52.1) 13.0 (45.8) 11.3 (39.8) 9.6 (33.8) 7.8 (27.5) CDE.18C-1 20.8 (73.2) 19.6 (69.0) 17.5 (61.6) 15.2 (53.5) 13.0 (45.8) 10.7 (37.7) CDE-.22C-1 26.7 (94.0) 24.2 (85.2) 21.7 (76.4) 19.0 (66.9) 16.2 (57.0) 13.3 (46.8) CDE-.25C-1 31.7 (111.6) 28.7 (101.0) 25.7 (90.5) 22.7 (79.9) 19.3 (67.9) 16.0 (56.3) CDE-.30C-1 36.2 (127.4) 32.8 (115.5) 29.5 (103.8) 26.0 (91.5) 22.3 (78.5) 18.5 (65.1) CDE-.35C-1 38.6 (135.9) 36.0 (126.7) 33.0 (116.2) 29.2 (102.8) 25.2 (88.7) 21.0 (73.9) Product Manual ALP2-2 13
Water Pressure Drops Figure 7, Water Pressure Drop Data NOTE: The above pressure drops are based on water. Consult your local McQuay office for glycol data. 14 Product Manual ALP2-2
Electrical Data Table 9, 60 Hz, Single Point Wire Sizing Ampacities and Recommended Power Lead Sizes ALP Unit 027C 032C 037C 041C Volts 60Hz 208 230 460 575 208 230 460 575 208 230 460 575 208 230 460 575 Minimum Circuit Ampacity MCA 105 105 53 46 119 119 59 52 152 152 81 60 181 171 85 67 3 Wires 1 Conduit 2 2 6 8 1 1 6 6 2/0 2/0 4 6 3/0 2/0 4 4 Recommended Copper Power Lead Wire Size 6 Wires 1 Conduit Hub Dia. 1.50 1.50 1.00 1.00 2.00 2.00 1.25 1.25 2.00 2.00 1.25 1.25 2.50 2.50 1.25 1.25 3 Wires In Each Of 2conduits Hub Dia. Maximum Fuse or HACR Breaker Size 175 175 80 70 200 200 100 80 250 250 125 100 300 250 125 110 See notes on page 15 Table 10, 60 Hz, Compressor and Condenser Fan Motor Amps Draw ALP UNIT 027C 032C 037C 041C Voltage 60 Hz (Note 6) 208 230 460 575 208 230 460 575 208 230 460 575 208 230 460 575 See notes on page 15. RATED LOAD AMPS NO. LOCKED ROTOR AMPS FAN MTRS OF FAN FAN MTRS ACROSS-THE-LINE PART WIND START COMPRESSOR (EA.) MTRS (EA.) START COMPRESSORS COMPRESSORS 1 1 1 74 74 37 31 85 85 42 36 112 112 60 42 153 140 71 54 4.0 4.0 2.0 2.3 4.0 4.0 2.0 2.3 4.0 4.0 2.0 2.3 4.0 4.0 2.0 2.3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 17.0 17.0 9.9 10.3 17.0 17.0 9.9 10.3 17.0 17.0 9.9 10.3 17.0 17.0 9.9 10.3 214 172 235 200 315 245 315 245 250 250 292 292 400 340 463 340 Electrical Data Notes 1. Unit wire size ampacity (MCA) is equal to 125% of the RLA of the largest motor plus 100% of the RLA of all other loads in the circuit. Wire sizing amps shown are for units with all loads on a common supply circuit, including control transformer. 2. The unit includes a factory wired control circuit transformer, no separate 115V power is required. If a separate 115V supply is used for the control circuit, the wire sizing amps is 2 amps for the ALP- 027C through 041C. 3. Recommended power lead wire sizes for three conductors per conduit are based on 100% conductor ampacity and no more than 3 conductors per conduit. Voltage drop has not been included. Therefore, it is recommended that power leads be kept short. All terminal block connections must be made with correctly sized copper (no aluminum) wire. Product Manual ALP2-2 15
4. The unit power terminal block may have two lugs per phase. Single or parallel conductors should be used for power connection as listed under Recommended Power Lead Wire Size. 5. Maximum Fuse Sizes are selected at approximately 150% of the largest compressor RLA, plus 100% of all other loads in the circuit. 6. The recommended power lead wire sizes are based on ambient temperatures of 86 F (30 C). Ampacity correction factors must be applied for other ambient temperatures. Refer to the National Electrical Code handbook. 7. 50 Hz: Electric data for 380/50/3 and 415/50/3 is the same as 460/60/3 Power Limitations Volts within 10 percent of nameplate rating. Maximum 3 percent phase unbalance. Figure 8, Typical Field Wiring Diagram 16 Product Manual ALP2-2
Physical Data Table 11, Condensing Units, ALP 027C- ALP 041C ALP MODEL NUMBER DATA 027C 032C 037C 041C BASIC DATA CAPACITY @ ARI CONDITIONS, TONS (kw) 26.2 (92) 29.2 (102) 36.6 (128) 41.8 (147) NO. OF REFRIGERANT CIRCUITS 1 1 1 1 R-22 OPERATING CHARGE, lb (kg) 15.7 (7.1) 15.7 (7.1) 15.7 (7.1) 21.7 (9.8) PUMPDOWN CAPACITY @ 90 F, lb (kg) 60.5 (27) 60.5 (27) 60.5 (27) 87.6 (40) CABINET DIMENSIONS, LxWxH, inches 95 ½ x57 ½ x46 95 ½ x57 ½ x46 95 ½ x57 ½ x46 95 ½ x57 ½ x46 LxWxH, (cm) (242x145x117) (242x145x117) (242x145x117) (242x145x117) UNIT WEIGHT, lb (kg) 1380 (625) 1450 (657) 1460 (661) 1600 (725) ADD L WT FOR COPPER FINS 350 (159) 340 (154) 340 (154) 530 (241) COMPRESSOR - COPLAMETIC SEMI HERMETIC NOMINAL HORSEPOWER 25 30 35 40 NO. OF CYLINDER PER COMPRESSOR 4 4 6 6 OIL CHARGE, oz (g) 136 (3855) 152 (4309) 160 (4536) 242 (6861) CAPACITY REDUCTION (Note 1) UNLOADING STEPS 0-50-100 0-50-100 0-33-67-100 0-33-67-100 CONDENSERS COIL FACE AREA, sq ft (m 2 ) 49.0 (4.5) 49.0 (4.5) 49.0 (4.5) 49.0 (4.5) FIN HEIGHT x LENGTH in. 84x84 84x84 84x84 84x84 (cm) (213x213) (213x213) (213x213) (213x213) FINS PER INCH x ROWS 16x2 16x2 16x2 16x3 CONDENSER FANS NO. OF FANS x DIAMETER 3-26 3-26 3-26 3-26 FAN HORSEPOWER 3-1.0 3-1.0 3-1.0 3-1.0 SPEED 1100 1100 1100 1100 60 Hz FAN TIP SPEED, ft/sec (m/s) 7760 (2367) 7760 (2367) 7760 (2367) 7760 (2367) 50 Hz FAN TIP SPEED, ft/sec (m/s) 6466 (1972) 6466 (1972) 6466 (1972) 6466 (1972) 60 Hz TOTAL AIR FLOW, cfm (m 3 /min) 21,525 (609) 20,925 (592) 20,925 (592) 20,025 (567) 50 Hz TOTAL AIR FLOW, cfm (m 3 /min) 17940 (443) 17440 (493) 17440 (493) 17440 (493) NOTES: 1. Capacity reduction shown in percent of compressor displacement reduction. See Part Load Performance Data for total unit capacity and power reduction. Product Manual ALP2-2 17
Dimensional Data Figure 9, ALP 027C - ALP 041C Table 12, Dimensions ALP Connection Locations Inches (mm) Connection Sizes Inches (mm) Isolator Locations Unit Size A B C D Liquid Hot gas bypass Suction R T 027C 032C 037C 041C 10 (254) 10 (254) 10 (254) 10 (254) 13 (330.2) 13 (330.2) 13 (330.2) 13 (330.2) 21.5 (546.1) 21.5 (546.1) 21.5 (546.1) 21.5 (546.1) 5.7 (144.8) 5.7 (144.8) 5.7 (144.8) 5.7 (144.8) 0.875 (22.23) 0.875 (22.23) 0.875 (22.23) 0.875 (22.23) 1.125 (28.58) 1.125 (28.58) 1.125 (28.58) 1.125 (28.58) 1.625 (41.28) 2.125 (53.98) 2.125 (53.98) 2.125 (53.98) 6.94 (176.28) 6.94 (176.28) 6.94 (176.28) 6.94 (176.28) 88.4 (2245.4) 88.4 (2245.4) 88.4 (2245.4) 88.4 (2245.4) 18 Product Manual ALP2-2
Figure 10, CDE.10C - CDE.35C Table 13, Evaporator Dimensions Dimensions Inches (mm) Weight Connections Model Lbs. (kg) Inches (mm) Number A B C D E F Empty Full Water (1) Refrig. (2) CDE.15C 20.5 (521) 17.5 (445) 6.9 (175) 9.4 (239) 1.1 (28) 3.1 (79) 38.9 (18) 47.3 (21) 1.5 (38) 1.6 (41) CDE.18C 20.5 (521) 17.5 (445) 6.9 (175) 9.4 (239) 1.1 (28) 4.0 (102) 49.3 (22) 60.5 (27) 1.5 (38) 1.6 (41) CDE.22C 20.5 (521) 17.5 (445) 6.9 (175) 9.4 (239) 1.1 (28) 4.9 (124) 59.7 (27) 73.7 (33) 1.5 (38) 1.6 (41) CDE.25C 20.5 (521) 17.5 (445) 6.9 (175) 9.4 (239) 1.1 (28) 5.9 (150) 70.1 (32) 86.9 (39) 1.5 (38) 1.6 (41) CDE.30C 20.5 (521) 17.5 (445) 6.9 (175) 9.4 (239) 1.1 (28) 6.8 (173) 80.5 (37) 100.1 (45) 1.5 (38) 1.6 (41) CDE.35C 20.5 (521) 17.5 (445) 6.9 (175) 9.4 (239) 1.1 (28) 7.8 (198) 90.9 (41) 113.3 (51) 1.5 (38) 1.6 (41) NOTES: 1. Water connections are NPT. 2. Refrigerant connections are sweat. Table 14, Evaporator Physical Data CDE Model Number Data.15C-1.18C-1.22C-1.25C-1.30C-1.35C-1 Dimensions L x W x H inches (mm) Direct Expansion Evaporator Plate-To-Plate 3.1 x 9.4 x 20.5 (53 x 239 x 521) 4 x 9.4 x 20.5 (102 x 239 x 521) 4.9 x 9.4 x 20.5 (124 x 239 x 521) 5.9 x 9.4 x 20.5 (150 x 239 x 521) 6.8 x 9.4 x 20.5 (173 x 239 x 521) 7.8 x 9.4 x 20.5 (198 x 239 x 521) Water Volume gallons (litres) 1.0 (3.8) 1.4 (5.3) 1.6 (6.1) 2.0 (6.1) 2.3 (8.7) 2.7 (10.2) Maximum Water Pressure psig (kpa) 430 (2966) 430 (2966) 430 (2966) 430 (2966) 430 (2966) 430 (2966) Number of Circuits 1 1 1 1 1 1 Evaporator Weights lbs (kg) Shipping 60 (27) 73 (33) 86 (39) 101 (46) 115 (52) 130 (59) Operating 48 (22) 61 (28) 74 (34) 87 (39) 100 (45) 114 (52) Product Manual ALP2-2 19
Sound Data Table 15, Sound Pressure Ratings ALP Unit Size Octave Band Sound Pressure Levels Per ARI Standard 370 (db) 63 hz 125 hz 250 hz 500 hz 1000 hz 2000 hz 4000 hz 8000 hz Overall "A" Weighted 027C 58 58 56 55 52 50 48 48 58 032C 58 59 57 55 53 51 48 49 59 037C 60 60 61 58 54 52 51 50 61 041C 61 62 63 59 55 54 53 51 63 NOTE: Per ARI 370 - Sound Rating of Large Outdoor Refrigerating and Air-Conditioning Equipment. Sound pressure levels taken at a distance of 30 feet Table 16, Sound Power Ratings ALP Unit Size Octave Band Sound Power Levels Per ARI Standard 370 (db) 63 hz 125 hz 250 hz 500 hz 1000 hz 2000 hz 4000 hz 8000 hz Overall "A" Weighted 027C 85 85 83 82 79 77 75 75 85 032C 85 86 84 82 80 78 75 76 86 037C 87 87 88 85 81 79 78 77 88 041C 88 89 90 86 82 81 80 78 89 Per ARI 370 - Sound Rating of Large Outdoor Refrigerating and Air-Conditioning Equipment Sound levels are as important as unit cost and efficiency, and must be addressed before to the start of any development program. Efforts by McQuay Design Engineers to design chillers that are sensitive to the sound requirements of the market, combined with inherently quiet scroll compressors, have paid off. Background Information Sound is a vibration in an elastic medium and is essentially a pressure and particle displacement phenomena. A vibrating body produces compression waves and as the waves are emitted from the vibrating body, molecules are ultimately compressed. These values are transmitted through gas, liquid, solid-anything which is elastic or viscous. The sound data provided in this section is presented with both sound pressure and sound power levels. Sound power is the total sound energy radiated by a source per unit of time integrated over the surface through which the sound is radiated. Sound power is a calculated quantity and cannot be measured directly like sound pressure. Sound power is not dependent on the surrounding environment or distance from the source, as is sound pressure. Sound pressure varies with the distance from the source and is dependent on its surroundings. For example, a brick wall located 10 feet from a unit will affect the sound pressure measurements differently than a brick wall at 20 feet. Sound pressure is measured in decibels (db), which is a dimensionless ratio (on a logarithmic scale) between measured sound pressure and a reference sound pressure level. Sound Pressure Levels - Full Load All sound pressure tables give the overall "A" weighted sound pressure levels which are considered typical of what may be measured in a free field with a hand held sound meter, in the absence of any nearby reflective surfaces. The sound pressure levels are measured at 30 feet (10 meters) from the side of the unit at 100% unit load and 95 F (35 C) ambient air temperature. 20 Product Manual ALP2-2
Sound Power Levels Acoustical consultants may require sound power octave band data to perform a detailed acoustical analysis. The tables that follow present sound power levels per ARI Standard 370, Sound Rating of Large Outdoor Refrigerating and Air Conditioning Equipment for ALP chillers. These standards were developed to establish uniform methods of determining the sound power radiated by large outdoor and indoor equipment. The aforementioned methods are based on providing sound power levels by octave band and the overall A weighted value. Measurements are taken over a prescribed area around the unit and the data is mathematically calculated to give the sound power, db. Sound Reduction due to Distance from the Unit The distance between a source of sound and the location of the sound measurement plays an important role in minimizing sound problems. The equation below can be used to calculate the sound pressure level at any distance if the sound power is known. Sound pressure can be calculated at any distance from the unit if the sound power is known. Lp=Lw-(20 log r) + (10 log Q) -.5 Lp = sound pressure Lw = sound power r = distance from unit in feet Q = directionality factor The directionality factor is a dimensionless number that compensates for the type of sound radiation from the source. Figure 11 shows the typical Q values of different reflecting surfaces. For a unit sitting on a flat roof with no other reflective surfaces or attenuation due to grass, snow, etc., between source and receiver: Q=2. With Q=2, the equation simplifies to: Figure 11, "Q" Values Lp = Lw - (20)(log r) + 2.5 Uniform Spherical Radiation Uniform Hemispherical Radiation Uniform Radiation over 1/4 of sphere Q=1 no reflecting surface Q=2 single reflecting surface Q=4 two reflecting surfaces Product Manual ALP2-2 21
Installation and Application Data Location and Space Requirements Condensing Units ALP units are designed for outdoor application and may be mounted on roof or at ground level. If possible orient the unit so that prevailing winds blow against either end of the unit, not against the coil face. Since these units are air cooled, the flow of air to and from the condenser coil must not be impeded. Warm air recirculation and/or coil starvation will cause a reduction in capacity, high discharge pressure and higher operating costs. Clearances The flow of air to and from the condenser coil must not be impeded. Restricting airflow or allowing air recirculation will result in a decrease in unit performance and efficiency because discharge pressures are increased. 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 above drawing. Do not allow debris to accumulate near the unit. Air movement may draw debris into the condenser coil causing coil starvation. Give special consideration to operation where snow accumulation or ice build up can occur. Keep condenser coils and fan discharges free of snow or other obstructions to permit adequate airflow for proper unit operation. 22 Product Manual ALP2-2
Location and Space Requirements - Evaporator The unit is designed for indoor application and must be located in a space where the temperature is maintained at 40 F (4 C) or above. A clearance of 2 to 3 feet (1 m) should be left on each side and ends. Foundation - Condensing Unit Unit should be set on a solid and level foundation: Roof Mounted Unit should be installed on steel channel or I-beam frame to support the unit above the roof. Ground Level Unit should be installed on substantial base that will not settle. A one piece concrete slab with footings extended below the frost line is recommended. Foundation - Evaporator A reasonably level concrete foundation or floor must be provided to serve as a platform on which to mount the evaporator. Floors must be sufficiently strong to support the evaporator weight. If necessary, structural members should be provided to transfer the weight of the evaporator to the nearest beams. Vibration Isolation Vibration mounts are recommended for roof mounted units or other locations where noise might be objectionable (adjacent to occupied spaces such as offices, meeting rooms, etc.). Vibration eliminators are recommended for piping connected to the unit to avoid transmission of noise into occupied spaces. Water Piping - Evaporator When used, chilled water piping should be arranged so the circulating pump discharges directly into the evaporator. A 40 mesh strainer should be installed at the evaporator inlet. A tee must be provided in the return water line (or supply water line) to the evaporator in which to mount a thermostat bulb for capacity control. Wells or taps should be provided for pressure and temperature readings. Good piping practice should be followed in providing sufficient water volume in the system to prevent unit short cycling. Freeze Protection - Evaporator A pressure or temperature sensing freezestat should be provided for circuit of the evaporator. The control should shut down the condensing unit whenever a freeze condition can occur. A water flow switch must also be provided in order to avoid operation at low or no flow conditions. NOTE: The flow switch is a safety control and should not be used as an on/off switch. Product Manual ALP2-2 23
Refrigerant Piping Careful design of refrigerant piping is necessary for proper system operation. The refrigerant piping generally should be designed to accomplish the following: 1. To assure proper refrigerant feed to the evaporator. 2. To provide practical refrigerant line sizes without excessive pressure drop. 3. To maintain uniform return of lubricating oil to the compressor. 4. To prevent refrigerant from entering the compressor and causing damage such as slugging. General Limit the length of refrigerant piping by locating the condensing unit as close the evaporator as possible. Liquid Lines Standard practice is to size liquid lines for one degree F. (0.5 degree C) change in saturation temperature that corresponds to approximately 2.9 psi (20 kpa) pressure drop. The design of McQuay condensing units is such that the liquid refrigerant is subcooled 12 degrees F (6.6 degrees C). This allows normal liquid lift without refrigerant flashing before the expansion valve. Maximum liquid lift at full load conditions is 65 feet (20 m). Filter-Drier To minimize the possibility of system failure due to dirt and moisture, a replaceable element liquid line filter-drier should be furnished and installed in the field. A moisture indicator sight glass should be installed between the filter-drier and expansion valve to aid in maintaining the system. Suction Lines Standard practice is to size suction lines for two degrees F (one degree C) change in saturation temperature which corresponds to approximately 2.93 psi (20 kpa) pressure drop for R-22. Maximum saturation suction gas temperature for McQuay condensing units is 50 F (10 C) at any condensing temperature. Suction lines should be insulated, especially where exposed to high ambient temperature. VAV Direct Expansion Systems Variable air volume (VAV) application to direct expansion cooling coil systems is increasingly attractive because of the potential energy savings in fan motor power. Extra care must be exercised in the design of VAV direct expansion systems because of the potential for coil icing, oil trapping, loss of stable expansion valve control, excessive compressor cycling, and nuisance operation of protective controls. Equipment damage and nuisance tripping can be avoided by proper total system design. Special consideration must be given to reduced load operating conditions as well as peak design, and coil selection, capacity unloading, and system control modified as required to provide a trouble-free system. It is good engineering practice to match the suction temperature of the cooling coil and condensing unit between 44 and 47 degrees F at full load. As ambient temperatures drop and the air handling unit air flow reduces, the suction temperature will also drop. If this full load suction temperature range is used, the suction temperature can drop drastically before coil freezing becomes a problem. Do not exceed 50 degrees F suction temperature at any load point because motor cooling can become marginal. It is also wise to use the hot gas bypass option with VAV systems because small loads are common. The hot gas bypass value option can reduce compressor cycling at small loads. VAV systems are typically controlled by maintaining a constant leaving air temperature that will keep the condensing 24 Product Manual ALP2-2
unit operating with small loads. It is also recommended that five minute (or longer) time delay relays be included in the control sequences to prevent the compressor from immediately restarting after it shuts down. Figure 12, Typical Refrigerant Piping Diagram Electrical Hook-Up Refer to the unit s installation and maintenance manual for a full set of wiring diagrams. All wiring must be done in accordance with applicable local and national codes. Single point power connection and a single large power terminal block is provided. Wiring within the unit is sized in accordance with the U.S. National Electrical Code. A single field supplied disconnect is required. Main Power Supply Disconnect Switch Disconnecting means are addressed by Article 440 of the U.S. National Electrical Code (NEC) which requires disconnecting means capable of disconnecting air conditioning and refrigerating equipment including motor-compressors, and controllers from the circuit feeder. The disconnect switch should be selected and located within the NEC guidelines. Location requirements per NEC are that the disconnect be located in a readily accessible position within sight (50 ft. [15 m]) of the unit. Maximum recommended fuse size or HACR breaker size is given in the electrical data tables beginning on page 15 of this catalog. Locations outside the U.S. should adhere to local code requirements. Control Circuit Terminals are provided in the unit control center (terminals 1 and NB, Typical Field Wiring Diagram) for field hook-up of the control circuit to a 115V power supply. A control circuit transformer is factory installed as standard to eliminate the need for a separate power supply to the control circuit. Terminals are also provided for field connection of the chilled water flow switch (chilled water systems only), liquid line solenoid valves, system time clock, ambient thermostat, and/or remote on-off switch and temperature control thermostat. Product Manual ALP2-2 25
Winter Start and Operation FanTrol The standard ALP Air Cooled Condensing Unit is equipped with FanTrol head pressure control which automatically cycles the condenser fans in response to a combination of ambient temperature and refrigerant pressure. This will maintain adequate head pressures for unit operation in low ambient air temperatures as shown in Table 17. Optional SpeedTrol is available for operation at ambient temperatures below those allowed by FanTrol. Note: For FanTrol operation below 30 F (1 C), the optional low ambient start control (2 ¾ minute bypass of the low-pressure cutout) is required. SpeedTrol Optional SpeedTrol head pressure control permits operation below the minimum ambient temperatures shown. Operation down to 0 F (-18 C) ambient can be obtained; however, the actual minimum ambient temperature that can be reached with SpeedTrol is dependent on wind conditions. Field supplied wind baffles or dampers may be required. SpeedTrol controls by modulating the speed of the last fan on each circuit after FanTrol has cycled the other fans off. The SpeedTrol fan motor is specially designed for variable speed application. Motor speed is controlled through solid-state circuitry sensing discharge pressure. The SpeedTrol head pressure control system includes the low ambient start timer that locks out the low pressure cutout switch for up to 2 ¾ minutes to allow adequate head pressure build-up during the unit start-up period. Table 17, Minimum Ambient Air Temperature ALP Unit Size Unit With Standard Capacity Reduction (2) F ( C) Unit With Hot Gas Bypass F ( C) 027C 35 (2) 50 (10) 032C 30 (-1) 45 (7) 037C 15 (-9) 45 (7) 041C 10 (-12) 40 (4) 1. Winds can have an effect on the allowable minimum ambient air temperature and it is recommended that the unit be oriented so that prevailing winds blow parallel to the unit length. Wind deflectors may be required 2. With low ambient start control. 26 Product Manual ALP2-2
Optional Equipment Factory Installed Optional Equipment Units are equipped with factory installed equipment as contained in four preset options groups as shown in the following table. Option Option A Option B Option C Option D Capacity Control Control Transformer X X X X FanTrol (Operation to 40 F) X SpeedTrol with Low Ambient Start X X X Suction, Discharge, and Oil Gauges X X X Copper Fins X Coated Aluminum Fins X Field Installed Kits Hot Gas Bypass The field installed hot gas bypass kit allows the unit to operate down to 10% of full load capacity. The kit includes a hot gas bypass valve and solenoid valve. This option requires field refrigerant piping. Vibration Isolators Spring or rubber-in-shear vibration isolators are available for field installation to reduce vibration transmission through the unit base. Flow Switch Paddle type flow switch for field mounting and wiring to control panel terminals. (Some form of "no flow" interlock is mandatory). High Ambient Unloader Pressurestat Optional field installed high ambient unloader Pressurestat senses head pressure exceeding 375psig (2585 kpa) and unloads the compressor to keep head pressure under control. This option allows unit to run partly loaded instead of shutting down due to high head pressure. High Suction Pressure Unloader Kit Optional field installed kit to unload the compressor under high suction pressure conditions to prevent motor overload. Low Ambient Air Temperature Lockout Kit Optional field installed kit to prevent unit operation during low ambient air temperatures. Copper Fin Condenser Coils Copper fin condenser coils are available as an option on all models. Protective Fin Coating ElectroFin flexible dip baked epoxy coating provides corrosion resistance to a wide range of chemicals and salt water and is available on both aluminum and copper coils. Phase Loss/Voltage Protection Phase failure protection is available as a field installed option on all units to guard against compressor motor burnout: phase loss with under/overvoltage protection and multiple LED indication of fault type. Product Manual ALP2-2 27
Guide Specifications Specifications are available in editable form on disk. Contact your local McQuay representative. SECTION 15XXX AIR-COOLED RECIPROCATING CONDENSING UNITS ALP 027C-ALP 041C, 25 to 40 Tons PART 1 - GENERAL 1.01 SUMMARY Section includes design, performance criteria, refrigerants, controls, and installation requirements for air-cooled reciprocating condensing units. 1.02 REFERENCES Comply with applicable Standards/Codes of ANSI/ASHRAE 15, ARI Standard 365, ETL, CSA, NEC, and OSHA as adopted by the State. 1.03 SUBMITTALS A. Submit shop drawings and product data in accordance with specification requirements. B. Submittals shall include the following: 1. Dimensioned plan and elevation view drawings, required clearances, and location of all field connections. 2. Summary of all auxiliary utility requirements such as: electricity, water, compressed air, etc. Summary shall indicate quality and quantity of each required utility. 3. Single line schematic drawing of the power field hookup requirements, indicating all items which are furnished. 4. Schematic diagram of control system indicating points for field connection. Diagram shall fully delineate field and factory wiring. 5. Certification of factory run test of unit signed by company officer. 6. Installation manuals. 1.04 QUALITY ASSURANCE A. Qualifications: Equipment manufacturer must specialize in the manufacture of the products specified and have five years experience with the equipment and refrigerant offered. B. Regulatory Requirements: Comply with the codes and standards specified. C Condensing unit manufacturer plant must be ISO 9002 Registered. 28 Product Manual ALP2-2
1.05 DELIVERY AND HANDLING A. Condensing units shall be delivered to the job site with the factory holding charge intact and a factory charge of oil. B. Comply with the manufacturers instructions for rigging and handling equipment. 1.06. WARRANTY The refrigeration equipment manufacturer s guarantee shall be for a period of one year from date of equipment start up but not more than 18 months from shipment. The guarantee shall include parts and workmanship that have proven defective within the above period, excluding refrigerant. 1.07 MAINTENANCE Maintenance of the condensing units shall be the responsibility of the owner and shall be performed in accordance with manufacturer s instructions. PART 2PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS A. McQuay International B. (Approved Equal) 2.02 UNIT DESCRIPTION Provide and install as shown on the plans factory assembled, factory run tested, air-cooled reciprocating compressor condensing units in the quantity specified. Each unit shall consist of a semi-hermetic reciprocating compressor, air-cooled condenser section, control system, suction and liquid stub-out connections, and all components necessary for safe and controlled unit operation when connected to the specified low side equipment. 2.03 DESIGN REQUIREMENTS A. General: Provide air-cooled reciprocating condensing units as specified herein and as shown on the drawings. The units shall be in accordance with the standards referenced in section 1.02 and any local codes in effect. B. Performance: Refer to the performance schedule on the drawings. The unit shall operate to the percent of full load specified without hot gas bypass. C. Acoustics: Sound pressure levels for the unit shall not exceed the following specified levels. The manufacturer shall provide the necessary sound treatment to meet these levels if required. Sound data shall be provided with the quotation. Test shall be in accordance with ARI Standard 370. Octave Band 63 125 250 500 1000 2000 4000 8000 dba Product Manual ALP2-2 29
2.04 CONDENSING UNIT COMPONENTS A. Compressor: The compressor shall be accessible hermetic reciprocating type with discharge service valve, crankcase oil heater and suction strainer. Compressor shall have a forced feed lubrication system with a reversible oil pump and initial oil charge. The compressor motor shall be refrigerant gas cooled, high torque, hermetic induction type, four-pole, with inherent thermal protection on all three phases and shall be mounted on RIS vibration isolator pads. B. Condenser: The condenser coils shall have 3/8 inch (10mm) seamless copper tubes mechanically bonded into plate type fins. The fins shall have full drawn collars to completely cover the tubes. A subcooling coil shall be an integral part of the main condenser coil. Condenser fans shall be propeller type arranged for vertical air discharge and individually driven by direct drive fan motors. Each fan shall be equipped with a heavy-gauge fan guard. Fan motors shall be weather protected, single-phase, direct-drive, 1140 rpm, open drip-proof type. C. Refrigerant Circuit: The refrigerant piping between the condensing unit and the evaporator shall be furnished by the contractor and field installed. It shall include a liquid line shutoff valve, refrigerant filter-drier, sight glass with moisture indicator, liquid line solenoid valve, thermal expansion valve, and insulated suction line. D. Control System: A centrally located weatherproof control panel shall contain the field power connection points, control interlock terminals, and terminals to connect contractor furnished and field installed thermostat. Power and starting components shall include control circuit transformer, factory fusing of fan motors and control circuit, individual contactors for each fan motor, solid-state start timer, solid-state compressor three-phase motor overload protection, inherent fan motor overload protection and unit power terminal blocks for connection to remote fused disconnect switch furnished by contractor. Hinged access doors shall be lockable. Deadfront panels are required to protect against accidental contact with line voltage when accessing the control system limited recycling pumpdown control, high and low pressure safety switches, water temperature controller, freeze protection pressurestats, and fan cycling controls. 30 Product Manual ALP2-2
2.05. OPTIONS AND ACCESSORIES The following options are to be included: Part winding start; standard for 208/230 V, not available on 380, 415, 460, 575 Volt Three phase power loss with under and over voltage protection Refrigerant and oil pressure gauges High ambient stat to unload compressor at pressures above 375 psig (2586 kpa) Low ambient lockout thermostat Low ambient head pressure control to 0 F (-17.8 C) Low ambient start kit Copper fin condenser coils Electrofin coating on aluminum fins Spring vibration isolators for field installation Rubber-in-Shear vibration isolators Hot gas bypass PART 3 - EXECUTION 3.01 INSTALLATION A. Install in strict accordance with manufacturer s requirements, shop drawings, and contract documents. B. Adjust and level the unit on supports or slab as specified.. C. Coordinate electrical installation with electrical contractor. D. Coordinate controls with control contractor. E. Provide all appurtenances required to insure a fully operational and functional system. 3.02 START-UP A. Insure proper system charge of refrigerant and oil. B. Provide testing, and starting of the system, and instruct the Owner in its proper operation and maintenance. Product Manual ALP2-2 31
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