Professional Documents
Culture Documents
Pmals 4
Pmals 4
Group: Chiller
Date: January, 2001
Supersedes: PM ALS-3
And now, the new vintage "C" chillers are equipped with state-of-the-art
solid state starters to provide stepless acceleration, controlled deceleration,
and advanced motor/compressor protection features. McQuay is the only
manufacturer to provide this advanced technology on air-cooled chillers.
UNSURPASSED EFFICIENCY
• Single-screw compressor design
• Electronic expansion valve control
• Built-in economizer
• High efficiency lanced condenser fins
QUIET OPERATION
• Tuned discharge chamber
• Composite gaterotor material
• Liquid refrigerant-cooled motor
• Virtually vibration-free operation
OUTSTANDING RELIABILITY
• Rugged compressor design
• Solid State Starters for smooth acceleration and deceleration
• Low thrust loads on bearings
• Advanced composite gaterotor material
• Liquid refrigerant-cooled motors
• Multiple compressors with independent refrigerant circuits
• Proactive control logic
• Full factory run-testing for trouble-free operation
• McQuayService start-up
SUPERIOR CONTROL LOGIC
• Precise control and improved efficiency with fuzzy logic
• Easy to read 32-character LCD display
• Remote PC monitoring capability
• Open Protocol interface with virtually all BMS
• Superior reliability under extreme operating conditions
Unsurpassed Efficiency
• Zero clearance fit between the two gaterotors and main screw rotor virtually eliminates
leakage between the high and low pressure sides during compression. Special gaterotor
material made from an advanced composite, temperature stable material makes a zero
clearance design possible.
• An internal economizer system enhances the unit's refrigeration effect providing more
BTUs per pound of refrigerant circulated. The result is higher efficiency and lower
operating costs when compared to typical chillers without economizers.
• The ALS air-cooled chiller is equipped with the most advanced means of refrigerant
flow control available. An electronic expansion valve coupled with MicroTech fuzzy
logic control provides excellent operating efficiencies both at full and part load operation.
Unmatched Serviceability
• Field serviceability has not been sacrificed to meet design performance objectives on the ALS
chiller. Inspection covers allow for an excellent visual inspection of the main screw and
gaterotors. Compressors are equipped with suction and discharge service valves
• Compressors are located on the outside edges of the base allowing ready access.
Standard Solid State Starters
The addition of solid state starters as standard (a McQuay exclusive) on the "C" vintage
units takes a giant step forward in motor/compressor protection from failures from machine
or electrical faults and includes self-diagnostics, metering and display. The starters provide
smooth, slow stepless acceleration and controlled slow deceleration, reducing mechanical
and electrical stress for even greater compressor/motor life. Some of the information
available to the operator or service technician on each starter LED display follows:
Operating Messages Fault Messages
Line voltage not present System power not three phase
Voltage present, starter ready Phase sequence incorrect
Motor accelerating Line frequency less than 25 Hz
Motor at full speed Line frequency more than 72 Hz
Motor at full speed, ramp time expired Excessive current unbalance
Stop command received, motor decelerating Operating parameters lost
Thermal overload has reached 90% to 99% No current after "Run" command
Thermal overload at 100%, motor stopped Undercurrent trip occurred
Thermal overload reduced to 60%, motor can restart Overcurrent trip occured
Passcode enabled Control power too low
Passcode disabled Motor stalled during acceleration
Thermal overload content in percentage External fault
Gateway
MicroTech BACdrop
The McQuay BACdrop Gateway panel allows any BACnet based building automation
system (BAS) to communicate with MicroTech controllers. The panel translates between
the standard BACnet protocol (ANSI/ASHRAE 135-1995) and the MicroTech protocol. No
modifications to the MicroTech hardware or software are necessary. Since BACnet is a
standard, public protocol no license agreement is necessary.
Screw
Gaterotor Gaterotor
Economizer Design
The ALS screw compressor uses
an integral economizer where
centrifugal force is utilized to
separate the flash gas from the
liquid refrigerant prior to it entering
the evaporator. A small centrifugal
liquid/vapor separator mounted on
the rear of the compressor shaft
achieves the separation. The
economizer itself is located within
the envelope of the
motor/compressor housing.
ALS 420
ALS 206
ALS 218-260
ALS 141
Standards
ARI has established standards to provide uniform methods for the determination of the sound
levels of equipment. For large air-cooled chillers it is ARI Standard 370, Sound Ratings of
Large Outdoor Refrigeration and Air-Conditioning Equipment.
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 gases, liquids or solids-anything that 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.
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 (two reflecting surfaces,
the roof and the wall) will affect the sound pressure measurements differently than a unit
mounted on a roof with only one reflecting surface (the roof). 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.
Uniform Spherical Radiation Uniform Hemispherical Radiation Uniform Radiation over ¼ of sphere
Q=1 no reflecting surface Q=2 single reflecting surface Q=4 two reflecting surfaces
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 r = distance from unit in feet
Lw = sound power Q = directionality factor
With Q=1, Unit suspended in space (theoretical condition), the equation simplifies to:
Lp = Lw – (20)(log r) –0.5
With Q=2, for a unit sitting on a flat roof or ground with no adjacent vertical wall as a
reflective surface, the equation simplifies to:
Lp = Lw – (20)(log r) + 2.5
With Q=4 for a unit sitting on a flat roof or ground with one adjacent vertical wall as a
reflective surface, the equation simplifies to:
Lp = Lw – (20)(log r) + 5.5
The equations are reduced to table form in Table 13 for various distances and the two
most usual cases of “Q” type of location.
Table 13, dB Conversion of Sound Power to Pressure for Distance
Distance from Sound DB Reduction from Sound Power at the Source to
Source Sound Pressure at Referenced Distance
ft. (m) Q=2 Q=4
30 (9) 27.1 24.0
50 (15) 31.6 28.5
75 (23) 35.1 32.0
100 (30) 37.6 34.5
150 (46) 41.1 38.0
200 (61) 43.6 40.5
300 (91) 47.6 44.0
Figure 5 gives the reduction in sound pressure due to distance.
Sound Isolation
The low sound level for the ALS screw chiller satisfies most customer requirements.
However, there may be applications where even lower sound levels may be required. The
most effective isolation method is to locate the unit away from sound sensitive areas. Avoid
locations beneath windows or between structures where normal operating sounds may be
objectionable. Isolating water lines, electrical conduit and the unit itself can reduce
structurally transmitted sound. Wall sleeves and rubber isolated piping hangers can be used
to reduce transmission of water or pump noise into occupied spaces, and flexible electrical
connections can be used to isolate sound through electrical conduit. Spring isolators are
effective in reducing the low amplitude sound generated by screw compressors and can be
used for unit isolation in sound sensitive areas.
Note: The effect of adjacent walls on air recirculation and restriction must always be
considered when employing sound barrier walls.
NOTES:
1. Table based on 75°C field wire except (*) which require 90°C field wire.
2. Complete notes are on page 45
208 245 245 306 306 7.8 20 30.5 735 735 918 918
230 222 222 277 277 7.2 20 27.6 666 666 831 831
325C 380 60 135 135 168 168 4.1 20 20.0 405 405 504 504
460 111 111 139 139 3.6 20 13.8 333 333 417 417
575 90 90 111 111 3 20 11.5 270 270 333 333
208 245 306 306 306 7.8 20 30.5 735 918 918 918
230 222 277 277 277 7.2 20 27.6 666 831 831 831
335C 380 60 135 168 168 168 4.1 20 20.0 405 504 504 504
460 111 139 139 139 3.6 20 13.8 333 417 417 417
575 90 111 111 111 3 20 11.5 270 333 333 333
208 306 306 306 306 7.8 20 30.5 918 918 918 918
230 277 277 277 277 7.2 20 27.6 831 831 831 831
350C 380 60 168 168 168 168 4.1 20 20.0 504 504 504 504
460 139 139 139 139 3.6 20 13.8 417 417 417 417
575 111 111 111 111 3 20 11.5 333 333 333 333
208 306 306 306 350 7.8 20 30.5 918 918 918 1050
230 277 277 277 316 7.2 20 27.6 831 831 831 948
365C 380 60 168 168 168 192 4.1 20 20.0 504 504 504 576
460 139 139 139 158 3.6 20 13.8 417 417 417 474
575 111 111 111 126 3 20 11.5 333 333 333 378
208 306 306 350 350 7.8 24 30.5 918 918 1050 1050
230 277 277 316 316 7.2 24 27.6 831 831 948 948
375C 380 60 168 168 192 192 4.1 24 20.0 504 504 576 576
460 139 139 158 158 3.6 24 13.8 417 417 474 474
575 111 111 126 126 3 24 11.5 333 333 378 378
208 306 350 350 350 7.8 24 30.5 918 1050 1050 1050
230 277 316 316 316 7.2 24 27.6 831 948 948 948
385C 380 60 168 192 192 192 4.1 24 20.0 504 576 576 576
460 139 158 158 158 3.6 24 13.8 417 474 474 474
575 111 126 126 126 3 24 11.5 333 378 378 378
208 350 350 350 350 7.8 24 30.5 1050 1050 1050 1050
230 316 316 316 316 7.2 24 27.6 948 948 948 948
400C 380 60 192 192 192 192 4.1 24 20.0 576 576 576 576
460 158 158 158 158 3.6 24 13.8 474 474 474 474
575 126 126 126 126 3 24 11.5 378 378 378 378
208 350 350 350 350 10.0 24 48.1 1050 1050 1050 1050
230 316 316 316 316 9.2 24 43.5 948 948 948 948
420C 380 60 192 192 192 192 5.5 24 26.4 576 576 576 576
460 158 158 158 158 4.6 24 21.8 474 474 474 474
575 126 126 126 126 3.8 24 17.4 378 378 378 378
NOTE: Complete notes are on page 45
NOTES:
1. Terminal size amps are the maximum amps that the power block is rated for.
2. See Table 27 for multiple point with Disconnect Switch connections
3. Complete notes are on page 45
208 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
230 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
245C 380 60 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
460 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
575 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
208 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
230 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
260C 380 60 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
460 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
575 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
208 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
230 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
270C 380 60 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
460 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
575 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
208 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
230 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
275C 380 60 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
460 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
575 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
208 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
230 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
295C 380 60 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
460 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
575 840 840 840 (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM
NOTES:
1. Terminal size amps are the maximum amps that the power block is rated for.
2. See Table 28 for multiple point with Disconnect Switch connections
3. Complete notes are on page 45
208 400 400 400 (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM
230 400 400 400 (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM
245C 380 60 225 225 225 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
460 150 225 225 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
575 150 150 150 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
208 400 400 400 (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM
230 400 400 400 (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM
260C 380 60 225 225 225 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
460 225 225 225 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
575 150 150 150 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
208 400 400 600 (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 250 to 350 MCM
230 400 400 600 (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 250 to 350 MCM
270C 380 60 225 225 250 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 350 MCM
460 225 225 225 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
575 150 150 225 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
208 400 600 600 (2) 3/0 to 250 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM
230 400 600 600 (2) 3/0 to 250 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM
275C 380 60 225 250 250 (1) 4 to 4/0 (1) 4 to 350 MCM (1) 4 to 350 MCM
460 225 225 225 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
575 150 225 225 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
208 600 600 600 (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM
230 600 600 600 (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM
295C 380 60 250 250 250 (1) 4 to 350 MCM (1) 4 to 350 MCM (1) 4 to 350 MCM
460 225 225 225 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
575 225 225 225 (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/0
NOTES:
1. Terminal size amps are the maximum amps that the disconnect switch is rated for.
2. Complete notes are on page 45
83.4
Power (2118)
Dimensions, ALS
Center Compressor
#2
Control wiring
entry knockouts
for ½ (13)
Power entry location this side only.
conduit both Air
sides of unit. 2 additional knockouts 6.0 (152)
above and below this opening Standard Coil Guards Discharge
6.0
(152) for multiple power supply.
Figure 8, Dimensions, ALS 141C – ALS 218C
92.5
(2350)
141C
150C
171C
186C
190C
200C
206C
218C
51
52
8.0 (203) Victaulic Connections
Couplings by Others.
Note: Remote evaporator 220.1 (5590)
connections in this location.
142.7 (3625)
Control wiring #2
entry knockouts
for ½ (13)
conduit both Power entry location this side only.
94.5
(2400)
Note: See page 55 for lifting locations, mounting locations, weights and mounting loads.
65.6
(1666)
28.5 (724)
10.0 6.50
(256) (165)
C/G 155 (3917)
355.0 (9017)
M2 M4 M6
36 (914)
102 (2591)
192 (4877)
CONTROL
83.4
BOX
(2118)
161 (4089)
46 (1168)
M1 M3 M5
L1 L3 2 (51)
Typical Spacing
for Isolator
Mounting (6)
Lifting Weight for Each Point lb Mounting Loads for Each Point
ALS (kg) lb. (kg) Operating Wt Shipping Wt. Copper Fin
Model lb. (kg) lb. (kg) Add
L1 & L2 L3 & L4 M1 & M2 M3 & M4 M5 & M6
141 2585 (1171) 2125 (963) 1835 (831) 1785 (809) 1230 (557) 9700 (4394) 9420 (4267) 1370 (620)
150 2570 (1164) 2205 (999) 1830 (829) 1805 (818) 1305 (591) 9880 (4476) 9550 (4326) 1370 (620)
171 2570 (1164) 2210 (1001) 1830 (829) 1810 (820) 1305 (591) 9890 (4472) 9560 (4331) 1370 (620)
186 2575 (1166) 2210 (1001) 1830 (829) 1810 (820) 1310 (593) 9900 (4485) 9570 (4335) 1370 (620)
NOTES:
1. 2 ½ in. (63.5 mm) lifting holes at location "L" on side of base rail.
2. 1 in. (25.4 mm) mounting holes at location "M" on bottom of base rail.
M2 M4 M6
36 (914)
123 (3124)
224 (5690)
CONTROL
83.4
BOX
(2118)
195 (4953)
46 (1168)
M1 M3 M5
L1 L3 2 (51)
Typical Spacing
for Isolator
Mounting (6)
Lifting Weight for Each Point lb Mounting Loads for Each Point
ALS (kg) lb. (kg) Operating Wt Shipping Wt. Copper Fin
Model lb. (kg) lb. (kg) Add
L1 & L2 L3 & L4 M1 & M2 M3 & M4 M5 & M6
190 2915 (1320) 2230 (1010) 2010 (910) 2135 (967) 1165 (527) 10620 (4811) 10290 (4661) 1610 (730)
200 2920 (1323) 2230 (1010) 2015 (913) 2135 (967) 1165 (527) 10630 (4815) 10300 (4666) 1610 (730)
206 2940 (1332) 2310 (1046) 2000 (906) 2240 (1015) 1240 (562) 10960 (4965) 10500 (4756) 1610 (730)
218 2960 (1341) 2405 (1089) 1985 (899) 2425 (1098) 1365 (618) 11550 (5232) 10730 (4861) 1610 (730)
83.4
(2118)
2 (51)
Typical Spacing
for Isolator
Mounting (8)
ALS Lifting Weight for Each Point lb (kg) Mounting Loads for Each Point lb. (kg) Operating Wt Shipping Wt. Copper Fin
Model L1 & L2 L3 & L4 L5 L6 M1 & M2 M3 & M4 M5 & M6 M7 M8 lb. (kg) lb. (kg) Add
245 2845 (1289) 2445 (1108) 1420 (643) 2050 (928) 1745 (790) 2240 (1015) 2030 (920) 1150 (521) 1660 (752) 14840 (6722) 14030 (6356) 2020 (915)
260 2850 (1291) 2445 (1108) 1420 (643) 2050 (928) 1745 (790) 2245 (1017) 2030 (920) 1150 (521) 1660 (752) 14850 (6727) 14040 (6360) 2020 (915)
270 2845 (1289) 2455 (1112) 1430 (648) 2060 (933) 1750 (793) 2245 (1017) 2035 (922) 1155 (523) 1165 (528) 14880 (6741) 14090 (6383) 2020 (915)
275 2850 (1291) 2455 (1112) 1430 (648) 2060 (933) 1755 (793) 2245 (1017) 2035 (922) 1155 (523) 1665 (528) 14890 (6745) 14100 (6387) 2020 (915)
295 2865 (1298) 2455 (1112) 1430 (648) 2060 (933) 1755 (793) 2250 (1019) 2035 (922) 1155 (523) 1165(528) 14900 (6750) 14110 (6392) 2020 (915)
NOTES:
1. 2 ½ in. (63.5 mm) lifting holes at location "L" on side of base rail.
2. 1 in. (25.4 mm) mounting holes at location "M" on bottom of base rail.
83.4
(2118)
2 (51)
Typical Spacing
for Isolator
Mounting (10)
ALS Lifting Weight for Each Point lb (kg) Mounting Loads for Each Point lb. (kg) Operating Wt Shipping Wt. Copper Fin
Model L1 & L2 L3 & L4 L5 & L6 L7 & L8 M1 & M2 M3 & M4 M5 & M6 M7 &M8 M9 & M10 lb. (kg) lb. (kg) Add
325 2625 (1189) 1895 (858) 2805 (1271) 1835 (831) 2060 (933) 1955 (886) 1485 (673) 2245 (1017) 1895 (858) 19280 (8734) 18320 (8299) 2750 (1246)
335 2625 (1189) 1895 (858) 2805 (1271) 1840 (833) 2065 (935)) 1955 (886) 1485 (673) 2245 (1017) 1895 (858) 19290 (8738) 18330 (8303 2750 (1246)
350 2625 (1189) 1895 (858) 2805 (1271) 1840 (833) 2065 (935) 1955 (886) 1485 (673) 2245 (1017) 1895 (858) 19290 (8738) 18330 (8303) 2750 (1246)
365 2625 (1189) 1900 (861) 2805 (1271) 1840 (833) 2070 (938) 1955 (886) 1485 (673) 2245 (1017) 1895 (858) 19300 (8743) 18340 (8308) 2750 (1246)
375 2635 (1194) 1905 (863) 2815 (12750 1845 (836) 2075 (940) 1960 (888) 1490 (675) 2255 (1021) 1900 (861) 19360 (8770) 18400 (8335) 2750 (1246)
385 2640 (1196) 1905 (863) 2815 (12750 1845 (836) 2075 (940) 1965 (890) 1490 (675) 2255 (1021) 1900 (861) 19370 (8775) 18410 (8340) 2750 (1246)
400 2640 (1196) 1905 (863) 2815 (12750 1845 (836) 2075 (940) 1965 (890) 1490 (675) 2255 (1021) 1900 (861) 19370 (8775) 18410 (8340) 2750 (1246)
420 2640 (1196) 1905 (863) 2815 (12750 1845 (836) 2075 (940) 1965 (890) 1495 (677) 2260 (1024) 1920 (870) 19430 (8802) 18510 (8385) 2750 (1246)
Rigging
Care must be taken to avoid dropping the unit during unloading or moving as this can result in
serious property damage and personal injury. Do not push or pull the unit from anything
other than the base, and block the forklift away from the unit to prevent damage to the sheet
metal cabinet and end frame. Do not lift the unit with a fork lift truck. To lift the unit, two
(or three or four depending on unit size) 2 1/2 inch (65mm) diameter lifting holes are
provided on each side in the base of the unit. Lengthwise and crosswise spreader bars must
be used between rigging lines to prevent damage to the condenser coils or unit cabinet and to
keep the lines coming up from the rigging holes to the spreaders vertical.
Unit Placement
For roof mounted applications, the unit must be installed on a steel channel or I-beam frame
to support the unit above the roof. For ground level applications, the unit must be installed on
a substantial base that will not settle. McQuay recommends a one piece concrete slab with
footings extended below the frost line, and the installation engineer should determine its
necessity. The foundation must be level within 1/2 inch (13mm) over its length and width
and strong enough to support the unit's operating weight as listed in the Physical Data tables.
On ground level applications fin protection against vandalism is recommended, either by the
optional factory installed condenser coil guard or a field installed screen fence. Note that the
fence must allow free flow of air to the condenser coil for proper unit operation.
Clearances
Air-cooled units require free air flow to and from the condenser coils. Units should be
installed per the listed installation clearances. There must be no obstructions above the fan
discharge that may cause air recirculation. Air restriction and recirculation can cause high
pressure trips and will reduce capacity, efficiency, and compressor life. Do not install
ductwork on condenser fans. Structures, other equipment, fencing, plants, and trees must be
considered for air flow interference. Ventilators and any sources of contaminated or heated
discharges gases and air will affect system performance. Pit type installation must meet
McQuay’s requirements.
Service Access
Each end of the unit must be accessible after installation for periodic service work.
Compressors, filter-driers, and manual liquid line shutoff valves must be accessible on each
side of the unit adjacent to the control box. High pressure and low pressure transducers are
mounted on the compressor. The cooler barrel heater thermostat is located on the cooler.
Compressor overloads, microprocessor, and most other operational, safety and starting
controls are located in the unit control box.
The electric disconnect switch should be mounted adjacent to the unit but not directly on unit
sheet metal components.
On all ALS units the condenser fans and motors can be removed from the top of the unit.
The complete fan/motor assembly can be removed for service. The fan blade and fan motor
rain shield must be removed for access to wiring terminals at the top of the motor.
Notes:
1. Minimum side clearance between two units is 12 feet (3.7 meters).
2. Unit must not be installed in a pit or enclosure that is deeper or taller than the height of the unit
unless extra clearance is provided per note 4.
3. Minimum clearance on each side is 8 feet (2.4 meters) when installed in a pit no deeper than the
unit height.
4. Minimum side clearance to a side wall or building taller than the unit height is 8 feet (2.4 meters)
provided no solid wall above 6 feet (1.8 meters) is closer than 12 feet (3.7 meters) to the opposite
side of the unit.
5. The removable post for compressor service access must not be blocked at either side of the unit.
6. Do not mount electrical conduits, etc., above the side rail on either side of the unit. Do not block
service access to compressor controls or refrigerant driers or valves.
7. There must be no obstruction of the fan discharge.
Notes:
1. Minimum side clearance between two units is 12 feet (3.7 meters).
2. Unit must not be installed in a pit or enclosure that is deeper or taller than the height of the unit
unless extra clearance is provided per note 4.
3. Minimum clearance on each side is 8 feet (2.4 meters) when installed in a pit no deeper than the
unit height.
4. Minimum side clearance to a side wall or building taller than the unit height is 8 feet (2.4 meters)
provided no solid wall above 6 feet (1.8 meters) is closer than 12 feet (3.7 meters) to the opposite
side of the unit.
5. The removable post for compressor service access must not be blocked at either side of the unit.
6. Do not mount electrical conduits, etc., above the side rail on either side of the unit. Do not block
service access to compressor controls or refrigerant driers or valves.
7. There must be no obstruction of the fan discharge.
Notes:
1. Minimum side clearance between two units is 12 feet (3.7 meters).
2. Unit must not be installed in a pit or enclosure that is deeper or taller than the height of the unit
unless extra clearance is provided per note 4.
3. Minimum clearance on each side is 8 feet (2.4 meters) when installed in a pit no deeper than the
unit height.
4. Minimum side clearance to a side wall or building taller than the unit height is 8 feet (2.4 meters)
provided no solid wall above 6 feet (1.8 meters) is closer than 12 feet (3.7 meters) to the opposite
side of the unit.
5. The removable post for compressor service access must not be blocked at either side of the unit.
6. Do not mount electrical conduits, etc., above the side rail on either side of the unit. Do not block
service access to compressor controls or refrigerant driers or valves.
7. There must be no obstruction of the fan discharge.
The following sections discuss the most common situations of condenser air restriction and
give capacity and power adjustment factors for each. Note that in unusually severe
conditions, the MicroTech controller would adjust the unit operation to remain online until a
less severe condition is reached.
Multiple Units
Chillers are frequently installed in multiple. Doing so provides standby reliability and
improved performance, and is recommended. Multiplicity of machines however can result in
unexpected problems where chiller controls or capacity reduction are overlooked in the
design. Single chiller installations are equally susceptible to application oversight. The
following offers supplemental information to that discussed in ASHRAE for the purpose of
minimizing installation problems.
Water Flow
Chilled water systems are normally designed with leaving chilled water temperatures of 40°F
to 46°F (5°C to 8°C), a 10 degree F (6 degree C) water temperature difference and 0.0001
fouling factor. Catalog performance tables display data for the chillers at these conditions.
Actual design may be different, and Product Manuals include adjustment factors or special
rating tables to account for other conditions.
1. Addition of secondary coolants such as ethylene glycol.
2. Variances from 10 degree F (6 degree C) water temperature differences
3. More than standard water fouling, and
4. Elevation and ambient air temperatures
Vent
Outlet
Note: The cross piping for the pressure gauge can be as small as ¼ inch. The purpose of this arrangement is to provide an easy
method to use one gauge to accurately measure both pressures
or
Feet of water x 0.433 = PSI
Freeze Protection
McQuay air-cooled chillers are equipped with thermostatically controlled heat tape under the
insulation of the evaporator barrels. The heater comes from the factory connected to the
control power circuit but can be rewired to a separate 120V (110V, 50 Hz) supply. If this is
done, the disconnect switch should be clearly marked to avoid accidental deactivation of the
heater during freezing temperatures. The heater will provide freeze protection to -20°F (-
29°C). However, this does not provide protection to the exposed chilled water piping.
Unless the evaporator is flushed and drained as described in note 4 two or more of the
following recommendations should be part of the system design and be implemented.
1. Continuous circulation of water through the piping and heat exchanger.
2. Addition of the required concentration of a glycol anti-freeze to the circuit. This will
result in decreased capacity and increased pressure drop. Note: Do not use
automotive grade antifreezes that contain inhibitors harmful to chilled water systems.
Only use glycols specifically designated for use in building cooling systems.
3. Addition of insulation and heat to any exposed piping and equipment.
4. Draining and flushing the chiller with glycol.
For example, assume that an ALS with two compressors has a design flow of 500 GPM and
the minimum vessel flow rate of 300 GPM. The allowable amount of flow change is 200
GPM. An ALS with two compressors has an allowable change rate of 10% of change per
minute. Therefore, the maximum rate of change recommended would be 20 GPM/minute
(200 X .10).
The water flow GPM through the vessel must remain between the minimum and maximum
values listed on Figure 3. If flow drops below the minimum allowable, large reductions in
heat transfer can occur. If the flow exceeds the maximum rate, excessive pressure drop
and tube erosion can occur.
Remote Evaporator
General
The multiple compressor ALS air-cooled chillers are available with remote evaporator. This
allows the main unit to be installed outdoors to save interior room and eliminates the need for
anti-freeze solutions and heat tracing of chilled water lines since the chilled water system is
indoors. There are some general guidelines to review before proceeding:
1. R-22 only.
2. Maximum line length of 50 ft (15 m) and Total Equivalent Length (TEL) of 120 ft
(37 m).
3. Evaporator not more than 6 ft (1.8 m) above the compressor or 16 ft (5 m) below
compressor.
4. No underground piping.
5. No hot gas bypass.
6. Units with remote evaporator are not included in the ARI Certification Program.
The remote evaporator is shipped separately, ready for quick and easy installation at the job
site. All refrigerant accessories such as liquid-vapor line shut-off valves, replaceable core
NOTE
All refrigerant piping must be reviewed by McQuay Application Engineers
prior to order entry and will be verified by McQuay startup technicians.
Liquid-Vapor Lines
The liquid-vapor line from the ALS condensing unit to the evaporator liquid connection is not
a conventional liquid line since it carries both liquid and vapor. The compressors on the ALS
units utilize a liquid cooled motor and an economizer. Therefore, the expansion valve which
feeds the full flow of liquid refrigerant into the compressor for motor cooling is mounted in
the liquid line between the condenser sub-cooling coil and the compressor inlet; not at the
evaporator inlet. The liquid-vapor line to the evaporator is a low pressure line downstream
of the expansion valve and the size is slightly larger than a normal liquid line. For liquid line
sizing see Table 40 and Table 41.
Insulation
All piping joints and fittings must be thoroughly leak tested before insulation is applied.
Suction lines must be insulated and should not be installed underground. Suction line
insulation must be selected to prevent condensation under local ambient conditions with the
NOTE: Keep the trap width at a minimum to avoid trapping excessive oil.
Startup Procedures
NOTE: McQuayService or an authorized McQuay service agent must do initial start-up and
commissioning.
Filter Driers
Following an initial 24 hour operation the pressure drop across the replaceable core, filter
drier should be checked. If this pressure drop exceeds the values given in Table 43 at the
various load conditions the filter drier cores must be replaced. Also, if the moisture
indicating sight glass shows a wet system condition after 24 hours of operation the filter
cores must be changed. This should remove any contaminants introduced during field piping.
The filter drier cores must also be changed anytime the system is opened for servicing.
Oil Charge
The oil charge is 3 gallons of oil per circuit.
Notes:
1. The only approved oil is that identified on the label attached to the compressors. All
POE oils are hygroscopic and care must be exercised in handling the oil to avoid
absorption and retention of moisture.
2. Do not leave the oil container open for more than a minute while charging oil. Do not
use oil that has not been properly sealed and stored.
Dimensions
Use the ALS dimension drawings Figure 8 to Figure 10 for the ALS with remote evaporator.
The refrigerant connections are located approximately where the refrigerant connections to
the unit mounted evaporator are on a packaged chiller. The remote evaporator dimensions
are Figure 32 through Figure 34.
OUTLET INLET
152
OUTLET INLET
ALS Evaporator Water Vol. Refrig Vol. Weights lb. (kg) R-22 Operating Charge lb. (kg)
Model Model gal. (l) cu. ft. (l) Operating Shipping Circuit 1 Circuit 2 Circuit 3 Circuit 4
325-400 CDE350283101 115 (435) 4.1 (116) 2529 (1148) 1423 (646) 49 (22) 49 (22) 49 (22) 49 (22)
420 CDE350283111 110 (416) 4.7 (133( 2575 (1169) 1484 (674) 56 (25) 56 (25) 56 (25) 56 (25)
Condenser Coils
The 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. The fins have full drawn collars to completely
cover the copper tube for protection against atmospheric corrosion and provide excellent
heat transfer. An integral subcooler with a liquid sightglass on the inlet provides sufficient
subcooling to effectively eliminate the possibility of liquid flashing and increase unit
efficiency. Standard PVC coated wire mesh guards protect the coils.
Control Center
The ALS screw chiller is shipped with all operating and equipment protection controls,
control transformer and solid state motor starting and protection equipment, all factory wired,
operationally tested, and ready for service. Included are:
Controlled acceleration Electronic thermal overload Stalled motor protection
Controlled deceleration Over/under current protection Single phase protection
Phase rotation protection Current unbalance protection High load current
All controls are centrally located in a weather-resistant, hinged control center, with key-
locked doors to prevent unauthorized entry. Panel access doors include steel rod door
retainers to prevent flapping while open. Dead front panels help protect service personnel
from accidental contact with line voltage components.
Ice storage
The unit is equipped with control logic to handle the low temperatures associated with
thermal storage applications. They are also supplied with additional evaporator insulation.
Electrical
Multipoint power blocks
Available on all units, standard on 208/230 volt power on model ALS 245C and larger.
Disconnect switch(s)
A single point factory installed nonfused disconnect switch with through-the-door handle is
available on all units except 208/230 volt power on models ALS 245C and larger which
require multiple disconnects.
Multiple point factory installed disconnect switches are available on all units.
Disconnect switches are available for field mounting. Through-the-door handles are optional
and require cutting of the door in the field.
Circuit Breakers
Circuit breakers are available on all single point power connection which excludes 208/230
volts on model ALS 245C and larger.
Unit
Black Fin coil
Aluminum fin stock is precoated with a phenolic epoxy coating with 1000 hour salt spray
resistance (ASTM B117-90).
Copper fin condenser coils
Copper fin condenser coils are available as an option on all models.
Vibration isolators
Spring vibration isolators are available for field installation under the unit base frame on
sound sensitive applications. Consult the local McQuay sales office for seismic isolation.
1.01 SUMMARY
PART 2--PRODUCTS
A. McQuay International
B. (Approved Equal)
2.02 UNIT DESCRIPTION
Provide and install as shown on the plans factory assembled, factory charged, and
factory run tested air-cooled rotary screw compressor packaged chillers in the
quantity specified. Each chiller shall consist of multiple semi-hermetic rotary screw
compressors, direct expansion evaporator, air-cooled condenser section, control
system and all components necessary for safe and controlled unit operation.
2.03 DESIGN REQUIREMENTS
3.01 INSTALLATION