User manual | Packaged Air-Cooled Water Chiller Installation, Operation and Maintenance Manual

Installation, Operation and Maintenance Manual

IOMM ALR-1

Group: Chiller

Part Number: 074646901

Effective: December 1998

Supersedes: IM ALR

Packaged Air-Cooled Water Chiller

ALR 110E - ALR 185E

Refrigerant R-22, 60 Hertz

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

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

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

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

Handling........................................................................................................................................................3

Location ........................................................................................................................................................4

Service Access...............................................................................................................................................5

Vibration Isolators........................................................................................................................................6

Water Piping..................................................................................................................................................7

Flow Switch..................................................................................................................................................8

Water Connections........................................................................................................................................9

Refrigerant Charge .......................................................................................................................................9

Glycol Solutions...........................................................................................................................................9

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

Physical Data ................................................................................................................12

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

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

Dimensional Data .........................................................................................................24

Unit Layout and Principles of Operation .................................................................25

Control Center ............................................................................................................................................25

Start-up and Shutdown ...............................................................................................27

Pre Start-up .................................................................................................................................................27

Start-up........................................................................................................................................................27

Sequence of Operation ...............................................................................................................................28

Unit Maintenance.........................................................................................................30

Preventative Maintenance Schedule ..........................................................................................................31

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

ALR Troubleshooting Chart ......................................................................................................................35

"McQuay" is a 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"

ALR 110E through 185E IOMM ALR-1

Introduction

General Description

McQuay air-cooled water chillers are complete, self-contained automatic refrigerating units. Every unit is completely assembled, factory wired, charged, and tested. Each unit consists of twin air-cooled condensers with integral subcooler sections, multiple accessible hermetic compressors, replaceable tube dual circuit shell-and-tube evaporator, and complete refrigerant piping. Liquid line components include manual liquid line shutoff valves, sight-glass/moisture indicators, solenoid valves, and double diaphragm hydraulic element thermal expansion valves. Other features include compressor crankcase heaters, an evaporator heater for chilled water freeze protection, limited pumpdown during “on” or

“off” periods, compressor lead-lag switch to alternate the compressor starting sequence, and sequenced starting of compressors.

The electrical control center includes all safety and operating controls necessary for dependable automatic operation. Condenser fan motors are fused in all three phases and started by their own three-pole contactors. Compressors are not fused but may be protected by optional circuit breakers, or by a field installed fused disconnect.

Inspection

Check all items carefully against the bill of lading. Inspect all units for damage upon arrival. Report shipping damage and file a claim with the carrier. Check the unit name plate before unloading, making certain it agrees with the power supply available. McQuay is not responsible for physical damage after unit leaves the factory.

Note: Unit shipping and operating weights are available

in the Physical Data tables beginning on page 12.

Installation

Note: Installation is to be performed by qualified

personnel who are familiar with local codes and regulations.

WARNING

Sharp edges and coil surfaces are a potential hazard. Avoid contact with them.

Handling

Be careful to 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 (see Figure 1).

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).

IOMM ALR-1 ALR110E through 185E

Figure 1, Suggested pushing arrangement

Blocking required across full width

Figure 2, Suggested lifting arrangement

Spreader bars recommended (Use

Caution)

NOTE: Number of fans can vary from this diagram. Lifting method remains the same.

Must use these rigging holes. (Be aware of control box location)

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

12.

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

ALR 110E through 185E IOMM ALR-1

IOMM ALR-1

Clearances

The flow of air to and from the condenser coil must not be limited. Restricting air flow or allowing air recirculation will result in a decrease in unit performance and efficiency. There must be no obstruction above the unit that would deflect discharge air downward where it could be recirculated back to the inlet of the condenser coil. The condenser fans are propeller type and will not operate with ductwork on the fan outlet.

Install the unit with enough side clearance for air entrance to the coil and for servicing. Provide service access to the evaporator, compressors, electrical control panel and piping components as shown in Figure 3.

Do not allow debris to accumulate near the unit. Air movement may draw debris into the condenser coil causing air starvation. Give special consideration to low ambient operation where snow can accumulate. Keep condenser coils and fan discharge free of snow or other obstructions to permit adequate airflow.

Figure 3, Clearance requirements

5 ft. (1524mm) Clearance for air inlet

4 Ft. (1220mm) clearance for service access

"10 feet (3048) for evaporator tube removal

5 Ft. (1524mm) clearance for air inlet

Sound Isolation

The ultra-low sound levels of the ALR reciprocating chiller is suitable for most applications. When additional sound reduction is necessary, locate the unit away from sound sensitive areas. Avoid locations beneath windows or between structures where normal operating sounds may be objectionable. Reduce structurally transmitted sound by isolating water lines, electrical conduit and the unit itself. Use wall sleeves and rubber isolated piping hangers to reduce transmission of water or pump noise into occupied spaces. Use flexible electrical conduit to isolate sound 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.

Service Access

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

Freezestats and cooler barrel thermostats are near the cooler. Most other operational, safety and starting controls are located in the unit control box.

The condenser fan and motors can be removed from the top of the unit.

ALR110E through 185E

Vibration Isolators

Vibration isolators are recommended for all roof mounted installations or wherever vibration transmission is a consideration. Table 1 lists isolator loads and type. Table 2 lists spring isolator part numbers for all unit sizes. See Dimensional Data beginning on page 24 for dimensions required to secure each isolator to the mounting surface.

Table 1, Isolator Loads and Type

ALR

UNIT

SIZE

110E

120E

130E

135E

140E

145E

TYPE

CP-2-28

CP-2-31

ISOLATOR LOADS AND TYPE FOR EACH MOUNTING LOCATION

S T

1339

1362

1492

1506

1556

1572

607

618

677

683

706

713

TYPE

CP-2-28

CP-2-31

CP-2-32

1364

1490

1570

1670

1752

1680

150E

160E

170E

180E

CP-2-32

CP-4-27

1601

1948

2052

726

884

931

CP-2-32

1704

1962

2002

185E CP-4-27 2052 931 CP-2-32

NOTE: Two of each isolator type is required for a total of six per unit.

2002

619

676

712

758

795

762

773

890

908

TYPE

CP-2-31

CP-2-32

CP-4-27

CP-2-32

1697

1748

1838

1904

1912

2093

2120

1848

1849

Table 2, Spring Flex Isolator Part Numbers

TYPE

CP1-25

CP1-26

CP1-27

CP1-28

CP1-31

CP1-32

CP2-25

CP2-26

CP2-27

CP2-28

CP2-31

CP2-32

CP4-26

CP4-27

CP4-28

CP4-31

CP4-32

COLOR

Red

Purple

Orange

Green

Gray

White

Red

Purple

Orange

Green

Gray

White

Purple

Orange

Green

Gray

White

McQuay

Part No.

477927A-25

477927A-26

477927A-27

477927A-28

477927A-31

477927A-32

477929A-25

477929A-26

477929A-27

477929A-28

477929A-31

477929A-32

580513A-26

580513A-27

580513A-28

580513A-31

580513A-32

900

1200

1500

1800

2200

2600

2400

3000

3600

4400

5200

Lb.

Max. Load

Each

450

600

750

900

1100

1300

204

272

340

408

499

590

408

544

681

817

998

1180

1089

1361

1633

1996

2359

770

793

834

864

867

949

962

838

839

ALR 110E through 185E IOMM ALR-1

IOMM ALR-1

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 volume in the system should be sufficient to prevent frequent “on-off” cycling.

Turnover rate should not be less than 15 minutes for normal variable cooling loads. Turnover rate for process cooling or a constant load, should not be less than 6 minutes.

11. When glycol is added to the water system for freeze protection, the refrigerant suction pressure will be lower, cooling performance less, and water side pressure drop greater. If the percentage of glycol is high, or if propylene is used instead of ethylene glycol, the added pressure drop and loss of performance could be substantial. Reset the freezestat and low leaving water alarm temperatures. The freezestat is factory set to default at 36

F (2.2

C). Reset the freezestat setting to approximately 4 to 5 degrees F (2.3 to 2.8 degrees C) 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.

ALR110E through 185E

Figure 4, Typical field evaporator water piping

Flow Switch

Mount a water flow switch in either the entering or leaving water line to shut down the unit when water flow is interrupted.

A flow switch is available from McQuay (part number 00175033-00). It is a “paddle” type switch and adaptable to any pipe size from 3” (76mm) to 8” (203mm) nominal. Certain minimum flow rates are required to close the switch and are listed in Table 3. Installation should be as shown in Figure 5.

Connect the normally open contacts of the flow switch in the unit control center at terminals 5 and 6.

There is also a set of normally closed contacts on the switch that can be used for an indicator light or an alarm to indicate when a “no flow” condition exists. Freeze protect any flow switch that is installed outdoors.

NOTE: Differential pressure switches are not recommended for outdoor installation.

Table 3, Flow switch minimum flow rates

NOMINAL PIPE SIZE

INCHES (MM)

1 (25.4)

11/4 (31.8)

11/2 (38.1)

2 (50.8)

21/2 (63.50)

3 (76.20)

4 (101.6)

5 (127.0)

6 (152.4)

MINIMUM REQUIRED FLOW TO

ACTIVATE SWITCH - GPM (L/s)

6.00 (0.38)

9.80 (0.62)

12.70 (0.80)

18.80 (1.20)

24.30 (1.50)

30.00 (1.90)

39.70 (2.50)

58.70 (3.70)

79.20 (5.00)

Figure 5, Flow switch installation

ALR 110E through 185E IOMM ALR-1

Water Connections

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

Note: On units sizes 160E through 185E there is a diagonal bracket

off of a vertical support which will interfere with the water connection if brought in from the side. This brace can be removed, but only after the unit is in place.

Note: The procedure does not specify the type of glycol. Use the derate factors found in Table 4 for corrections when using ethylene glycol and those in Table 5 for propylene glycol.

Refrigerant Charge

All units are designed for use with HCFC-22 are shipped with an operating charge. The operating charge (using HCFC-22) for each unit is shown in the Physical Data tables beginning on page 12.

Glycol Solutions

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

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

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

Glycol GPM

(

Delta

−

)

(from table)

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

Glycol L / s

4.18

Delta

−

Flow

(from table)

3. Pressure drop -- To determine pressure drop through the evaporator, when using glycol, enter the water pressure drop curve on page 11 at the actual glycol GPM. Multiply the water pressure drop by PD correction factor from Table 4 or Table 5 to obtain corrected glycol pressure drop.

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

Test coolant with a clean, accurate glycol solution hydrometer (similar to that found in service stations) to determine the freezing point. Obtain percent glycol from the freezing point table below.

On glycol applications it is normally recommended by the supplier that a minimum of 25% solution by weight be used for protection against corrosion.

IOMM ALR-1 ALR110E through 185E

CAUTION

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

Automotive antifreeze contains inhibitors which will cause plating on the copper tubes within the chiller evaporator. The type and handling of glycol used must be consistent with local codes.

Table 4, Ethylene glycol

E.G.

Freeze Point

°F °C

-3

-8

-7

-28

-14

-22

-33

Cap.

0.991

0.982

0.972

0.961

0.946

Table 5, Propylene glycol

P.G.

Freeze Point

°F °C

-5

-27

-3

-7

-13

-21

-33

Cap.

0.987

0.975

0.962

0.946

0.929

0.996

0.992

0.986

0.976

0.966

0.992

0.985

0.978

0.971

0.965

GPM

1.013

1.040

1.074

1.121

1.178

GPM

1.010

1.028

1.050

1.078

1.116

1.070

1.129

1.181

1.263

1.308

1.068

1.147

1.248

1.366

1.481

Table 6, Capacity and power derates

ALTITUDE

SEA

LEVEL

2000 feet

4000 feet

6000 feet

Chilled Water

Delta-T

°C

3.3

4.4

5.6

6.7

6.8

8.9

3.3

4.4

5.6

6.7

6.8

8.9

3.3

4.4

5.6

6.7

6.8

8.9

3.3

4.4

5.6

6.7

6.8

8.9

°F

0.997

1.000

0.966

0.969

0.973

0.978

0.982

0.986

0.00025 (0.044)

Cap.

0.992

0.995

1.000

1.005

0.995

0.997

1.000

1.002

1.010

1.014

0.978

0.982

0.986

0.992

1.005

1.007

1.005

1.007

1.009

1.011

1.014

1.016

1.018

1.021

1.025

1.027

1.028

0.953

0.955

0.959

0.963

0.968

0.972

1.025

1.028

1.031

1.034

1.036

1.037

0.985

0.989

0.957

0.961

0.965

0.970

0.973

0.975

0.944

0.947

0.952

0.956

0.959

0.961

Fouling Factor

0.00075 (0.132)

Cap.

0.996

0.982

0.969

0.975

0.980

0.984

0.986

0.989

0.991

0.993

0.990

0.993

0.995

0.998

1.001

1.002

0.999

1.001

1.005

1.008

1.011

1.015

0.930

0.934

0.939

0.942

0.946

0.949

1.009

1.011

1.013

1.017

1.020

1.024

0.919

0.921

0.894

0.896

0.900

0.904

0.909

0.911

0.00175 (0.308)

Cap.

0.911

0.914

0.919

0.923

0.935

0.937

0.939

0.941

0.928

0.930

0.903

0.905

0.909

0.914

0.943

0.944

0.943

0.945

0.947

0.949

0.952

0.953

0.951

0.953

0.956

0.958

0.960

0.961

0.884

0.887

0.890

0.895

0.899

0.902

0.961

0.962

0.964

0.966

0.968

0.969

ALR 110E through 185E IOMM ALR-1

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 which 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.

Varying chilled water flow through the evaporator while the compressor(s) are operating is not recommended.

Figure 6, Evaporator water pressure drop curve

IOMM ALR-1 ALR110E through 185E

Physical Data

Table 7 , Physical Data ALR 110E through 135E

PHYSICAL DATA

Standard Staging - Circuit #1 in Lead

Standard 6 Stages

110E

ALR MODEL NUMBER

120E 130E

BASIC DATA

Unit Capacity @ ARI Conditions (1), Tons (kW)

Number Of Refrigerant Circuits

Unit Operating Charge, R-22, Lb.

Unit Operating Charge, R-22, (kg)

Cabinet Dimensions, LxWxH, In.

Cabinet Dimensions, LxWxH, (mm)

Unit Operating Weight, Lbs. (kg)

Unit Shipping Weight, Lbs. (kg)

Add'l Weight If Copper Finned Coils, Lbs. (kg)

Ckt.1

Ckt.2

107.8 (379.0)

(36.3)

229 x 83 x 89

(5809 x 2118 x 2369)

8800 (3992)

8505 (3858)

1105 (501)

Ckt.1

Ckt.2

120.7 (424.4)

(36.3)

229 x 83 x 89

(5809 x 2118 x 2369)

9200 (4173)

8760 (3974)

1105 (501)

Ckt.1

Ckt.2

130.6 (459.2)

120

(38.6)

120

(38.6)

229 x 83 x 93

(5809 x 2118 x 2369)

9800 (4445)

9350 (4241)

1652 (750)

Ckt.1

Ckt.2

135.5 (476.4)

120

(38.6)

120

(38.6)

229 x 83 x 93

(5809 x 2118 x 2369)

10160 (4609)

9735 (4416)

1652 (750)

COMPRESSORS

Type

Nominal Horsepower

Number Of Cylinders Per Compressor

Semi-Hermetic

30-30

6 - 6

30-35

6 - 6

Semi-Hermetic

30-35

6 - 6

35-35

6 - 6

Semi-Hermetic

35-35

6 - 6

35-35

6 - 6

Semi-Hermetic

35-40

6 - 6

35-40

6 - 6

Oil Charge Per Compressor, Oz.

Oil Charge Per Compressor, (g)

140 - 140 140 - 140 140 - 140 140 - 140 140 - 140 140 - 140 140 - 255 140 - 255

(3969 -

3969)

(3969 -

3969)

(3969 -

3969)

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

(3969 -

3969)

(3969 -

3969)

(3969 -

3969)

(3969 -

7229)

(3969 -

7229)

0-16-32-40-48-71-100 0-15-32-39-48-74-100 0-17-33-42-50-75-100

135E

0-16-32-40-48-74-100

Standard Staging - Circuit #2 in Lead

Standard 6 Stages 0-16-32-40-48-76-100 0-17-32-41-48-76-100 0-17-33-42-50-75-100 0-16-32-40-48-74-100

Optional Staging - Circuit #1 in Lead

Optional 8 Stages 0-16-32-40-48

-64-84-92-100

0-15-32-39-48

-67-84-91-100

Optional Staging - Circuit #2 in Lead

Optional 8 Stages 0-16-32-40-48

-68-84-92-100

0-17-32-41-48

-65-84-91-100

CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING

0-17-33-42-50

-67-83-92-100

0-17-33-42-50

-67-83-92-100

0-16-32-40-48

-66-84-92-100

0-16-32-40-48

-66-84-92-100

Coil Face Area,Sq. Ft.

Coil Face Area, (M

)

Finned Height x Finned Length, In.

Finned Height x Finned Length, (mm)

Fins Per Inch x Rows Deep

Maximum Relief Valve Pressure Setting, psig (kPa)

CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE

115.6

(10.3)

80 x 208

115.6

(10.3)

80 x 208

115.6

(10.3)

80 x 208

115.6

(10.3)

80 x 208

115.6

(10.3)

80 x 208

115.6

(10.3)

80 x 208

115.6

(10.3)

80 x 208

115.6

(10.3)

80 x 208

(2032 x

5283)

16 x 2

(2032 x

5283)

16 x 2

(2032 x

5283)

16 x 2

(2032 x

5283)

16 x 2

(2032 x

5283)

16 x 3

(2032 x

5283)

16 x 3

(2032 x

5283)

16 x 3

(2032 x

5283)

16 x 3

450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)

Number Of Fans - Fan Diameter, In. (mm)

Number Of Motors - HP (kW)

Fan And Motor RPM, 60/50Hz

10 - 28 (711)

10 - 1.5 (1.1)

1100/915

60 Hz Fan Tip Speed, FPM

60 Hz Total Unit Airflow, CFM

8063

94710

DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE

10 - 28 (711)

10 - 1.5 (1.1)

1100/915

8063

94710

12 - 28 (711)

12 - 1.5 (1.1)

1100/915

8063

108240

12 - 28 (711)

12 - 1.5 (1.1)

1100/915

8063

108240

Diameter, in. - Length, Ft.

Diameter, (mm) - Length, (mm)

Water Volume, Gallons, (L)

Maximum Water Pressure, psig (kPa)

Maximum Refrigerant Working Pressure, psig (kPa)

Water Inlet / Outlet Victaulic Connections, In. (mm)

Drain - NPT int, In. (mm)

Vent - NPT int, In. (mm)

14 - 10

(356 - 3048)

36.10 (136.6)

175 (1207)

225 (1552)

6 (152.4)

.375 (9.5)

NOTE:

1. Nominal capacity based on 95°F ambient air and 54°F/44°F water range.

16 - 10

(406 - 3048)

43.6 (165)

175 (1207)

225 (1552)

6 (152.4)

.375 (9.5)

16 - 10

(406 - 3048)

43.6 (165)

175 (1207)

225 (1552)

6 (152.4)

.375 (9.5)

16 - 10

(406 - 3048)

43.6 (165)

175 (1207)

225 (1552)

6 (152.4)

.375 (9.5)

ALR 110E through 185E IOMM ALR-1

Table 8, Physical Data ALR 140E through 160E

PHYSICAL DATA

BASIC DATA

Unit Capacity @ ARI Conditions (1), Tons (kW)

Number Of Refrigerant Circuits

Unit Operating Charge, R-22, Lbs

Unit Operating Charge, R-22, (kg)

Cabinet Dimensions, LxWxH, In.

Cabinet Dimensions, LxWxH, (mm)

Unit Operating Weight, Lbs. (kg)

Unit Shipping Weight, Lbs. (kg)

Add'l Weight If Copper Finned Coils, Lb. (kg)

Ckt.1

125

(45.4)

140E

Ckt.2

139.7 (491.2)

125

(45.4)

229 x 83 x 93

(5809 x 2118 x 2369)

10440 (4736)

10040 (4554)

1652 (750)

ALR MODEL NUMBER

145E

Ckt.1

Ckt.2

144.7 (508.8)

130

(45.4)

130

(45.4)

229 x 83 x 93

(5809 x 2118 x 2369)

10690 (4849)

10290 (4668)

1652 (750)

150E

Ckt.1

Ckt.2

149.9 (527.0)

130

(45.4)

130

(45.4)

229 x 83 x 93

(5809 x 2118 x 2369)

10850 (4922)

10450 (4740)

1652 (750)

160E

Ckt.1

Ckt.2

157.8 (554.8)

140

(49.9)

140

(49.9)

263 x 83 x 93

(6690 x 2118 x 2369)

11515 (5223)

11115 (5042)

1930 (876)

COMPRESSORS

Type

Nominal Horsepower

Number Of Cylinders Per Compressor

Oil Charge Per Compressor, Oz.

Semi-Hermetic

40-40

6 - 6

40-40

6 - 6

Semi-Hermetic

40-40

6 - 6

Oil Charge Per Compressor, (g) (7229 -

7229)

(7229 -

7229)

(7229 -

7229)

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

40-40

6 - 6

(7229 -

7229)

Semi-Hermetic

40-40

6 - 6

40-50

Semi-Hermetic

40-50 40-50

255 - 255 255 - 255 255 - 255 255 - 255 255 - 255 255 - 255 255 - 255 255 - 255

(7229 -

7229)

6 - 8

(7229 -

7229)

6 - 8

(7229 -

7229)

6 - 8

(7229 -

7229)

Standard Staging - Circuit #1 in Lead

Standard 6 Stages (N/A on MicroTech Units) 0-17-33-42-50-75-100 0-17-33-42-50-75-100 0-15-32-40-48-72-100 0-17-33-42-50-77-100

Standard Staging - Circuit #2 in Lead

Standard 6 Stages (N/A on MicroTech Units) 0-17-33-42-50-75-100 0-17-33-42-50-75-100 0-15-32-40-48-76-100 0-17-33-42-50-77-100

Optional Staging - Circuit #1 in Lead

Optional 8 Stages (Std. on MicroTech Units) 0-17-33-42-50

-67-83-92-100

0-17-33-42-50

-67-83-92-100

0-15-32-40-64

-64-84-92-100

0-17-33-42-50

-63-71-86-100

Optional Staging - Circuit #2 in Lead

Optional 8 Stages (Std. on MicroTech Units) 0-17-33-42-50 0-17-33-42-50 0-15-32-40-48 0-17-33-42-50

-67-83-92-100 -67-83-92-100

CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING

Coil Face Area,Sq. Ft.

Coil Face Area, (M

)

Finned Height x Finned Length, In.

Finned Height x Finned Length, (mm)

Fins Per Inch x Rows Deep

Maximum Relief Valve Pressure Setting, psig (kPa)

CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE

115.6

135 135

(10.3)

80 x 208

(10.3)

80 x 208

(10.3)

80 x 208

(10.3)

80 x 208

(10.3)

80 x 208

(10.3)

80 x 208

(12.5)

80 x 243

(12.5)

80 x 243

(2032 x

5283)

16 x 3

(2032 x

5283)

16 x 3

(2032 x

5283)

16 x 3

(2032 x

5283)

16 x 3

(2032 x

5283)

16 x 3

(2032 x

5283)

16 x 3

(2032 x

6172)

16 x 3

(2032 x

6172)

16 x 3

450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)

Number Of Fans - Fan Diameter, In. (mm)

Number Of Motors - HP (kW)

Fan And Motor RPM, 60/50Hz

60 Hz Fan Tip Speed, FPM

60 Hz Total Unit Airflow, CFM

12 - 28 (711)

12 - 1.5 (1.1)

1100/915

8063

108240

DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE

Diameter, in. - Length, Ft.

Diameter, (mm) - Length, (mm)

Water Volume, Gallons, (L)

Maximum Water Pressure, psig (kPa)

Maximum Refrigerant Working Pressure, psig (kPa)

Water Inlet / Outlet Victaulic Connections, In. (mm)

Drain - NPT int, In. (mm)

Vent - NPT int, In. (mm)

16 - 10

(406 - 3048)

43.6 (165)

175 (1207)

225 (1552)

6 (152.4)

0.375 (9.5)

NOTE:

1. Nominal capacity based on 95°F ambient air and 54°F/44°F water range.

12 - 28 (711)

12 - 1.5 (1.1)

1100/915

8063

108240

18 - 10

(457 - 3048)

57.30 (216.9)

175 (1207)

225 (1552)

6 (152.4)

0.375 (9.5)

-68-84-92-100

12 - 28 (711)

12 - 1.5 (1.1)

1100/915

8063

108240

18 - 10

(457 - 3048)

57.30 (216.9)

175 (1207)

225 (1552)

6 (152.4)

0.375 (9.5)

-63-71-86-100

14 - 28 (711)

14 - 1.5 (1.1)

1100/915

8063

126280

18 - 10

(457 - 3048)

57.30 (216.9)

175 (1207)

225 (1552)

6 (152.4)

0.375 (9.5)

IM ALR ALR 110E through 185E

Table 9, Physical Data ALR 170E through 185E

PHYSICAL DATA

BASIC DATA

Unit Capacity @ ARI Conditions (1), Tons (kW)

Number Of Refrigerant Circuits

Unit Operating Charge, R-22, Lb.

Unit Operating Charge, R-22, (kg)

Cabinet Dimensions, LxWxH, In.

Cabinet Dimensions, LxWxH, (mm)

Unit Operating Weight, Lbs. (kg)

Unit Shipping Weight, Lbs. (kg)

Add'l Weight If Copper Finned Coils, Lb. (kg)

Ckt.1

140

(52.2)

170E

Ckt.2

167.2 (587.9)

140

(52.2)

263 x 83 x 93

(6690 x 2118 x 2369)

11805 (5355)

11405 (5174)

1930 (876)

ALR MODEL NUMBER

180E

Ckt.1

Ckt.2

177.3 (623.4)

145

(54.4)

145

(54.4)

263 x 83 x 93

(6690 x 2118 x 2369)

11805 (5355)

11405 (5174)

1930 (876)

185E

Ckt.1

Ckt.2

185.8 (653.3)

145

(54.4)

145

(54.4)

263 x 83 x 93

(6690 x 2118 x 2369)

11805 (5355)

11405 (5174)

1930 (876)

COMPRESSORS

Type

Nominal Horsepower

Number Of Cylinders Per Compressor

Oil Charge Per Compressor, Oz.

Semi-Hermetic

50-50

8 - 8

50-50

8 - 8

Semi-Hermetic

50-60

8 - 8

Oil Charge Per Compressor, (g) (7229 -

7229)

(7229 -

7229)

(7229 -

7229)

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

50-60

8 - 8

(7229 -

7229)

Semi-Hermetic

60-60

8 - 8

60-60

255 - 255 255 - 255 255 - 255 255 - 255 255 - 255 255 - 255

(7229 -

7229)

8 - 8

(7229 -

7229)

Standard Staging - Circuit #1 in Lead

Standard 6 Stages (N/A on MicroTech Units) 0-19-37-44-50-75-100 0-17-34-40-46-73-100 0-19-37-44-50-75-100

Standard Staging - Circuit #2 in Lead

Standard 6 Stages (N/A on MicroTech Units) 0-19-37-44-50-75-100 0-17-34-40-46-73-100 0-19-37-44-50-75-100

Optional Staging - Circuit #1 in Lead

Optional 8 Stages (Std. on MicroTech Units) 0-19-37-44-50

-62-75-87-100

0-17-34-40-46

-67-89-94-100

0-19-37-44-50

-62-75-87-100

Optional Staging - Circuit #2 in Lead

Optional 8 Stages (Std. on MicroTech Units) 0-19-37-44-50 0-17-34-40-46 0-19-37-44-50

-62-75-87-100 -67-89-94-100

CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING

Coil Face Area,Sq. Ft.

Coil Face Area, (M

)

Finned Height x Finned Length, In.

Finned Height x Finned Length, (mm)

Fins Per Inch x Rows Deep

Maximum Relief Valve Pressure Setting, psig (kPa)

CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE

135 135 135 135 135 135

(12.5)

80 x 243

(12.5)

80 x 243

(12.5)

80 x 243

(12.5)

80 x 243

(12.5)

80 x 243

(12.5)

80 x 243

(2032 x

6172)

16 x 3

(2032 x

6172)

16 x 3

(2032 x

6172)

16 x 3

(2032 x

6172)

16 x 3

(2032 x

6172)

16 x 3

(2032 x

6172)

16 x 3

450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)

Number Of Fans - Fan Diameter, In. (mm)

Number Of Motors - HP (kW)

Fan And Motor RPM, 60/50Hz

60 Hz Fan Tip Speed, FPM

60 Hz Total Unit Airflow, CFM

DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE

Diameter, in. - Length, Ft.

Diameter, (mm) - Length, (mm)

Water Volume, Gallons, (L)

Maximum Water Pressure, psig (kPa)

Maximum Refrigerant Working Pressure, psig (kPa)

Water Inlet / Outlet Victaulic Connections, In. (mm)

Drain - NPT int, In. (mm)

Vent - NPT int, In. (mm)

14 - 28 (711)

14 - 1.5 (1.1)

1100/915

8063

126280

18 - 10

(457 - 3048)

57.30 (216.9)

175 (1207)

225 (1552)

6 (152.4)

.375 (9.5)

NOTE:

1. Nominal capacity based on 95°F ambient air and 54°F/44°F water range.

14 - 28 (711)

14 - 1.5 (1.1)

1100/915

8063

126280

18 - 10

(457 - 3048)

57.30 (216.9)

175 (1207)

225 (1552)

6 (152.4)

.375 (9.5)

-62-75-87-100

14 - 28 (711)

14 - 1.5 (1.1)

1100/915

8063

126280

18 - 10

(457 - 3048)

57.30 (216.9)

175 (1207)

225 (1552)

6 (152.4)

.375 (9.5)

ALR 110E through 185E IM ALR

IM ALR

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 may 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. An optional factory mounted transformer may be installed.

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 optional 115V control transformer.

If the evaporator heater is on a separate disconnect switch from the main unit power supply, the unit may be shut down without defeating the freeze protection provided by the cooler heater.

Table 10, ALR 110E - 135E Electrical Data, Single Point

ALR

Minimum

Circuit

POWER SUPPLY

Field Wire

Unit Volts HZ.

Ampacity

Size (MCA) Quantity

Wire

Gauge Quantity

Hub

Nominal

Size

208

230

110E 460 60

575

494

483

244

184

350

250

3/0

4.00 (102)

2.50 (64)

2.00 (51)

208

230

120E 460 60

575

208

230

130E 460 60

575

208

230

135E 460 60

575

547

517

270

196

584

546

289

206

615

579

298

220

Table continued next page

See page 22 for all Electrical Data notes.

500

400

300

3/0

500

350

4/0

350

300

4.00 (102)

2.50 (64)

2.00 (51)

4.00 (102)

2.50 (64)

2.00 (51)

2.50 (64)

2.00 (51)

FIELD FUSE SIZE

Recommended

600

300

200

600

300

225

700

600

300

225

700

350

250

Maximum

600

500

300

225

600

300

225

700

600

300

225

700

350

250

ALR 110E through 185E

Table 10, ALR 140E - 185E Electrical Data, Single Point (Continued)

ALR

Minimum

Circuit

Unit Volts HZ.

Ampacity

Size (MCA)

208

230

140E 460

575

208

230

145E 460

575

643

609

306

232

643

609

306

232

208

230

150E 460

575

208

230

160E 460

575

677

653

328

257

716

700

352

281

208

230

170E 460

575

208

230

180E 460

575

208

230

185E 460

575

770

388

321

860

413

337

940

435

351

See page 22 for all Electrical Data notes.

POWER SUPPLY

Field Wire Hub

Wire

Quantity Gauge Quantity

Nominal

Size

500

350

250

500

350

250

3.00 (76)

2.50 (64)

3.00 (76)

2.50 (64)

500

400

300

500

300

600

400

300

600

500

350

300

500

3.00 (76)

2.50 (64)

3.00 (76)

2.50 (64)

3.00 (76)

4.0 (102)

3.00 (76)

4.0 (102)

3.00 (76)

FIELD FUSE SIZE

Recommended Maximum

800

350

300

800

400

300

700

350

250

700

350

250

800

450

350

1000

500

400

1000

500

400

800

450

300

800

400

300

700

350

250

700

350

250

800

450

350

1000

500

400

1000

500

400

ALR 110E through 185E IM ALR

Table 11, ALR 110E - 160E Electrical Data, Multiple Point

ALR

Electrical Circuit #1 - Fans and Transformer

Min.

Volts HZ. Circuit

Power Supply

Field Wire Hub

Field

Fusing

Electrical Circuit #2 - Compressor Circuit #1

Min.

Power Supply

Rec. Max.

Circuit Field Wire Hub

Field Fusing

Rec.

Electrical Circuit #3 - Compressor Circuit #2

Min.

Max. Circuit

Power Supply

Field Wire Hub

Field Fusing

Rec.

Max.

Unit

Size Amps Wire Hub Fuse Fuse Amps Wire

110E

208

230

460

575

(MCA) Qty. Gauge Qty. Size Size Size (MCA) Qty. Gaug e

60 3 6 60 60 214 3 4/0

1 1.50

(38)

1 1.50

(38)

1 1.00

(25)

1 1.00

(25)

214

106

4/0

120E

208

230

460

575

1 1.50

(38)

1 1.50

(38)

1 1.00

(25)

1 1.00

(25)

247

235

122

3 250

250

208 71 3 4 80 80 273 3 300

130E

135E

140E

145E

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

1 2.00

(51)

1 2.00

(51)

1 1.25

(32)

1 1.00

(25)

1 2.00

(51)

1 2.00

(51)

1 1.25

(32)

1 1.00

(25)

1 2.00

(51)

1 2.00

(51)

1 1.25

(32)

1 1.00

(25)

1 2.00

(51)

1 2.00

(51)

1 1.25

(32)

1 1.00

(25)

252

135

290

271

140

102

304

286

144

108

304

286

144

108

250

1/0

350

300

1/0

350

1/0

350

1/0

150E

160E

208

230

460

575

208

230

460

575

1 2.00

(51)

1 2.00

(51)

1 1.25

(32)

1 1.00

(25)

1 2.00

(51)

1 2.00

(51)

1 1.25

(32)

1 1.00

(25)

304

286

144

108

338

330

167

133

350

1/0

500

400

2/0

1/0

Qty.

Hub

Size

2.00

(51)

2.00

(51)

1.25

(32)

1.00

(25)

2.50

(64)

2.50

(64)

1.25

(32)

1.25

(32)

2.50

(64)

2.50

(64)

1.50

(38)

1.25

(32)

2.50

(64)

2.50

(64)

1.50

(38)

1.25

(32)

2.50

(64)

2.50

(64)

1.50

(38)

1.25

(32)

2.50

(64)

2.50

(64)

1.50

(38)

1.25

(32)

2.50

(64)

2.50

(64)

1.50

(38)

1.25

(32)

3.00

(76)

3.00

(76)

2.00

(51)

1.50

(38)

Fuse Fuse

Size

250

125

100

300

150

110

350

300

175

110

350

175

125

35035

125

350

175

125

350

175

125

400

200

175

Size

300

150

110

350

300

150

125

350

175

125

400

350

200

150

400

175 200

150

400

200

150

400

200

150

400

225

200

Amps

(MCA)

247

235

122

273

252

135

273

252

135

290

271

140

102

304

286

144

108

304

286

144

108

338

330

167

133

338

330

167

133

Wire

Qty. Gauge Qty.

250

300

250

1/0

300

250

1/0

350

300

1/0

350

1/0

350

1/0

500

400

2/0

1/0

500

400

2/0

1/0

Hub

Size

2.50

(64)

2.50

(64)

1.50

(38)

1.25

(32)

2.50

(64)

2.50

(64)

1.50

(38)

1.25

(32)

2.50

(64)

2.50

(64)

1.50

(38)

1.25

(32)

2.50

(64)

2.50

(64)

1.50

(38)

1.25

(32)

3.00

(76)

3.00

(76)

2.00

(51)

1.50

(38)

3.00

(76)

3.00

(76)

2.00

(51)

1.50

(38)

2.50

(64)

2.50

(64)

1.50

(38)

1.25

(32)

2.50

(64)

2.50

(64)

1.25

(32)

1.25

(32)

Fuse Fuse

Size

300

150

110

350

300

175

110

350

300

175

110

350

175

125

350

175

125

350

175

125

400

200

175

400

200

175

Size

350

300

150

125

350

175

125

350

175

125

400

350

200

150

400

200

150

400

200

150

400

225

200

400

225

200

Continued next page

IM ALR ALR 110E through 185E

Table 11, ALR 170E - 185E Electrical Data, Multiple Point (Continued

ALR

Electrical Circuit #1 - Fans and Transformer

Min.

Circuit

Power Supply

Field Wire Hub

Field Fusing

Rec.

Max.

Electrical Circuit #2 - Compressor Circuit #1

Min.

Circuit

Power Supply

Field Wire Hub

Field

Fusing

Electrical Circuit #3 - Compressor Circuit #2

Min.

Power Supply

Rec. Max. Circuit Field Wire Hub

Field

Fusing

Rec. Max.

Unit Volts HZ

Size

208

230

170E 460 60

575

208

230

180E 460 60

575

208

230

185E 460 60

575

Amps Wire Hub Fuse Fuse Amps Wire Hub Fuse Fuse Amps Wire Hub Fus Fuse e

(MCA) Qty Gauge Qty Size Size Size (MCA) Qty Gauge Qty Size Size Size (MCA) Qty Gauge Qty Size Size Size

1 2.00

(51)

1 2.00

(51)

1 1.25

(32)

1 1.00

(25)

1 2.00

(51)

1 2.00

(51)

1 1.25

(32)

1 1.00

(25)

1 2.00

(51)

1 2.00

(51)

1 1.25

(32)

1 1.00

(25)

See page 22 for all Electrical Data notes.

365

185

153

415

199

162

455

210

169

500

3/0

2/0

300

3/0

2/0

350

4/0

2/0

1 3.00

(76)

1 3.00

(76)

1 2.00

(51)

1 2.00

(51)

1 3.00

(76)

1 3.00

(76)

1 2.00

(51)

1 2.00

(51)

1 4.00

(102)

1 4.00

(102)

1 2.00

(51)

1 2.00

(51)

450 500 365

450

225

175

500

225

200

600

250

200

500

250

200

600

250

225

600

300

225

365

185

153

415

199

162

455

210

169

500

3/0

2/0

300

3/0

2/0

350

4/0

2/0

3.00

(76)

3.00

(76)

2.00

(51)

2.00

(51)

3.00

(76)

3.00

(76)

2.00

(51)

2.00

(51)

4.00

(102)

4.00

(102)

2.00

(51)

2.00

(51)

450 500

450

225

175

500

225

200

600

250

200

500

250

200

600

250

225

600

300

225

Table 12, ALR 110E -135E Compressor and Condenser Fan Motor Amp Draw

Rated Load Amps Locked Rotor Amps

ALR

Unit

Size

Volts HZ.

No.

Compressors

No.

2 3

No.

Fan

Motors

No. Of

Fan

Motors

(Each) Motors (Each)

Compressors

Across-The-Line Reduced Inrush

No. 1 No. 2 No. 3 No. 4 No. 1 No. 2 No. 3 No. 4

110E

208

230

460

575

120E

130E

135E

208

230

460

575

208

230

460

575

208

230

460

575

121

112

121

112

121

112

121

112

121

112

Continued on next page

See page 22 for all Electrical Data notes.

121

112

121

112

135

127

121

112

121

112

135

127

121

112

5.8

2.8

2.3

5.8

2.8

2.3

5.8

2.8

2.3

5.8

2.8

2.3

650

594

297

245

565

283

230

650

594

297

245

565

283

230

23.7

21.4

10.7

11.5

23.7

21.4

10.7

11.5

23.7

21.4

10.7

11.5

23.7

21.4

10.7

11.5

650

594

297

245

650

594

297

245

754

594

297

245

565

283

230

650

594

297

245

650

594

297

245

650

594

297

245

565

283

230

400

340

195

152

340

156

138

400

340

195

152

340

156

138

650

594

297

245

650

594

297

245

754

594

297

245

650

594

297

245

400

340

195

152

400

340

195

152

463

340

195

152

340

156

138

400

340

195

152

400

340

195

152

400

340

195

152

340

156

138

400

340

195

152

400

340

195

152

463

340

195

152

400

340

195

152

ALR 110E through 185E IM ALR

Table 12, ALR 140E - 185E Compressor and Condenser Fan Motor Amp Draw (Continued)

ALR

Unit

Size

Volts HZ.

No.

Rated Load Amps

Compressors

No.

Fan

Motors

No. Of

Fan

Motors

(Each) Motors (Each)

Locked Rotor Amps

Compressors

Across-The-Line Reduced Inrush

No. 1 No. 2 No. 3 No. 4 No. 1 No. 2 No. 3 No. 4

140E

145E

150E

160E

170E

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

135

127

135

127

162

135

127

135

127

135

127

135

127

162

135

127

135

127

180E

185E

208

230

460

575

208

230

460

575

202

162

202

162

See page 22 for all Electrical Data notes.

202

162

135

127

162

135

127

135

127

162

135

127

135

127

202

754

594

297

245

754

594

297

245

1070

510

405

754

594

297

245

754

594

297

245

1070

510

405

1070

510

405

23.7

21.4

10.7

11.5

23.7

21.4

10.7

11.5

23.7

21.4

10.7

11.5

23.7

21.4

10.7

11.5

23.7

21.4

10.7

11.5

23.7

21.4

10.7

11.5

23.7

21.4

10.7

11.5

5.8

2.8

2.3

5.8

2.8

2.3

5.8

2.8

2.3

5.8

2.8

2.3

5.8

2.8

2.3

5.8

2.8

2.3

5.8

2.8

2.3

463

340

195

152

463

340

195

152

654

330

262

463

340

195

152

463

340

195

152

654

330

262

654

330

262

754

594

297

245

754

594

297

245

1070

510

405

754

594

297

245

754

594

297

245

1070

510

405

1070

510

405

463

340

195

152

463

340

195

152

654

330

262

463

340

195

152

463

340

195

152

654

330

262

654

330

262

1070

510

405

754

594

297

245

1070

510

405

754

594

297

245

754

594

297

245

1070

510

405

1070

510

405

654

330

262

463

340

195

152

654

330

262

463

340

195

152

463

340

195

152

654

330

262

654

330

262

1070

510

405

1070

510

405

1070

510

405

754

594

297

245

754

594

297

245

1070

510

405

1070

510

405

654

330

262

654

330

262

654

330

262

463

340

195

152

463

340

195

152

654

330

262

654

330

262

IM ALR ALR 110E through 185E

Table 13, ALR 110E - 185E Field Wiring Data, Single Point Power

ALR

Unit

Size

Volts HZ.

Terminal

Amps

Wiring to

Standard Power Block

Connector Wire Range

(Copper Wire Only)

110E

120E

130E

135E

140E

145E

150E

160E

170E

180E

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

185E

208

230

460

575

840

(*)

840

(*)

840

(4 qty.) 1/0 - 600 MCM

(2 qty.) 1/0 - 600 MCM

Note:* There are 2 power blocks, each having 840 terminal amps. (1680 total terminal amps)

See page 22 for all other Electrical Data notes.

840

(*)

840

(*)

840

335

840

335

840

(*)

840

(*)

840

(*)

840

(*)

840

335

840

335

840

335

840

335

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(4 qty.) 1/0 - 600 MCM

(2 qty.) 1/0 - 600 MCM

(4 qty.) 1/0 - 600 MCM

(2 qty.) 1/0 - 600 MCM

(4 qty.) 1/0 - 600 MCM

(2 qty.) 1/0 - 600 MCM

(4 qty.) 1/0 - 600 MCM

(2 qty.) 1/0 - 600 MCM

N/A

400

N/A

400

N/A

400

N/A

400

N/A

600

400

N/A

600

400

N/A

600

400

N/A

400

250

N/A

400

250

600

400

250

600

400

250

Terminal

Amps

Wiring to

Optional Disconnect Switch

Connector Wire Range

(Copper Wire Only)

(2 qty.) 250 - 500 MCM

(1 qty.) 250 - 500 MCM

(1qty.) #4 - 350 MCM

(2 qty.) 250 - 500 MCM

(1 qty.) 250 - 500 MCM

(1qty.) #4 - 350 MCM

(1 qty.) 250 - 500 MCM

(1qty.) #4 - 350 MCM

(1 qty.) 250 - 500 MCM

(1qty.) #4 - 350 MCM

(1 qty.) 250 - 500 MCM

ALR 110E through 185E IM ALR

Table 14, ALR 110E - 185E Field Wiring Data, Multiple Point Power

ALR

Unit

Size

Volts HZ.

110E

120E

130E

135E

140E

145E

150E

160E

170E

180E

185E

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

208

230

460

575

See page 22 for all Electrical Data notes.

175

Circuit 1

Terminal Amps

Circuit 2 Circuit 3

175

335

175

335

175

335

175

840

335

175

335

175

840

335

840

335

175

840

335

175

335

175

840

335

840

335

840

335

840

335

840

335

840

335

840

335

840

335

840

335

840

335

Wiring to Standard Power Block

Connector Wire Range (Copper Wire Only)

Circuit 1 Circuit 2

(1 qty.) #12 - 2/0

(1 qty.) #4 - 400 MCM

(1 qty.) #12 - 2/0

Circuit 3

(1 qty.) #4 - 400 MCM

(1 qty.) #12 - 2/0

(1 qty.) #4 - 400 MCM

(1 qty.) #12 - 2/0

(1 qty.) #4 - 400 MCM

(1 qty.) #12 - 2/0

(1 qty.) #4 - 400 MCM

(1 qty.) #12 - 2/0

(1 qty.) #4 - 400 MCM

(1 qty.) #12 - 2/0

(1 qty.) #4 - 400 MCM

(1 qty.) #12 - 2/0

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(1 qty.) #12 - 2/0

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(1 qty.) #12 - 2/0

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

(2 qty.) 1/0 - 600 MCM

(1 qty.) #4 - 400 MCM

IM ALR ALR 110E through 185E

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 may 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 253V (except ALR110E through ALR155E: 187V to

220V)

Unit Nameplate - 230V/60Hz/3Ph: 187V to 253V (except ALR110E through ALR155E: 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 given in table apply to 75°C rated wire per NEC.

ALR 110E through 185E IM ALR

Figure 7, ALR 110E through 185E, Typical Field Wiring Diagram

IM ALR ALR 110E through 185E

Dimensional Data

Figure 8, 110E through 185E Dimensions

145E

150E

160E

170E

180E

185E

ALR

UNIT

SIZE

110E

120E

130E

135E

140E

229

(5817)

229

(5817)

263

(6680)

263

(6680)

263

(6680)

263

(6680)

"A" CONN.

LENGTH SIZE (1)

229

(5817)

(152.4)

229

(5817)

229

(5817)

229

(5817)

229

(5817)

(152.4)

118.5

(3010)

118.5

(3010)

153.2

(3891)

153.2

(3891)

153.2

(3891)

153.2

(3891)

EVAPORATOR

WATER CONNECTIONS

B C E

117.6

(2987)

13.8

(351)

19.5

(495)

118.5

(3010)

118.5

(3010)

118.5

(3010)

118.5

(3010)

12.9

(328)

12.9

(328)

12.9

(328)

12.9

(328)

19.5

(495)

19.5

(495)

19.5

(495)

19.5

(495)

12.9

(328)

12.9

(328)

47.6

(1209)

47.6

(1209)

47.6

(1209)

47.6

(1209)

20.5

(521)

20.5

(521)

20.5

(521)

20.5

(521)

20.5

(521)

20.5

(521)

CNT. OF GRAVITY

103.0

(2616)

105.0

(2667)

121.0

(3074)

119.0

(3023)

118.0

(2997)

118.0

(2997)

106.5

(2705)

106.5

(2705)

107.0

(2718)

105.0

(2667)

108.0

(2743)

41.7

(1059)

41.7

(1059)

41.7

(1059)

41.7

(1059)

41.7

(1059)

41.7

(1059)

41.7

(1059)

41.7

(1059)

41.7

(1059)

41.7

(1059)

41.7

(1059)

ISOLATOR LOCATION

(330)

(1473)

(2413)

(1473)

215

(5461)

215

(5461)

250

(6350)

250

(6350)

250

(6350)

250

(6350)

215

(5461)

215

(5461)

215

(5461)

215

(5461)

215

(5461)

NUMBER

FANS

ALR 110E through 185E IM ALR

Unit Layout and Principles of Operation

Figure 9, Major Component Locations

The figure below illustrates component locations for each unit size.

Control Center

All electrical controls are enclosed in a weatherproof control center with keylocked, hinged access doors. The control center has two separate compartments, high voltage and low voltage. All high voltage components are located in the compartment on the right side of the unit.

The low voltage components are located on the left side with the live terminals behind the deadfront panel. This protects service personnel from live terminals when accessing the adjustable controls.

Control center layouts



ALR 080E through 185E

Figure 10, Left Side, 115V Control

Section

Figure 11, Right Side, High Voltage

Power Section

IM ALR

Note: PB1, PB2, PB3 are used with multiple point power wiring.

ALR 110E through 185E

Figure 12,Recommended Field Installed Unit Disconnect Location

Note: Mount disconnect on stationary panel so it does not interfere

with hinged doors or with air intake into coil.

ALR 110E through 185E IM ALR

Start-up and Shutdown

Pre Start-up

1. Open all electric disconnects and check all electric connections for tightness. Check all compressor valve connections for tightness.

2. Inspect all water piping for flow direction and correct connections at the evaporator.

3. Verify thermostat water temperature sensor is installed in the leaving water line (supply to building). On all ALR units the sensor well and sensor are factory mounted.

4. Check compressor oil level. The oil level should be visible in the oil sightglass.

5. Check voltage of the unit power supply and make certain voltage is within

10% of nameplate rating.

6. Check unit power supply wiring for proper ampacity and a minimum insulation temperature of

7. Verify all mechanical and electrical inspections have been completed according to local codes.

8. Verify all auxiliary control equipment is operative and an adequate cooling load is available.

9. Open compressor suction and discharge shutoff valves until backseated. Always replace valve seal caps.

10. Open control stop switch S1(off) and place pumpdown switches PS1 and PS2 on “manual pumpdown,”. Turn on the main power and control disconnect switches. This will energize crankcase heaters. Wait at least 12 hours before starting up unit.

11. Open all water flow valves and start the chilled water pump. Check all piping for leaks and vent the air from the evaporator as well as from the system piping. Flush the evaporator and system piping to obtain clean, noncorrosive water in the evaporator.

NOTE: If LWC1 is a Unit 33 Metasys control,

the control must be energized before the chilled water flow switch is closed.

IM ALR

CAUTION

Most relays and terminals in the unit control center are energized with S1

and the control circuit disconnect on. Do not close S1 until start-up.

Start-up

1. Verify compressor suction and discharge shutoff valves are backseated. Always replace valve seal caps.

2. Open oil equalization line valve.

3. Open manual liquid line shutoff valve at the outlet of the condenser subcooler.

4. Set temperature controller LWC1 to the desired chilled water temperature. Set the control band.

5. Start auxiliary equipment by turning on the following:

Time clock

Ambient thermostat and/or remote on/off switch

Chilled water pump.

6. Verify pumpdown switches PS1 and PS2 are in “manual pumpdown” (open) position. If pressures on the low side of the system are above 60 psig (414 kPa), the unit will start and pump down.

ALR 110E through 185E

7. After compressor lockout timer TD1 has timed out, start the system by moving pumpdown switches PS1 and PS2 to “auto pumpdown” position.

8. After running the unit for a short time, check the following:

Oil level in each compressor crankcase

Rotation of fans

Flashing in refrigerant sightglass.

9. Verify superheat temperature is at the factory setting of 8 to 12 degrees F (4.4 to 6.7 degrees C).

10. After system performance has stabilized, complete the “Compressorized Equipment Warranty

Form” (Form No. 415415Y) to obtain full warranty benefits. Return the form to McQuay

International through your sales representative.

Sequence of Operation

The following sequence of operation is typical for ALR air-cooled water chiller, Models ALR 110E through ALR 185E. The sequence varies depending upon options.

Start - up

With the control circuit power on and the control stop switch S1 closed, 115V power is applied through the control circuit fuse F1 to the compressor crankcase heaters HTR1, HTR2, HTR3, and

HTR4, the compressor motor protections MP1, MP2, MP3 and MP4, and the primary of the 24V control circuit transformer. The 24V transformer provides power to the contacts of the low pressure controls LP1 and LP2 and the compressor lockout timer TD1 and TD2.

When the remote time clock or manual shutdown switch turns on the chilled water pump, the flow switch closes and 115V power is applied to the relay contacts on the leaving water control LWC1. The unit will automatically operate in response to the LWC1 if the manual pumpdown switches PS1 and

PS2 are closed ( in the “auto” position); the compressor lockout time relays R5, R6, R7, and R8; and the freezestats FS1 and FS2, high pressure controls HP1 and HP2, and the compressor motor protectors MP1, MP2, MP3, and MP4 do not sense failure conditions.

On a call for cooling, the leaving water control LWC1 completes the circuit to the liquid line solenoid valve SV1 for refrigerant circuit #1, opening the valve and allowing refrigerant to flow through the expansion valve and into the evaporator. As the evaporator refrigerant pressure increases, the low pressure control LP1 closes. This energizes the compressor starting relay R9, starting the compressor via the compressor contactors M1 and M5. Closing the R9 contacts also energizes the condenser fan motor contacts M11 and M12 starting the fan motors.

As additional stages of cooling capacity are required, the leaving water control LWC1 energizes the liquid line solenoid valve SV2 of the refrigerant circuit #2. After the compressor sequencing time delay TD11 has closed, the same starting sequence is initiated in refrigerant circuit #2.

If still more cooling is required, the leaving water control will start the remaining compressors and then de-energize unloader solenoids until the capacity requirement is met.

ALR 110E through 185E IM ALR

Pumpdown

As the leaving water control is satisfied, it will unload the compressor(s) and then de-energize the liquid line solenoid valve(s) SV1 and SV2, causing the valve(s) to close. When the compressor has pumped most of the refrigerant out of the evaporator and into the condenser, the low pressure control(s) LP1 and LP2 will open. If the refrigerant leaks into the low side causing the pressure to close the low pressure controls LP1 and LP2, the compressor will start after a two-hour time delay.

For normal temperature controlled operation, the timer is bypassed and the compressor will start on a refrigerant pressure rise.

Note: Do not shut the unit down without going through the pumpdown cycle.

Flow switch, time clock, and ambient lockout thermostat must be wired to allow pumpdown when unit is turned off.

IM ALR ALR 110E through 185E

Unit Maintenance

General

On initial start-up and periodically during operation, it will be necessary to perform certain routine service checks. Among these are checking the liquid line sightglasses, taking condensing and suction pressure readings, and checking to see that the unit has normal superheat and subcooling readings. A recommended maintenance schedule is located at the end of this section.

It is suggested that the Maintenance Log be completed on a weekly basis. The log will serve as a useful tool for a service technician in the event service is required.

Compressor Maintenance

The reciprocating compressors are semi-hermetic and require no maintenance.

Lubrication

No routine lubrication is required ALR units. The fan motor bearings are permanently lubricated and no further lubrication is required. Excessive fan motor bearing noise is an indication of a potential bearing failure.

Compressor oil should be standard refrigeration mineral oil such as Suniso 3GS.

Electrical Terminals

WARNING

Electric shock hazard. Turn off all power before continuing with following service.

Electrical terminals should be checked semi-annually for tightness.

Condensers

The condensers are air-cooled and constructed of 3/8" (9.5mm) O.D. internally finned copper tubes bonded in a staggered pattern into louvered aluminum fins. No maintenance is ordinarily required except the routine removal of dirt and debris from the outside surface of the fins. McQuay recommends the use of foaming coil cleaners available at most air conditioning supply outlets. Use caution when applying such cleaners as they may contain potentially harmful chemicals. Care should be taken not to damage the fins during cleaning.

If the service technician has reason to believe that the refrigerant circuit contains noncondensables, purging may be required strictly following Clean Air Act regulations governing refrigerant discharge to the atmosphere. The purge Schrader valve is located on the vertical coil headers. Purge with the unit off, after shutdown of 15 minutes or longer, to allow air to collect at the top of the coil. Restart and run the unit for a brief period. If necessary, shut unit off and repeat the procedure.

NOTE: Follow all environment regulations when removing refrigerant from the unit.

Refrigerant Sightglass

The refrigerant sightglasses should be observed periodically. (A weekly observation should be adequate.) A clear glass of liquid indicates that there is adequate refrigerant charge in the system to insure proper feed through the expansion valve. Bubbling refrigerant in the sightglass, during stable run conditions, indicates that the system may be short of refrigerant charge. Refrigerant gas flashing in the sightglass could also indicate an excessive pressure drop in the liquid line, possibly due to a clogged filter-drier or a restriction elsewhere in the liquid line. See Table 15 for maximum allowable pressure drops). If subcooling is low add charge to clear the sightglass. If subcooling is normal (10

F) and flashing is visible in the sightglass check the pressure drop across the filter-drier.

ALR 110E through 185E IM ALR

IM ALR

Subcooling should be checked at full load with 70

F to 80

F (21

C to 27

C) outdoor air temperature and all fans running.

An element inside the sightglass indicates the moisture condition corresponding to a given element color. If the sightglass does not indicate a dry condition after about 12 hours of operation, the circuit should be pumped down and the filter-drier changed.

Preventative Maintenance Schedule

PREVENTATIVE MAINTENANCE SCHEDULE

OPERATION WEEKLY MONTHLY

(Note 1)

General

Complete unit log and review (Note 3)

Visually inspect unit for loose or damaged components

Inspect thermal insulation for integrity

Clean and paint as required

Electrical

Check terminals for tightness, tighten as necessary

Clean control panel interior

Visually inspect components for signs of overheating

Verify compressor heater operation

Test and calibrate all safety an operating controls

Megger compressor motor every five years *

Refrigeration

Leak test

Check sight glasses for clear flow

Check filter-drier pressure drop (see manual for spec)

Perform compressor vibration test

Condenser

Clean condenser coils (Note 4)

Check fan blades for tightness on shaft (Note 5)

Check fans for loose rivets and cracks

Check coil fins for damage

Notes:

1. Monthly operations include all weekly operations.

2. Annual (or spring start-up) operations includes all weekly and monthly operations.

3. Log readings may be taken daily for a higher level of unit observation.

4. Coil cleaning may be required more frequently in areas with a high level of airborne particles.

5. Be sure fan motors are electrically locked out.

* Never Megger motors while they are in a vacuum.

ANNUAL

(Note 2)

ALR 110E through 185E

CAUTION

1. Service on this equipment is to be performed by qualified refrigeration personnel familiar with equipment operation, maintenance, correct servicing procedures, and the safety hazards inherent in this work. Causes for repeated tripping of safety controls must be investigated and corrected.

2. Disconnect all power before doing any service inside the unit.

3. Anyone servicing this equipment shall comply with the requirements set forth by the

EPA in regards to refrigerant reclamation and venting.

Filter-Driers

A replacement of the filter-drier is recommended any time excessive pressure drop is read across the filter-drier and/or when bubbles occur in the sightglass with normal subcooling. The maximum recommended pressure drops across the filter-drier are as follows:

Table 15, Filter-Drier Pressure Drop

PERCENT CIRCUIT

LOADING (%)

100%

75%

50%

25%

MAXIMUM RECOMMENDED PRESSURE

DROP ACROSS FILTER DRIER PSIG (KPA)

10 (69)

8 (55.2)

5 (34.5)

4 (27.6)

The filter-drier should also be changed if the moisture indicating liquid line sightglass indicates excess moisture in the system.

During the first few months of operation the filter-drier replacement may be necessary if the pressure drop across the filter-drier exceeds the values listed in the paragraph above. Any residual particles from the condenser tubing, compressor and miscellaneous components are swept by the refrigerant into the liquid line and are caught by the filter-drier.

Liquid Line Solenoid Valve

The liquid line solenoid valves that shut off refrigerant flow in the event of a power failure does not normally require any maintenance. The solenoids may, however, require replacement of the solenoid coil or of the entire valve assembly.

The solenoid coil can be checked to see that the stem is magnetized when energized by touching a screwdriver to the top of the stem. If there is no magnetization either the coil is bad or there is no power to the coil.

The solenoid coil may be removed from the valve body without opening the refrigerant piping after pumpdown. For personal safety shut off and lock out the unit power.

The coil can then be removed from the valve body by simply removing a nut or snap-ring located at the top of the coil. The coil can then be slipped off its mounting stud for replacement.

To replace the entire solenoid valve follow the steps involved when changing a filter-drier.

ALR 110E through 185E IM ALR

IM ALR

Evaporator

The evaporator is the direct expansion, shell-and-tube type with refrigerant flowing through the tubes and water flowing through the shell over the tubes. The tubes are internally finned to provide extended surface as well as turbulent flow of refrigeration through the tubes. Normally no service work is required on the evaporator.

Refrigerant Charging

ALR air-cooled chillers are shipped factory charged with a full operating charge of refrigerant but there may be times that a unit must be recharged at the job site. Follow these recommendations when field charging. Refer to the unit operating charge found in the Physical Data Tables.

Unit charging can be done at any steady load condition (preferably at 75 to 100% load) and at any outdoor temperature (preferably higher than 70

F (21.1

C). Unit must be allowed to run 5 minutes or longer so that the condenser fan staging is stabilized at normal operating discharge pressure. For best results charge with two or more condenser fans operating on each refrigerant circuit.

The ALR units have a condenser coil design with approximately 15% of the coil tubes located in a subcooler section of the coil to achieve liquid cooling to within 5

F (3

C) of the outdoor air temperature when all condenser fans are operating. This is equal to about 15

F-20

F (8.3

C-11.1

C) subcooling below the saturated condensing temperature when the pressure is read at the liquid valve between the condenser coil and the liquid line filter drier. Once the subcooler is filled, extra charge will not lower the liquid temperature and does not help system capacity or efficiency. However, a little extra (10-15 lbs) will make the system less sensitive.

Note: As the unit changes load or fans cycle on and off, the subcooling will vary but should recover

within several minutes and should never be below 6

F (3.3

C) subcooling at any steady state condition. Subcooling will vary somewhat with evaporator leaving water temperature and suction superheat. As the evaporator superheat decreases the subcooling will drop slightly.

One of the following three scenarios will be experienced with an undercharged unit:

1. If the unit is slightly undercharged the unit will show bubbles in the sightglass. Recharge the unit as described in the charging procedure below.

2. If the unit is moderately undercharged it will normally trip on freeze protection. Recharge the unit as described in the charging procedure below. However, freezestat trips can also be an indication of low flow or poor heat transfer due to tube fouling. Anti-freeze solutions may also cause freezestat trips.

3. If the unit is severely undercharged the unit will trip due to lack of liquid flow to the expansion valve. In this case either remove the remaining charge by means of a proper reclamation system and recharge the unit with the proper amount of refrigerant as stamped on the unit nameplate, or add refrigerant through the suction valve on the compressor slowly. Feed liquid into the suction valve when the compressor is running. If the unit is severely undercharged the unit may nuisance trip during this charging procedure. If this happens close off the refrigerant from the tank and restart the unit. Once the unit has enough charge so that it does not trip out, continue with step 2 of the charging procedure below.

Procedure to charge a moderately undercharged ALR unit:

1. If a unit is low on refrigerant you must first determine the cause before attempting to recharge the unit. Locate and repair any refrigerant leak. Evidence of oil is a good indicator of leakage, however oil may not be visible at all leaks. Liquid leak detector fluids work well to show bubbles at medium size leaks but electronic leak detectors may be needed to locate small leaks.

2. Add the charge to the system through the suction shutoff valve or through the Schrader fitting on the tube entering the evaporator between the compressor and the evaporator head.

ALR 110E through 185E

3. The charge can be added at any load condition between 25-100% load per circuit but at least two fans should be operating per refrigerant circuit if possible. The suction superheat should be in the

F-12

F (3.3

C-6.6

C) range.

4. Add sufficient charge to clear the liquid line sightglass and until all flashing stops in the sightglass.

Add an extra 15-20 lbs. of reserve to fill the subcooler if the compressor is operating at 50-100% load.

5. Check the unit subcooling value by reading the liquid line pressure and temperature at the liquid line near the filter-drier. The subcooling values should be between 6

F-20

F (6.6

C-11.1

C). The subcooling values will be highest at 75-100% load, approximately 12

F-20

F (6.6

C-11.1

C) and lowest at 50% load, approximately 6

F-12

F (3.3

C-6.6

C).

6. With outdoor temperatures above 60

F (15.6

C) all condenser fans should be operating and the liquid line temperature should be within 5

F-10

F (2.8

C-5.6

C) of the outdoor air temperature.

At 25-50% load the liquid line temperature should be within 5

F (2.8

C) of outdoor air temperature with all fans on. At 75-100% load the liquid line temperature should be within 10

(5.6

C) of outdoor air temperature with all fans on.

7. Overcharging of refrigerant will raise the compressor discharge pressure due to filling of the condenser tubes with excess refrigerant.

ALR 110E through 185E IM ALR

ALR Troubleshooting Chart

POSSIBLE CAUSES PROBLEM

Compressor will not

Run

1. Main Switch.

2. Fuse Blown. Circuit breakers open

Compressor noisy or vibrating

High Discharge

Pressure

Low Discharge

Pressure

High Suction

Pressure

Low Suction

Pressure

Compressor will not stage up

Compressor

Staging

Intervals to Short

Compressor Oil

Level Too high or

Too Low

Compressor loses

Oil

Motor Overload

Relays or Circuit

Breakers Open

Compressor

Thermal Protection

Switch Open

3. Thermal overloads tripped

4. Defective contactor or coil.

5. System Shutdown by safety devices

6. No cooling required

7. Liquid line solenoid will not open

8. Motor electrical trouble

9. Loose wiring

1. Compressor running in reverse

2. Improper piping support on suction or discharge

3. Worn compressor isolator bushing

4. Worn Compressor

1. Noncondensables in system

2. System overcharged with refrigerant

3. Discharge shutoff valve partially closed

4. FanTrol wiring not correct

5. Fan not running

6. Dirty condenser coil

1. Wind blowing into coil at low ambient

2. Faulty condenser temperature regulation

3. Insufficient refrigerant in system

4. Low suction pressure

5. Only one compressor operating

1. Excessive water temperature

2. Excessive load

3. Expansion valve overfeeding

4. Compressors running in reverse

1. Lack of refrigerant

2. Clogged liquid line filter drier

3. Expansion valve malfunctioning

4. Condensing temperature to low

5. Compressor will not unload

6. Insufficient water flow

7. Evaporator head ring gasket slippage

8. Evaporator dirty

1. Defective capacity control

2. Faulty thermostat stage or broken wire

3. Stages not set for application

1. Thermostat control band not set properly

2. Erratic water thermostat

3. Insufficient water flow

1. Low oil level

2. Loose fitting on oil line

3. Level too high

4. Insufficient water flow - Level too high

5. Excessive liquid in crankcase - Level too high

1. Lack of refrigerant

2. Excessive compression ring blow-by

3. Suction superheat too high

4. Crankcase heater burnout

1. Low voltage during high load conditions

2. Defective or grounded wiring in motor

3. Loose power wiring

4. High condenser temperature

5. Power line fault causing unbalanced voltage

1. Operating beyond design conditions

2. Discharge valve partially shut

3. Blown compressor internal gasket

POSSIBLE CORRECTIVE STEPS

1. Close Switch.

2. Check electrical circuits and motor windings for shorts or grounds. Investigate for possible overloading. Replace fuse or reset breakers after fault is corrected. Check for loose or corroded connections.

3. Overloads are auto-reset Check unit closely when unit comes back on line. Allow time for auto-reset.

4. Repair or replace

5. Determine type and cause of shutdown and correct it before resetting safety switch

6. None. Wait until unit class for cooling

7. Repair or replace solenoid coil. Check wiring

8. Check motor for opens, shorts, or burnout

9. Check all wire junctions. Tighten all terminal screws

1. Check unit and compressor for correct phasing

2. Relocate, add, or remove hangers

3. Replace

4. Replace

1. Purge the noncondensables used accepted practice

2. Remove excess, check liquid subcooling

3. Open valve

4. Check FanTrol wiring

5. Check electrical circuit, Check fan motor

6. Clean coil

1. Shield coil from direct wind

2. Check condenser control operation

3. Check for leaks. Repair and add charge

4. See corrective steps for Low Suction Pressure

5. See corrective steps for Compressor Will Not Stage Up

1. Check control settings

2. Reduce load or add additional equipment

3. Check remote bulb. Regulate superheat

4. Check for proper phasing

1. Check for leaks, Repair and add charge. Check liquid sightglass

2. Check pressure drop across filter drier. Replace

3. Check and reset for proper superheat

4. Check means for regulating condenser temperature

5. See corrective steps for Compressor Staging Intervals Too

Low

6. Adjust flow

7. Take pressure drop across vessel and contact factory to obtain design pressure drop for that vessel

8. Clean chemically

1. Replace

2. Replace

3. Reset thermostat setting for application

1. Set control band wider

2. Replace

3. Adjust flow

1. Check and add oil

2. Check and tighten system

3. Adjust thermal expansion valve

4. Adjust flow

5. Check crankcase heater. Reset expansion valve for higher superheat. Check liquid line solenoid valve operation.

1. Check for leaks and repair. Add refrigerant

2. Replace compressor

3. Adjust superheat

4. Replace crankcase heater

1. Check supply voltage for excessive line drop

2. Replace compressor motor

3. Check all connections and tighten

4. See corrective steps for High Discharge Pressure

5. Check supply voltage. Notify power company. Do not start until fault is corrected.

1. Add facilities so conditions are within allowable limits

2. Open valve

3. Replace gasket

IM ALR ALR 110E through 185E

Post Office 2510, Staunton, Virginia 24402-2510 USA (540) 248-0711

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Table of Contents

Introduction

General Description

Inspection

Note: Unit shipping and operating weights are available

Installation

Note: Installation is to be performed by qualified

WARNING

Handling

Location

Service Access

Vibration Isolators

Water Piping

Flow Switch

NOTE: Differential pressure switches are not recommended for outdoor installation.

Water Connections

Note: On units sizes 160E through 185E there is a diagonal bracket

Refrigerant Charge

Glycol Solutions

Evaporator Water Flow and Pressure Drop

Physical Data

Electrical Data

Field Wiring

Notes for “Electrical Data Single Point” and “Electrical Data Multiple Point” Power:

Notes for “Field Wiring Data” - Both Single and Multiple Point Power:

Dimensional Data

Unit Layout and Principles of Operation

Control Center

Note: PB1, PB2, PB3 are used with multiple point power wiring.

Note: Mount disconnect on stationary panel so it does not interfere

Start-up and Shutdown

Pre Start-up

NOTE: If LWC1 is a Unit 33 Metasys control,

Start-up

Sequence of Operation

Note: Do not shut the unit down without going through the pumpdown cycle.

Unit Maintenance

NOTE: Follow all environment regulations when removing refrigerant from the unit.

Preventative Maintenance Schedule

PREVENTATIVE MAINTENANCE SCHEDULE

Notes:

Refrigerant Charging

Note: As the unit changes load or fans cycle on and off, the subcooling will vary but should recover

One of the following three scenarios will be experienced with an undercharged unit:

Procedure to charge a moderately undercharged ALR unit:

ALR Troubleshooting Chart

Related manuals

Table of contents