Air-Cooled Rotary Screw Chillers

Transcription

1 Product Manual PM ALS-4 Group: Chiller Date: January, 2001 Supersedes: PM ALS-3 Air-Cooled Rotary Screw Chillers Models ALS 141C to ALS 420C 120 to 420 Tons, 420 to 1470 kw HCFC Hz

2 Table of Contents Introduction...3 Customer Benefits...4 Controls...6 Design Advantages...10 Selection Procedures...12 Performance Adjustment Factors...13 Performance Data...15 Pressure Drop...22 Sound Data...23 Electrical Data...28 Field Wiring Diagram...46 Physical Data...47 Dimensions, ALS...51 Installation and Application...56 Chilled Water Systems...66 Electrical Connections...70 Remote Evaporator...70 Dimensions, Remote Evaporator...77 Standard Features...81 Optional Features...84 Specifications...86 Remote evaporator applications are not included in ARI Program Our facility is ISO Certified "McQuay" is a registered trademark of McQuay International 2001 McQuay International "Information covers McQuay International products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice" 2 ALS 141C 420C Product Manual ALS-4

3 Introduction The McQuay ALS air-cooled chillers are equipped with McQuay single-rotor screw compressors, high efficiency lanced condenser fins, multi-circuit DX evaporator and fuzzy logic MicroTech control theory to offer the utmost in quiet and efficient operation. 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 Product Manual ALS-4 ALS 141C 420C 3

4 Customer Benefits 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. Figure 1, StarGate Compressor Cutaway 4 ALS 141C 420C Product Manual ALS-4

5 Outstanding Reliability Features Full factory testing of the unit with water hookups provides a trouble-free start-up. Extensive quality control checks during testing means that each equipment protection and operating control is properly adjusted and operates correctly before it leaves the factory. Factory installed options minimize field expenses and startup labor. The rugged design of the single-screw compressor with its compliant gaterotors allows it to tolerate liquid slugging. The ALS screw chiller will start and operate under conditions that would destroy a reciprocating compressor. The elimination of many moving parts such as pistons, valves, and connecting rods found on reciprocating compressors results in the enhanced reliability of the single-screw compressor. Due to symmetrical compression taking place on both sides of the main screw rotor, balanced forces result in the elimination of the large thrust loads inherent in twin-screw compressors. Very low loading enhances the bearing and compressor reliability. Integral to the basic design of the single-screw compressor, the main screw rotor shaft and the gaterotor shafts cross at right angles in the compressor. The result is ample space to locate heavy duty bearings and increase compressor reliability since no limitations are placed on bearing design as found in twin-screw compressors. The compressor motor on the ALS screw chiller is liquid refrigerant cooled, allowing motor operation at lower temperatures, enhancing system reliability and motor life when compared to suction or discharge gas cooled designs. Recent technological advancements have made available a composite material that prevents premature wear on the gaterotor. The composite material is made from a material designed for strength, temperature stability and durability. 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 Line voltage not present Voltage present, starter ready Motor accelerating Motor at full speed Motor at full speed, ramp time expired Stop command received, motor decelerating Thermal overload has reached 90% to 99% Thermal overload at 100%, motor stopped Thermal overload reduced to 60%, motor can restart Passcode enabled Passcode disabled Thermal overload content in percentage Fault Messages System power not three phase Phase sequence incorrect Line frequency less than 25 Hz Line frequency more than 72 Hz Excessive current unbalance Operating parameters lost No current after "Run" command Undercurrent trip occurred Overcurrent trip occured Control power too low Motor stalled during acceleration External fault Product Manual ALS-4 ALS 141C 420C 5

6 Controls MicroTech, The Ultimate Control System A fuzzy logic control system is employed in the ALS screw chiller that optimizes the suction line superheat and the positioning of the electronic expansion valve at all compressor capacities resulting in maximized unit operating efficiencies. Fuzzy logic control is based on approximate reasoning that maintains tighter control of the system. The MicroTech chiller controller, already proven superior to all other chiller control systems on reciprocating and centrifugal chillers, is employed in the ALS screw chiller. This advanced microprocessor-based control maintains a precise and stable leaving evaporator temperature set point. Utilization of fuzzy logic means compressor cycling is minimized, reducing wear on both compressor and starting components. Stand-alone unit controls designed with the system operator in mind provide access to the unit temperatures, pressures, set points, operating states, schedules, and alarm messages. The MicroTech controller includes password protection to guard against unauthorized or accidental setpoint or parameter changes. Complete instrumentation with state-of-the-art pressure transducers, temperature sensors and optical oil level sensors for unparalleled operator information and diagnostics. Superior head pressure control that maximizes unit efficiency by determining optimum condenser fan operation. At least 5 and as many as 7 stages of heat rejection per circuit are provided. An optional Remote Monitoring and Sequencing (RMS) panel provides monitoring and control of remote chillers via a single twisted pair of wires. The RMS panel allows the user to access information such as unit status, temperatures and pressures, all control set points, alarm conditions, time and date of alarm conditions, as well as the ability to clear alarms remotely. Up to three chillers can be sequenced and monitored from one RMS panel. A personal computer equipped with optional MicroTech Monitor software can be used to provide a high-level interface with the MicroTech controller. It can be connected to the controller either directly or remotely via phone lines with an optional modem. The optional MicroTech Network Master Panel (NMP) allows multiple screw chiller controllers to be incorporated into a building-wide network with other MicroTech unit and auxiliary controllers. In conjunction with a personal computer, it provides the building operator with the capability to perform advanced equipment control and monitoring from a central or remote location. Open Protocol is a commitment from McQuay International to provide a cost effective means to building automation through a strategic and joint effort with major temperature control companies. This optional feature provides an interface between MicroTech controllers and the building automation system. The result can be reduced installation costs, greater reliability and a seamless operator interface with all equipment in the building. 6 ALS 141C 420C Product Manual ALS-4

7 MicroTech Controller Utilizing Fuzzy Logic McQuay International has combined microprocessor power and versatility and our extensive experience in chiller design to create the MicroTech screw chiller controller utilizing a fuzzy logic control system. The MicroTech control provides low maintenance, high performance and energy efficient operation that is so vital to profitable building operation in today's economic climate. Fuzzy Logic Control Traditional control systems on today's chillers do not adequately provide precision temperature control of the system. McQuay International has implemented an advanced digital control method based upon fuzzy logic that maintains tighter and more stable control of the chiller system. Conventional control logic operates on the true/false, black and white theory. However, in practical applications everything is not black and white, but rather can be found somewhere in between as shades of gray. Terms such as hot and cold in conventional control techniques are replaced by ambiguous words like warm and cool. Fuzzy logic does not maintain that a statement has to be true or false, but instead measures the degree of truth within the statement and begins to take action immediately. Unlike traditional controllers that rely on a linear control theory, the fuzzy logic system is based upon approximate reasoning with a set of fuzzy rules. Fuzzy rules are "if-then" statements with varying degrees of precision. A simple analogy of a "if-then" statement could be a car in traffic. If the distance between two cars is adequate, then the car behind will continue at the same speed. If the distance between the two cars increases, then the car in the rear can accelerate slowly. If the distance between the two cars is reduced slightly, then the car behind brakes slowly. If the distance between them is reduced quickly, then the car in the rear must brake much more quickly. Fuzzy logic operates on this same principle. The MicroTech controller supplied on the ALS chillers utilizes fuzzy logic in the control of suction line superheat and the positioning of the electronic expansion valve in response to system load. Expansion valve hunting, not uncommon on traditional thermostatic expansion valves, has been eliminated. Optimized superheat is maintained under all conditions providing excellent control. Proactive Control The MicroTech Control continuously monitors all important system parameters and will take measures to avoid unit shutdown if a system imbalance or upset occurs. An alarm circuit is energized under these circumstances. Product Manual ALS-4 ALS 141C 420C 7

8 Stand-alone Unit Controls The MicroTech unit controller is a microprocessor-based direct digital control system designed to provide sophisticated monitoring and control. Designed with the system operator in mind, the MicroTech controller features an easy to use 12-key keypad and 32-character display that provides access to temperatures, pressures, set points, operating states, schedules and alarm messages in either English or Metric units. The controller includes password protection to guard against unauthorized or accidental set point or parameter changes. The MicroTech unit controller can be used as a stand-alone controller, or it can be integrated into a MicroTech network by using the Network Master Panel or the Remote Monitoring and Sequencing Panel. Regardless of whether the controller is stand-alone or included in a network, an IBM-compatible computer containing MicroTech Monitor software can be connected to give the operator full-screen unit monitoring and control capability. Electronic Expansion Valve The ALS air-cooled chiller is equipped with the most advanced means of refrigerant flow control available. An electronic expansion valve coupled with a MicroTech unit controller and fuzzy control logic provide excellent operating efficiencies both at full and part load operation. Unlike conventional thermal expansion valves which require a large pressure drop across the valve and result in higher condenser head pressure, the electronic valve does not need a large pressure drop across it to operate effectively. During part load operation the electronic valve allows the system to operate at lower condensing pressure, minimizes suction line superheat and provides for a more stable system operation. Unit efficiencies are dramatically improved. The electronic expansion valve is an excellent choice of control for the ALS chiller line, providing precise control with a very fast response time. Optional Remote Monitoring and Sequencing Panel The MicroTech Remote Monitoring and Sequencing (RMS) panel provides monitoring of remote chillers via a single twisted pair of wires. The RMS panel allows the user to access information such as unit status, temperatures and pressures, all control set points, alarm conditions, time and date of alarm conditions, as well as the ability to clear alarms remotely. The RMS panel is equipped with a keypad/display that is identical to the chiller controller's keypad/display. With a special keystroke combination, the RMS keypad/display can be interfaced with any Microtech chiller controller. It then operates identically to the chillermounted keypad/display. Thus the operator has full access to all networked chillers from a single remote location. Panel-mounted LEDs clearly indicate with which controller the RMS Panel keypad/display is currently interfaced. Any chiller alarm or loss of communication alarm that occurs will be indicated by a panelmounted alarm LED. An alarm will also cause the panel-mounted annunciator to sound. The volume can be adjusted with a small potentiometer. Any alarm in the network can be cleared at the RMS panel keypad. 8 ALS 141C 420C Product Manual ALS-4

9 Optional Personal Computer Monitoring (Part Number ) A personal computer equipped with MicroTech Monitor software can be used to provide a high-level interface with the MicroTech controller. It can be connected to the controller either directly or remotely via phone lines with an optional modem. If the controller is part of a MicroTech network personal computer, monitoring can be done via network communications. Optional Network Master Panel (Part Number ) The MicroTech Network Master Panel (NMP) allows multiple screw chiller controllers to be incorporated into a building-wide network with other MicroTech unit and auxiliary controllers. In conjunction with a personal computer, it provides the building operator with the capability to perform advanced equipment control and monitoring from a central or remote location. This is strictly for use in a McQuay Controls building automation system. Optional Open Protocol Open Protocol is a commitment from McQuay International to provide a cost effective means to building automation through a strategic and joint effort with major temperature control companies. Open Protocol provides an interface between one or multiple MicroTech controllers and the building automation system. The result can be reduced installation costs, greater reliability and a seamless operator interface with all equipment in the building. A nominal licensing fee per site is required (license Part Number ). Open Protocol Master (OPM) (Part Number ) The MicroTech Open Protocol Master (OPM) panel is usually required to provide the temperature control company a single-point connection when two or more MicroTech controllers are being networked with the temperature control company's system. MicroTech BACdrop Gateway 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 ) 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. Product Manual ALS-4 ALS 141C 420C 9

10 Design Advantages Ultra-low Sound Levels The issue of objectionable sound or "noise" can no longer be treated lightly as manufacturers may have done in the past. To an owner, sound levels can be as important as unit efficiency and must be addressed prior to the start of any development program. Concentrated efforts to design the quietest air-cooled chiller in the market has paid off with the ALS chiller line. Unique compressor and system design allow the ALS air-cooled chiller to produce sound levels considerably lower than competitive reciprocating and twin-screw compressor units in the market today. The gaterotor material is manufactured from an advanced engineered composite, and the difference in material density and coefficient of elasticity from the main screw rotor reduces noise levels through the compression chamber. The discharge housing is designed as a "tuned sound attenuator" to cancel out any noise pulsation. Also, the rotor injection attenuates sound levels within the compressor. Balanced Forces on Compressor The single-screw compressor has a well-balanced compression mechanism that cancels the screw rotor load in both the radial and axial directions. Inherent to the basic single-screw compressor design is the virtually load free operation that gives main bearings a design life 3-4 times greater than twin-screws, and eliminates expensive and complicated thrust balancing schemes. The two exactly opposed gaterotors create two exactly opposed compression cycles. Compression is made at the lower and upper parts of the screw rotor at the same time, thus canceling the radial loads. Also, both ends of the screw rotor are subjected to suction pressure only, which cancels the axial loads and eliminates the huge thrust loads inherent in twin-screw compressors. Figure 2, Balanced Forces Screw Gaterotor Gaterotor Reliable Bearing Design Since the main rotor shaft and gaterotor shafts cross at right angles in the single-screw compressor, sufficient space to locate each bearing is obtained. Because of this unique characteristic for the single-screw compressor, bearing life can be designed much higher compared to twin-screws. 10 ALS 141C 420C Product Manual ALS-4

11 Tolerant of Liquid Return Tolerance to liquid return is provided by the heavy construction of the screw components and by McQuay's Compliant Gate feature. If any liquid starts to enter the main rotor, the build up of pressure immediately causes the gate rotor to raise off the main rotor against spring pressure. This relieves the refrigerant pressure and the refrigerant is pumped out. When the refrigerant has been discharged, the spring returns the gaterotor to its normal position. This increases system reliability because it permits normal operation under abnormal conditions that would be catastrophic (liquid return) for many other compressor designs. 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. Low Vibration Levels The extremely low vibration levels, inherent with the single-screw design, will not pass through system piping and allow objectionable resonated sound to be carried into the building. Because the moving components in the McQuay ALS screw compressor are purely rotational, the dynamic forces and vibration created by the system are very low. This reduced vibration results in less movement to refrigerant lines and other parts of the system. The vibration limit on the test stand is 0.14 in/sec (3.56 mm/sec) and compressors test far below this limit. Liquid Refrigerant-Cooled Motor The compressor motor for the ALS screw chiller is liquid-refrigerant cooled. The liquid refrigerant allows the motor to operate at lower temperatures and enhances system reliability and motor life when compared to suction gas-cooled designs found on twin-screw or competitor's reciprocating compressors. Wide Application Range The capability to handle wide application ranges makes the ALS screw chiller a superior choice for comfort cooling, ice storage, and process applications. McQuay International has been a proven leader in chiller applications and once again has developed a line of chillers unsurpassed in performance and quality. Product Manual ALS-4 ALS 141C 420C 11

12 Selection Procedures 60 Hz - I-P Units The Performance Data on the following pages are based on a 10 degree F (5.5 degree C) delta-t through the evaporator (2.4 gpm/ton). Adjustment factors for other delta-ts can be found in Table 3. The minimum leaving chilled water temperature without glycol is 40.0 F (4.4 C). For brine selections refer to Table 1 and Table 2 for ethylene or propylene glycol adjustment factors. Ratings are based on a ft 2 x hr x F/BTU ( m 2 x C/kW) fouling factor in the evaporator and sea level operation. For other fouling factors or elevations refer to Table 3. For applications outside the catalog ratings contact your local McQuay sales representative. Selection Example Given: 120 tons 95 F ambient air temperature, 4,000 feet elevation 288 gpm, 54 F to 44 F, evaporator fouling factor 1. Use the following formula (for water only) to calculate any missing elements: (gpm x delta-t) /24 = tons 2. From Performance Data R-22, IP Units Table 4, an ALS 141C at the given conditions will produce tons with a compressor kw input of and a unit EER of 9.6. Correct for elevation from Table 3: Capacity: tons x = tons Power: kw x = kw EER = Output / Input = 9.6 x / = Determine the evaporator pressure drop. Using Figure 3, enter at 288 gpm and follow up to the ALS 141C line intersect. Read horizontally to obtain an evaporator pressure drop of 11.5ft. Selection example utilizing ethylene glycol Given: 150 tons, 95 F ambient temperature 56 F to 44 F chilled fluid temperature evaporator fouling factor. Protect against freezing to 0 F 1. From Table 1 select an ethylene glycol concentration of 40% to protect to 0 F. 2. Adjustment factors at 40% glycol: Capacity = 0.961, Power = 0.976, Flow = 1.121, Pressure Drop = Adjustment Factor for 12 degree chilled water range from Table 3 is Capacity, Power. 12 ALS 141C 420C Product Manual ALS-4

13 4. Select an ALS 171C with a capacity of tons and correct with 40% ethylene glycol factors. Correct capacity: x x tons = tons. Correct compressor power: x x kw = kw 5. Correct chilled fluid flow: Fluid flow (water) at 150 tons gpm (water) = (tons x 24) / delta-t gpm = (150 tons x 24) / 12 degrees = 300 gpm Fluid flow (40% EG solution): 300 gpm (water) x flow correction factor = 336 gpm (ethylene glycol) 6. Determine the evaporator pressure drop. Using Figure 3, enter at 300 gpm (water) and follow to the ALS 171C line intersect. Read horizontally to obtain an evaporator pressure drop of 9.6 ft. 7. Correct the pressure drop for 40% EG solution: 9.6 ft x pressure drop correction factor = 12.1 ft for ethylene glycol. Performance Adjustment Factors Ethylene and Propylene Glycol Factors ALS chiller units are designed to operate with leaving chilled fluid temperatures of 20.0 F to 60.0 F (-6.7 C to 15.5 C). Leaving chilled fluid temperatures below 40 F (4.4 C) result in evaporating temperatures at or below the freezing point of water and a glycol solution is required. McQuay also recommends double insulation, and the system designer should determine its necessity. The use of glycol will reduce the performance of the unit depending on its concentration. This should be taken into consideration during initial system design. On glycol applications the supplier normally recommends that a minimum of 25% solution by weight be used for protection against corrosion. Altitude Correction Factors Performance tables are based on sea level altitude. At elevations higher than sea level, the performance of the unit will be decreased due to the lower air density. For performance at elevations other than sea level refer to Table 3. Evaporator Temperature Drop Factors Performance tables are based on a 10 degree F (5.6 degree C) temperature drop through the evaporator. Other delta-ts will require adjustment factors found in Table 3. Temperature drops outside a 6 to 16 degree F (3.3 to 8.9 degree C) range may adversely affect the system's capability to maintain acceptable control and are not recommended. The maximum water temperature that can be circulated through the evaporator in a nonoperating mode is 100 F (37.8 C). High temperatures can result in poor performance and damage to the equipment. Product Manual ALS-4 ALS 141C 420C 13

14 Fouling Factor Performance tables are based on water with a fouling factor of ft 2 x hr x F/BTU ( m 2 x C/kW) per ARI 550/ As fouling is increased, performance decreases. For performance at other fouling factors refer to Table 3. Foreign matter in the chilled water system will adversely affect the heat transfer capability of the evaporator and could increase the pressure drop and reduce the water flow. For optimum unit operation, proper water treatment and filtration must be maintained. Table 1, Ethylene Glycol % Freeze Point E.G. F C Capacity Power Flow PD Table 2, Propylene Glycol % Freeze Point P.G. F C Capacity Power Flow PD Units operating with glycol are not included in the ARI Certification Program Table 3, Correction Factors ALTITUDE Chilled Water Fouling Factor Delta-T (0.0176) (0.044) (0.132) (0.308) F C Cap. Power Cap. Power Cap. Power Cap. Power SEA LEVEL feet (610 m) feet (1220 m) feet (1830 m) ALS 141C 420C Product Manual ALS-4

15 Performance Data R-22, IP Units Table 4, ALS 141C ALS 218C AMBIENT AIR TEMPERATURE ALS LWT 75 F 85 F 95 F 105 F 115 F SIZE ( F) Cap. PWR Cap. PWR Cap. PWR Cap. PWR Cap. PWR EER EER EER EER Tons kwi Tons kwi Tons kwi Tons kwi Tons kwi C C C C C C C C NOTES: 1. Rated in accordance with ARI Standard 550/590. Shaded and bold ratings are certified in accordance with the ARI Water-Chilling Packages Using the Vapor Compression Cycle Certification Program, which is based on ARI Standard 550/ Units with remote evaporators are not included in the ARI Certification Program. 3. Ratings based on HCFC-22, evaporator fouling factor of , 10 degree delta-t, evaporator flow of 2.4 gpm/ton and sea level altitude. 4. For units with SpeedTrol option multiply capacity and EER by For units operating at 208 volt, multiply capacity by Interpolation is allowed, extrapolation is not permitted. Consult McQuay for performance outside the cataloged ratings. 6. KW input is for compressors only. EER is for the entire unit, including compressors, fan motors and control power. Total power to the unit can be calculated by: kw = tons x 12 / EER 7. Compressor loading and unloading is adaptively determined by system load, ambient air temperature, and other inputs to the MicroTech control algorithms. EER Product Manual ALS-4 ALS 141C 420C 15

16 Table 5, ALS 245C ALS 350C, I-P Units AMBIENT AIR TEMPERATURE ALS LWT 75 F 85 F 95 F 105 F 115 F SIZE ( F) Cap. PWR Cap. PWR Cap. PWR Cap. PWR Cap. PWR EER EER EER EER Tons kwi Tons kwi Tons kwi Tons kwi Tons kwi C C C C C C C C NOTES: 1. Rated in accordance with ARI Standard 550/590. Shaded and bold ratings are certified in accordance with the ARI Water-Chilling Packages Using the Vapor Compression Cycle Certification Program, which is based on ARI Standard 550/ Units with remote evaporators are not included in the ARI Certification Program. 3. Ratings based on HCFC-22, evaporator fouling factor of , 10 degree delta-t, evaporator flow of 2.4 gpm/ton and sea level altitude. 4. For units with SpeedTrol option multiply capacity and EER by For units operating at 208 volt, multiply capacity by Interpolation is allowed, extrapolation is not permitted. Consult McQuay for performance outside the cataloged ratings. 7. KW input is for compressors only. EER is for the entire unit, including compressors, fan motors and control power. Total power to the unit can be calculated by: kw = tons x 12 / EER 8. Ratings are valid for operation on 3 phase, 60 Hz, and 208//230/380/460/575 volts. 9. Compressor loading and unloading is adaptively determined by system load, ambient air temperature, and other inputs to the MicroTech control algorithms. EER 16 ALS 141C 420C Product Manual ALS-4

17 Table 6, ALS 365C ALS 420C, I-P Units AMBIENT AIR TEMPERATURE ALS LWT 75 F 85 F 95 F 105 F 115 F SIZE ( F) Cap. PWR Cap. PWR Cap. PWR Cap. PWR Cap. PWR EER EER EER EER Tons kwi Tons kwi Tons kwi Tons kwi Tons kwi C x C x C x C x C x NOTES: 1. Rated in accordance with ARI Standard 550/590. Shaded and bold ratings are certified in accordance with the ARI Water-Chilling Packages Using the Vapor Compression Cycle Certification Program, which is based on ARI Standard 550/ Units with remote evaporators are not included in the ARI Certification Program. 3. Ratings based on HCFC-22, evaporator fouling factor of , 10 degree delta-t, evaporator flow of 2.4 gpm/ton and sea level altitude. 4. For units with SpeedTrol option multiply capacity and EER by For units operating at 208 volt, multiply capacity by Interpolation is allowed, extrapolation is not permitted. Consult McQuay for performance outside the cataloged ratings. 7. KW input is for compressors only. EER is for the entire unit, including compressors, fan motors and control power. Total power to the unit can be calculated by: kw = tons x 12 / EER 8. Ratings are valid for operation on 3 phase, 60 Hz, and 208//230/380/460/575 volts. 9. Compressor loading and unloading is adaptively determined by system load, ambient air temperature, and other inputs to the MicroTech control algorithms. EER Product Manual ALS-4 ALS 141C 420C 17

18 R-22, SI Units Table 7, ALS 141C - ALS 218C AMBIENT AIR TEMPERATURE ALS LWT 30 C (86 F) 35 C (95 F) 40 C (104 F) 45 C (113 F) 50 C (122 F) SIZE C ( F) Cap. PWR Cap. PWR Cap. PWR Cap. PWR Cap. PWR COP COP COP COP kw kwi kw kwi kw kwi kw kwi kw kwi COP 5.0 (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) NOTES: 1. Rated in accordance with ARI Standard 550/ Units with remote evaporators are not included in the ARI Certification Program. 3. Ratings based on HCFC-22, evaporator fouling factor of , 5.8 C degree delta-t, and sea level altitude. 4. For units with SpeedTrol option multiply capacity and COP by For units operating at 208 volt, multiply capacity by Interpolation is allowed, extrapolation is not permitted. Consult McQuay for performance outside the cataloged ratings. 7. KW input is for compressors only. COP is for the entire unit, including compressors, fan motors and control power. Total power to the unit can be calculated by: kw = kw(output) / COP. 8. Ratings are valid for operation on 3 phase, 60 Hz, and 208//230/380/460/575 volts. 9. Compressor loading and unloading is adaptively determined by system load, ambient air temperature, and other inputs to the MicroTech control algorithms. 18 ALS 141C 420C Product Manual ALS-4

19 Table 8, ALS 245C - ALS 350C, SI Units AMBIENT AIR TEMPERATURE ALS LWT 30 C (86 F) 35 C (95 F) 40 C (104 F) 45 C (113 F) 50 C (122 F) SIZE C ( F) Cap. PWR Cap. PWR Cap. PWR Cap. PWR Cap. PWR COP COP COP COP kw kwi kw kwi kw kwi kw kwi kw kwi COP 5.0 (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) NOTES: 1. Rated in accordance with ARI Standard 550/ Units with remote evaporators are not included in the ARI Certification Program. 3. Ratings based on HCFC-22, evaporator fouling factor of , 5.8 C degree delta-t, and sea level altitude. 4. For units with SpeedTrol option multiply capacity and COP by For units operating at 208 volt, multiply capacity by Interpolation is allowed, extrapolation is not permitted. Consult McQuay for performance outside the cataloged ratings. 7. KW input is for compressors only. COP is for the entire unit, including compressors, fan motors and control power. Total power to the unit can be calculated by: kw = kw(output) / COP. 8. Ratings are valid for operation on 3 phase, 60 Hz, and 208//230/380/460/575 volts. 9. Compressor loading and unloading is adaptively determined by system load, ambient air temperature, and other inputs to the MicroTech control algorithms. Product Manual ALS-4 ALS 141C 420C 19

20 Table 9, ALS 365C - ALS 420C, SI Units AMBIENT AIR TEMPERATURE ALS LWT 30 C (86 F) 35 C (95 F) 40 C (104 F) 45 C (113 F) 50 C (122 F) SIZE C ( F) Cap. PWR Cap. PWR Cap. PWR Cap. PWR Cap. PWR COP COP COP COP kw kwi kw kwi kw kwi kw kwi kw kwi COP 5.0 (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) (41.0) (42.8) C 7.0 (44.6) (46.4) (48.2) (50.0) NOTES: 1. Rated in accordance with ARI Standard 550/ Units with remote evaporators are not included in the ARI Certification Program. 3. Ratings based on HCFC-22, evaporator fouling factor of , 5.8 C degree delta-t, and sea level altitude. 4. For units with SpeedTrol option multiply capacity and COP by For units operating at 208 volt, multiply capacity by Interpolation is allowed, extrapolation is not permitted. Consult McQuay for performance outside the cataloged ratings. 7. KW input is for compressors only. COP is for the entire unit, including compressors, fan motors and control power. Total power to the unit can be calculated by: kw = kw(output) / COP. 8. Ratings are valid for operation on 3 phase, 60 Hz, and 208//230/380/460/575 volts. 9. Compressor loading and unloading is adaptively determined by system load, ambient air temperature, and other inputs to the MicroTech control algorithms. 20 ALS 141C 420C Product Manual ALS-4

21 Table 10, ALS 141C ALS 420C, R-22 Unit Capacity Power Unit Capacity Power % Load Size Tons Unit kw EER IPLV Size % Load Tons Unit kw EER IPLV C C C C C C C C C C C C C C C C C C C C C NOTES: 1. Certified in accordance with the ARI Water-Chilling Packages Using the Vapor Compression Cycle Certification Program, which is based on ARI Standard 550/ Units with remote evaporators are not included in the ARI Certification Program. 3. Compressor unloading is adaptively determined by system load, ambient air temperature, and other inputs to the MicroTech control algorithms. Product Manual ALS-4 ALS 141C 420C 21

22 Pressure Drop Figure 3, Evaporator Pressure Drop, ALS 141C - ALS 420C ALS 206 ALS 420 ALS 141 ALS ALS ALS ALS Minimum/Maximum Flow Rates ALS Unit Size Minimum Flow gpm Pressure Drop ft. Maximum Flow gpm Pressure Drop ft. ALS Unit Size Minimum Flow gpm Pressure Drop ft. Maximum Flow gpm Pressure Drop ft ALS 141C 420C Product Manual ALS-4

23 Sound Data Sound levels can be as important as unit cost and efficiency, and must be addressed before the start of any project design. Efforts by McQuay design engineers to design chillers that are sensitive to the sound requirements of the market, combined with McQuay s inherently quiet rotary screw compressors, have paid off. 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. Sound Pressure Levels - Full Load All sound pressure tables give the overall "A" weighted sound pressure levels which are considered typical of what may be measured in a hemispherical field with a hand held sound meter in the absence of any nearby reflective surfaces other than the ground itself. The sound pressure levels in Table 11 are measured at 30 feet from the side of the unit, at 100% unit load, no reflecting walls (Q=2), and ARI conditions; 95 F (35 C) ambient air temperature and 54/44 F (12/7 C) chilled water temperatures. Sound Power Levels Acoustical consultants may require sound power octave band data to perform a detailed acoustical analysis. Sound measurements are taken over a prescribed area around the unit and the data is mathematically calculated to give the sound power in db. Product Manual ALS-4 ALS 141C 420C 23

24 Table 11, Sound Pressure Octave Band Data, 60 Hz Unit Octave Band & Center Frequency, Hz. Overall Model A-Weighted Note: Data at: r=30 ft.,.sound pressure at 30 feet (9.1 meters) from unit Q=2, unit on a flat roof or ground with no adjacent wall(s). Table 12, Sound Power Octave Band Data, 60 Hz Unit Octave Band & Center Frequency, Hz. Overall Model A-Weighted Note: Sound power octave band data, db per ARI Standard ALS 141C 420C Product Manual ALS-4

25 Sound Reduction Due to Distance from a Unit The distance between a source of sound and the location of the sound measurement plays an important role in minimizing sound problems. The equation below can be used to calculate the sound pressure level at any distance if the sound power is known. Results for typical distances are tabulated in Table 13. Another way of determining the effect of distance is to work from sound pressure only. Q, the directionality factor, is a dimensionless number that compensates for the type of sound reflection from the source. For example, a unit sitting on a flat roof or ground with no other reflective surfaces or attenuation due to grass, snow, etc., between source and receiver: Q=2. Figure 4, "Q" Definition, Plan View, Unit Located in Center Uniform Spherical Radiation Q=1 no reflecting surface Uniform Hemispherical Radiation Q=2 single reflecting surface Uniform Radiation over ¼ of sphere Q=4 two reflecting surfaces Sound pressure can be calculated at any distance from the unit if the sound power is known. Lp = sound pressure Lw = sound power Lp=Lw-(20 log r) + (10 log Q) -.5 r = distance from unit in feet 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) 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) 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 Source DB Reduction from Sound Power at the Source to Sound Pressure at Referenced Distance ft. (m) Q=2 Q=4 30 (9) (15) (23) (30) (46) (61) (91) Figure 5 gives the reduction in sound pressure due to distance. Product Manual ALS-4 ALS 141C 420C 25

26 Figure 5, Sound Pressure Attenuation Due to Distance from Unit Air-Cooled Unit Orientation to Minimize Sound The ALS chiller s sound is directional in nature allowing the contractor/engineer to position the unit to minimize potential noise problems. Because the sound pressure levels are lower at both ends of the unit than at the sides, the chiller should be oriented such that the control box end or end opposite the control box faces the direction where the lowest sound level is required. The control box end provides an excellent acoustic barrier to the compressor sound as it covers one full end of the unit. The sound pressure levels at the control box end will be 5 dba less than on the sides. On the end opposite the control box, the compressor sound is blocked by the coil structure and evaporator and is naturally attenuated by distance as the compressors are located approximately ¾ the length of the unit away from this end. The sound pressure levels at the end opposite the control box will be 4 dba less than on the sides. 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. 26 ALS 141C 420C Product Manual ALS-4

27 Figure 6, Sound Directionality Sound pressure levels per Table 11 Sound pressure levels here 5 dba lower than Table 11 C o n t r Compressor Evaporator Sound pressure levels here 4 dba lower than Table 11 o l Compressor Sound Pressure Levels, Low Ambient Operation Unit operation at a lower ambient temperature than 95 F will also result in lower sound pressure levels. The sound pressure level will decrease approximately 1 dba for ambient air temperatures between 85 F and 94 F, approximately 2 dba for ambient air temperatures between 75 F and 84 F, and approximately 3 dba for ambient air temperatures between 65 F and 74 F. Sound Pressure Levels, Multiple Units Multiple air-cooled unit installations will have a higher sound level than a single unit. Two units will have approximately 3 db higher sound level of one unit, 4 units will be approximately 6 db louder, and 8 units approximately 9 db louder than one unit. Sound Control Walls adjacent to a unit (20 feet {6.1 meters} or less) will reflect sound outwards, increasing the sound pressure on the side away from the wall. This sound increase could be as high as 3 db for one wall and as high as 6 db for a corner location. Unit orientation and/or distance as noted above will decrease sound levels. Sound pressure levels per Table 11 Sound levels can also be controlled by the installation of barrier walls. To be effective as sound blockers, walls must be solid with no open penetrations. Sound tends to leak out of openings. Block walls with filler material and slots on the side facing the unit are especially effective. The wall should be about 10 feet high (two feet higher than the unit) and located at least 10 feet away so as not to affect unit performance. A three-sided enclosure will be the most effective solution and will reduce sound levels by about 10 db. Remember that the wall will increase the sound level on the side opposite it by 3 to 6 db (one or three sided wall). Note: The effect of adjacent walls on air recirculation and restriction must always be considered when employing sound barrier walls. Product Manual ALS-4 ALS 141C 420C 27

28 Electrical Data Table 14, ALS 141C ALS 218C, Electrical Data, Single-Point ALS UNIT SIZE VOLTS HZ MINIMUM CIRCUIT AMPACITY (MCA) POWER SUPPLY FIELD WIRE HUB (Conduit Connection) FIELD FUSE SIZE or HACR BREAKER SIZE QTY WIRE NOMINAL RECOM- QTY GAUGE SIZE MENDED MAXIMUM C / C C /0 See Note C /0 See Note C /0 See Note * 869* 6 600* C /0 See Note * 869* 6 600* C /0 See Note * 897* 6 600* C /0 See Note Notes 1. (*) Table based on 75 C field wire except (*) which require 90 C field wire. 2. A HACR breaker is a circuit breaker designed for use on equipment with multiple motors. It stands for Heating, Air Conditioning, Refrigeration. 3. Complete notes are on page ALS 141C 420C Product Manual ALS-4

29 Table 15, ALS 245C ALS 420C, Electrical Data, Single-Point ALS UNIT SIZE VOLTS Note (1) HZ MINIMUM CIRCUIT AMPACITY (MCA) POWER SUPPLY FIELD WIRE HUB (Conduit Connection) FIELD FUSE SIZE or HACR BREAKER SIZE QTY WIRE NOMINAL RECOM- QTY GAUGE SIZE MENDED MAXIMUM C / C /0 See Note C /0 See Note C /0 See Note C /0 See Note C C C C * 866* 6 600* C * 890* 6 600* C * 914* 6 600* C * 948* 6 600* C NOTES: 1. Table based on 75 C field wire except (*) which require 90 C field wire. 2. Single point connections are not available with 208/230 volt power supply. 3. A HACR breaker is a circuit breaker designed for use on equipment with multiple motors. It stands for Heating, Air Conditioning, Refrigeration. 4. Complete notes are on page 45 Product Manual ALS-4 ALS 141C 420C 29

30 Table 16, ALS 141C ALS 218C, Electrical Data, Multiple-Point ALS UNIT SIZE VOLTS HZ MINIMUM CIRCUIT AMPS (MCA) ELECTRICAL CIRCUIT 1 (COMP 1) ELECTRICAL CIRCUIT 2 (COMP 2) POWER SUPPLY FIELD WIRE QTY WIRE GAUGE HUB (Conduit Connection) QTY HUB SIZE FIELD FUSING REC FUSE SIZE MAX FUSE SIZE MINIMUM CIRCUIT AMPS (MCA) POWER SUPPLY FIELD WIRE QTY WIRE GAUGE HUB (Conduit Connection) QTY HUB SIZE FIELD FUSING REC FUSE SIZE C / / / / / / C / / / / / / / / / C / / / / / / / / / C / / / / / / / /0 See C / / / / / /0 See C / / / / /0 See /0 See C / / / / /0 See /0 See C / / / / NOTE: 1. Table based on 75 C field wire 2. Complete notes are on page 45 MAX FUSE SIZE 30 ALS 141C 420C Product Manual ALS-4

31 Table 17, ALS 245C ALS 295C, Circuits # 1 & 2, Electrical Data, Multiple-Point (Circuit #3 on following page) ALS UNIT SIZE ELECTRICAL CIRCUIT 1 (COMP 1) ELECTRICAL CIRCUIT 2 (COMP 2) FIELD POWER SUPPLY POWER SUPPLY FIELD FUSING FUSING HUB HUB VOLTS HZ MINIMUM MIN. CIRCUIT FIELD WIRE (Conduit CIRCUIT REC MAX FIELD WIRE (Conduit REC MAX AMPS Connection) AMPS FUSE FUSE Connection) FUSE FUSE (MCA) (MCA) WIRE HUB SIZE SIZE WIRE HUB SIZE SIZE QTY QTY QTY QTY GAUGE SIZE GAUGE SIZE / / / / C / / / / / / / / / C / / / / / / / / / / C / / / / / / / / /0 See Note C / / / / / /0 See Note /0 See Note C / / / / NOTE: 1. Table based on 75 C field wire 2. Complete notes are on page 45 Product Manual ALS-4 ALS 141C 420C 31

32 Table 17, Electrical Data, ALS 245C 295C, (Circuit #3) ALS UNIT SIZE VOLTS HZ CIRCUIT MINIMUM AMPS (MCA) ELECTRICAL CIRCUIT 3 (COMP 3) POWER SUPPLY HUB FIELD WIRE (Conduit Connection) WIRE HUB QTY QTY GAUGE SIZE FIELD FUSING REC FUSE SIZE MAX FUSE SIZE / / C / / / / / C / / / /0 See Note C / / /0 See Note C / / /0 See Note C / / NOTES: 1. Table based on 75 C field wire 2. Complete notes are on page ALS 141C 420C Product Manual ALS-4

33 Table 18, ALS 325C ALS 420C, Electrical Data, Multiple-Point ELECTRICAL CIRCUIT 1 (COMP 1 & 3) ELECTRICAL CIRCUIT 2 (COMP 2 & 4) POWER SUPPLY FIELD FUSING POWER SUPPLY FIELD FUSING ALS UNIT SIZE VOLTS HZ MINIMUM CIRCUIT AMPS (MCA) HUB (Conduit Connectio n) MINIMUM CIRCUIT AMPS HUB (Conduit Connection) FIELD WIRE REC MAX FIELD WIRE FUSE FUSE QTY SIZE SIZE (MCA) WIRE HUB WIRE HUB QTY QTY QTY GAUGE SIZE GAUGE SIZE REC FUSE SIZE MAX FUSE SIZE C C C C C * C * 881* 6 600* * 6 600* C * 908* 6 600* * 6 600* C NOTES: 1. Table based on 75 C field wire except (*) which require 90 C field wire. 2. Complete notes are on page 45 Product Manual ALS-4 ALS 141C 420C 33

34 Table 19, ALS141C ALS 218C, Compressor and Condenser Fan Motor Amp Draw ALS UNIT SIZE VOLTS HZ RATED LOAD AMPS CIRCUIT #1 CIRCUIT #2 FAN MOTORS FLA (EACH) NO OF FAN MOTORS L R A FAN MOTORS (EACH) SOLID-STATE STARTING INRUSH AMPS PER COMPRESSOR CIRCUIT #1 CIRCUIT # C C C C C C C C NOTE: Complete notes are on page ALS 141C 420C Product Manual ALS-4

35 Table 20, ALS 245C ALS 295C, Compressor and Condenser Fan Motor Amp Draw ALS UNIT SIZE VOLTS HZ RATED LOAD AMPS COMPRESSORS NO. 1 NO. 2 NO. 3 FAN MOTORS FLA (EACH) NO OF FAN MOTORS SOLID STATE STARTING INRUSH L R A FAN AMPS PER COMPRESSOR MOTORS (EACH) NO. 1 NO. 2 NO C C C C C NOTE: Complete notes are on page 45 Product Manual ALS-4 ALS 141C 420C 35

36 Table 21, ALS 325C ALS 420C, Compressor and Condenser Fan Motor Amp Draw ALS UNIT SIZE VOLTS HZ RATED LOAD AMPS COMPRESSORS NO 1 NO 2 NO 3 NO 4 FAN MOTORS FLA (EACH) NO OF FAN MOTORS SOLID STATE STARTING INRUSH L R A FAN AMPS PER COMPRESSOR MOTORS (EACH) NO 1 NO 2 NO 3 NO C C C C C C C C NOTE: Complete notes are on page ALS 141C 420C Product Manual ALS-4

37 Table 22, ALS 141C ALS 218C, Customer Wiring Information With Single-Point Power ALS UNIT SIZE VOLTS HZ WIRING TO STANDARD UNIT POWER BLOCK TERMINAL SIZE AMPS CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY) WIRING TO OPTIONAL NONFUSED DISCONNECT SWITCH IN UNIT CONNECTOR WIRE RANGE SIZE PER PHASE (COPPER WIRE ONLY) (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM 141C (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 600 MCM 250 (1) 4 to 350 MCM (2) 2 to 600 MCM 800 (2) 500 to 700 MCM (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM 150C (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 600 MCM 800 (2) 500 to 700 MCM (2) 2 to 600 MCM 800 (2) 500 to 700 MCM 171C (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 600 MCM 1200 (3) 500 to 750 MCM (2) 2 to 600 MCM 800 (2) 500 to 700 MCM 186C (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 600 MCM 1200 (3) 500 to 750 MCM (2) 2 to 600 MCM 800 (2) 500 to 700 MCM 190C (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 750 MCM 1200 (3) 500 to 750 MCM (2) 2 to 600 MCM 1200 (3) 500 to 750 MCM 200C (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 750 MCM 1200 (3) 500 to 750 MCM (2) 2 to 600 MCM 1200 (3) 500 to 750 MCM 206C (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM (2) 2 to 750 MCM 1200 (3) 500 to 750 MCM (2) 2 to 600 MCM 1200 (3) 500 to 750 MCM 218C (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 400 (1) 250 to 500 MCM NOTE: 1. Terminal size amps are the maximum amps that the power block is rated for. 2. Complete notes are on page 45 Product Manual ALS-4 ALS 141C 420C 37

38 Table 23, ALS 245C ALS 420C, Customer Wiring Information, Single-Point Power ALS UNIT SIZE VOLTS HZ WIRING TO STANDARD UNIT POWER BLOCK TERMINAL SIZE AMPS CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY) WIRING TO OPTIONAL NONFUSED DISCONNECT SWITCH IN UNIT CONNECTOR WIRE RANGE SIZE PER PHASE (COPPER WIRE ONLY) (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM 245C (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 400 (2) 3/0 to 250 MCM (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM 260C (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM 270C (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM 275C (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 800 (2) 500 to 700 MCM 295C (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 800 (2) 500 to 700 MCM 325C (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 1200 (3) 500 to 750 MCM 335C (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 1200 (3) 500 to 750 MCM 350C (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 600 MCM 1200 (3) 500 to 750 MCM 365C (2) 2 to 600 MCM 800 (2) 500 to 700 MCM (2) 2 to 600 MCM 600 (2) 250 to 350 MCM (2) 2 to 750 MCM 1200 (3) 500 to 750 MCM 375C (2) 2 to 600 MCM 800 (2) 500 to 700 MCM (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM (2) 2 to 750 MCM 1200 (3) 500 to 750 MCM 385C (2) 2 to 600 MCM 1200 (3) 500 to 750 MCM (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM (2) 2 to 750 MCM 1200 (3) 500 to 750 MCM 400C (2) 2 to 600 MCM 1200 (3) 500 to 750 MCM (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM (2) 2 to 750 MCM 1200 (3) 500 to 750 MCM 420C (2) 2 to 600 MCM 1200 (3) 500 to 750 MCM (2) 2 to 600 MCM 800 (3) 3/0 to 400 MCM NOTE: 1. Terminal size amps are the maximum amps that the power block is rated for. 2. Complete notes are on page ALS 141C 420C Product Manual ALS-4

39 Table 24, ALS 141C ALS 218C, Wiring Information with Multiple-Point Power w/o Disconnect ALS UNIT SIZE WIRING TO UNIT POWER BLOCK VOLTS HZ TERMINAL SIZE (AMPS) CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY) CKT 1 CKT 2 CKT 1 CKT (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 141C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 150C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 171C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 186C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 190C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 200C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 206C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 218C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (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 27 for multiple point with Disconnect Switch connections 3. Complete notes are on page 45 Product Manual ALS-4 ALS 141C 420C 39

40 Table 25, ALS 245C ALS 295C, Wiring Information, Multiple-Point Power w/o Disconnect ALS UNIT SIZE VOLTS HZ TERMINBAL SIZE (AMPS) WIRING TO UNIT POWER BLOCK CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY) CKT 1 CKT 2 CKT 3 CKT 1 CKT 2 CKT (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 245C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 260C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 270C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 275C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 295C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (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 ALS 141C 420C Product Manual ALS-4

41 Table 26, ALS 325C 420C, Wiring Information, Multiple-Point Power w/o Disconnect UNIT SIZE VOLTS HZ TERMINAL SIZE (AMPS) WIRING TO UNIT POWER BLOCK POWER BLOCK CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY) ELEC CIRC #1 ELEC CIRC #2 ELEC CIRC #1 ELEC CIRC # (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 325C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 335C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 350C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 365C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 375C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 385C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 750 MCM (2) #2 to 750 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 400C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 750 MCM (2) #2 to 750 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM 420C (2) #2 to 600 MCM (2) #2 to 600 MCM (2) #2 to 600 MCM (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 29 for multiple point with Disconnect Switch connections 3. Complete notes are on page 45 Product Manual ALS-4 ALS 141C 420C 41

42 Table 27, ALS 141C 218C, Wiring Data with Multiple-Point Power w/ Disconnect Switch ALS UNIT SIZE WIRING TO UNIT DISCONNECT SWITCH VOLTS HZ TERMINAL SIZE (AMPS) CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY) CKT 1 CKT 2 CKT 1 CKT (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM 141C (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/ (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM 150C (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/ (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM 171C (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/ (2) 3/0 to 250 MCM (2) 250 to 350 MCM (2) 3/0 to 250 MCM (2) 250 to 350 MCM 186C (1) 4 to 4/0 (1) 4 to 350 MCM (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/ (2) 3/0 to 250 MCM (2) 250 to 350 MCM (2) 3/0 to 250 MCM (2) 250 to 350 MCM 190C (1) 4 to 4/0 (1) 4 to 350 MCM (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/ (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM 200C (1) 4 to 350 MCM (1) 4 to 350 MCM (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/ (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM 206C (1) 4 to 350 MCM (1) 4 to 350 MCM (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/ (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM 218C (1) 4 to 350 MCM (1) 4 to 350 MCM (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/0 NOTE: 1. Terminal size amps are the maximum amps that the disconnect switch is rated for. 2. Complete notes are on page ALS 141C 420C Product Manual ALS-4

43 Table 28, ALS 245C 295C, Customer Wiring, Multiple-Point Power w/ Disconnect Switch ALS UNIT SIZE VOLTS HZ TERMINBAL SIZE (AMPS) WIRING TO UNIT DISCONNECT SWITCH CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY) CKT 1 CKT 2 CKT 3 CKT 1 CKT 2 CKT (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM 245C (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/ (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM 260C (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/ (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 250 to 350 MCM (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (2) 250 to 350 MCM 270C (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 350 MCM (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/ (2) 3/0 to 250 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 3/0 to 250 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM 275C (1) 4 to 4/0 (1) 4 to 350 MCM (1) 4 to 350 MCM (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/ (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/ (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM 295C (1) 4 to 350 MCM (1) 4 to 350 MCM (1) 4 to 350 MCM (1) 4 to 4/0 (1) 4 to 4/0 (1) 4 to 4/ (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 Product Manual ALS-4 ALS 141C 420C 43

44 Table 29, ALS 315C 420C, Wiring Data, Multiple-Point Power w/disconnect Switch UNIT SIZE VOLTS HZ TERMINAL SIZE (AMPS) WIRING TO UNIT DISCONNECT SWITCH POWER BLOCK CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY) ELEC CIRC 1 ELEC CIRC 2 ELEC CIRC 1 ELEC CIRC (2) 500 to 700 MCM (2) 500 to 700 MCM (3) 3/0 to 400 MCM (3) 3/0 to 400 MCM 325C (2) 3/0 to 250 MCM (2) 3/0 to 250 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (2) 500 to 700 MCM (2) 500 to 700 MCM (2) 500 to 700 MCM (2) 500 to 700 MCM 335C (2) 3/0 to 250 MCM (2) 250 to 350 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (2) 500 to 700 MCM (2) 500 to 700 MCM (2) 500 to 700 MCM (2) 500 to 700 MCM 350C (2) 250 to 350 MCM (2) 250 to 350 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (2) 500 to 700 MCM (3) 500 to 750 MCM (2) 500 to 700 MCM (2) 500 to 700 MCM 365C (2) 250 to 350 MCM (2) 250 to 350 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (3) 500 to 750 MCM (3) 500 to 750 MCM (2) 500 to 700 MCM (2) 500 to 700 MCM 375C (2) 250 to 350 MCM (2) 250 to 350 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (3) 500 to 750 MCM (3) 500 to 750 MCM (2) 500 to 700 MCM (3) 500 to 750 MCM 385C (2) 250 to 350 MCM (2) 250 to 350 MCM (1) 250 to 500 MCM (2) 250 to 350 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (3) 500 to 750 MCM (3) 500 to 750 MCM (3) 500 to 750 MCM (3) 500 to 750 MCM 400C (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM (3) 500 to 750 MCM (3) 500 to 750 MCM (3) 500 to 750 MCM (3) 500 to 750 MCM 420C (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM (2) 250 to 350 MCM (1) 250 to 500 MCM (1) 250 to 500 MCM NOTES: 1. Terminal size amps are the maximum amps that the disconnect switch is rated for. 2. Complete notes are on page ALS 141C 420C Product Manual ALS-4

45 Electrical Data Notes 1. Allowable voltage limits Unit nameplate 208V/60Hz/3PH: 187V to 229V Unit nameplate 230V/60Hz/3Ph: 207V to 253V Unit nameplate 380V/60Hz/3Ph: 342V to 418V Unit nameplate 460V/60Hz/3Ph: 414V to 506V Unit nameplate 575V/60Hz/3Ph: 517V to 633V 2. 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 control transformer. Wire size ampacity for separate 115V control circuit power is 15 amps for ALS 141C through ALS 218C. 3. Compressor RLA values are for wire sizing purposes only but do reflect normal operating current draw at unit rated capacity. If unit is equipped with SpeedTrol condenser fan motors, the first motor on each refrigerant circuit is a single phase, 1 hp motor, with a FLA of 2.8 amps at 460 volts (5.6 amps at 208/230 volts). If the unit is not equipped with SpeedTrol, the standard fan motor will be 1 1/2 hp, 3-phase (for ALS 141C-295C except ALS 218C which will be 2 hp, 3-phase) with FLA as shown in the electrical tables. For ALS 325C-420C the standard fan motor will be 2 hp, 3-phase. 4. If the unit is equipped with SpeedTrol motors, the first motor on each refrigerant circuit is a single phase, 1 hp motor, with a LRA of 7.3 amps at 460 volts (14.5 amps at 208/230 volts). If the unit is not equipped with SpeedTrol, the standard fan motor will be 1 1/2 hp, 3-phase with a LRA as shown in the electrical tables. 5. Single point power supply requires a single disconnect to supply electrical power to the unit. This power must be fused. 6. Multiple point power supply requires two independent power circuits on ALS 141C-ALS 218C, ALS 325C-ALS 420C and three independent power circuits on ALS 245C-ALS 295C each with separate fused disconnects and a separate control circuit. 7. All field wiring to unit power block or optional nonfused disconnect switch must be copper. 8. Field wire size values given in tables apply to 75 C rated wire per NEC except for ALS 200C-ALS 218C for 208V single point, ALS 375C-ALS 420C for 380V single point, and ALS 400C-ALS420C for 208V multi-point application which require 90 C rated wire or as noted. 9. External disconnect switch(s) or HACR breakers must be field supplied. Note: On single point power units a non-fused disconnect switch in the cabinet is available as an option. 10. All wiring must be done in accordance with applicable local and national codes. 11. Recommended time delay fuse size or HACR circuit breakers is equal to 150% of the largest compressor motor RLA plus 100% of remaining compressor RLAs and the sum of condenser fan FLAs. 12. Maximum time delay fuse size or HACR circuit breakers is equal to 225% of the largest compressor-motor RLA plus 100% of remaining compressor RLAs and the sum of condenser fan FLAs. 13. MCA may vary slightly due to fan motor options such as Speedtrol, TEFC. Product Manual ALS-4 ALS 141C 420C 45

46 Field Wiring Diagram Figure 7, Typical Field Wiring Diagram 46 ALS 141C 420C Product Manual ALS-4

47 Physical Data Table 30, Physical Data, ALS 141C ALS 186C ALS MODEL NUMBER DATA 141C 150C 171C 186C Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2 BASIC DATA Unit ARI Conditions, tons (436) (489) (545) 170 (595) Unit Operating Charge R-22, lbs (kg) 140 (63.5) 140 (63.5) 140 (63.5) 150 (68.1) 150 (68.1) 150 (68.1) 150 (68.1) 160 (72.6) Cabinet Dimensions x 83.4 x x 83.4 x x 83.4 x x 83.4 x 92.5 Unit Operating Weight, lbs. (kg) 9700 (4395) 9880 (4475) 9890 (4480) 9900 (4485) Unit Shipping Weight, lbs (kg) 9420 (4270) 9550 (4325) 9560 (4330) 9570 (4335) COMPRESSORS, SCREW, SEMI-HERMETIC Nominal Capacity, tons (kw) 65 (230) 65 (230) 65 (230) 80 (280) 80 (280) 80 (280) 80 (280) 95 (335) CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER Coil Face Area, ft. (m 2 ) (10.7) (10.7) (10.7) (10.7) (10.7) (10.7) (10.7) (10.7) Finned Height x Finned Length 80 x x x x x x x x 208 Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE No. of Fans -- Fan Diameter, in. (mm) (711) (711) (711) (711) No. of Motors -- hp (kw) (1.1) (1.1) (1.1) (1.1) Fan & Motor RPM, 60Hz Hz Fan Tip Speed, fpm Hz Total Unit Airflow, ft 3 /sec EVAPORATOR, DIRECT EXPANSION Shell Dia.-Tube Length Evaporator R-22 Charge lbs (kg) 34 (15.4) 34 (15.4) 45 (20.4) 45 (20.4) 45 (20.4) 45 (20.4) 45 (20.4) 45 (20.4) Water Volume, gallons (liters) 34 (129) 40 (151) 40 (151) 40 (151) Max. Water Pressure, psi (kpa) 152 (1048) 152 (1048) 152 (1048) 152 (1048) Max. Refrigerant Pressure, psi (kpa) 300 (2068) 300 (2068) 300 (2068) 300 (2068) Table 31, Physical Data, ALS 190C ALS 218C ALS MODEL NUMBER DATA 190C 200C 206C 218C Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2 BASIC DATA Unit ARI Conditions, tons (606) (645) (666) (715) Unit Operating Charge R-22, lbs (kg) 170 (77.0) 180 (81.5) 180 (81.5) 180 (81.5) 185 (83.8) 185 (83.8) 210 (95.1) 210 (95.1) Cabinet Dimensions, x 83.4 x x 83.4 x x 83.4 x x 83.4 x 92.5 Unit Operating Weight, lbs. (kg) (4810) (4815) (4965) (5230) Unit Shipping Weight, lbs (kg) (4660) (4665) (4755) (4860) COMPRESSORS, SCREW, SEMI-HERMETIC Nominal Capacity, tons (kw) 80 (280) 95 (335) 95 (335) 95 (335) 95 (335) 95 (335) 95 (335) 95 (335) CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER Coil Face Area, ft. (m 2 ) (12.5) (12.5) (12.5) (12.5) (12.5) (12.5) (12.5) (12.5) Finned Height x Finned Length 80 x x x x x x x x 243 Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE No. of Fans -- Fan Diameter, in. (mm) (711) (711) (711) (711) No. of Motors -- hp (kw) (1.1) (1.1) (1.1) (1.5) Fan & Motor RPM, 60Hz Hz Fan Tip Speed, fpm Hz Total Unit Airflow, ft 3 /sec EVAPORATOR, DIRECT EXPANSION Shell Dia. -- Tube Length Evaporator R-22 Charge lbs (kg) 45 (20.4) 45 (20.4) 45 (20.4) 45 (20.4) 57 (25.8) 57 (25.8) 68 (30.8) 68 (30.8) Water Volume, gallons (liters) 40 (151) 40 (151) 55 (208) 98 (371) Max. Water Pressure, psi (kpa) 152 (1048) 152 (1048) 152 (1048) 152 (1048) Max. Refrigerant Pressure, psi (kpa) 300 (2068) 300 (2068) 300 (2068) 300 (2068) Product Manual ALS-4 ALS 141C 420C 47

48 Table 32, Physical Data, ALS 245C ALS 270C ALS MODEL NUMBER DATA 245C 260C 270C Ckt. 1 Ckt. 2 Ckt. 3 Ckt. 1 Ckt. 2 Ckt. 3 Ckt. 1 Ckt. 2 Ckt. 3 BASIC DATA Unit ARI Conditions, tons (790) (839) (886) (kw) Unit Operating Charge R-22, lbs (kg) 140 (63.5) 150 (68.1) 150 (68.1) 150 (68.1) 150 (68.1) 150 (68.1) 150 (68.1) 150 (68.1) 160 (72.6) Cabinet Dimensions, L x W x H, in. (mm) 355 x 83.4 x 94.5 (9017 x 2118 x 2400) 355 x 83.4 x 94.5 (9017 x 2118 x 2400) 355 x 83.4 x 94.5 (9017 x 2118 x 2400) Unit Operating Weight, lbs. (kg) (6725) (6730) (6740) Unit Shipping Weight, lbs (kg) (6355) (6360) (6385) COMPRESSORS, SCREW, SEMI-HERMETIC Nominal Capacity, tons (kw) 65 (230) 80 (280) 80 (280) 80 (280) 80 (280) 80 (280) 80 (280) 80 (280) 95 (335) CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER Coil Face Area, ft. (m 2 ) (10.7) (10.7) (10.7) (10.7) (10.7) (10.7) (10.7) (10.7) (10.7) Finned Height x Finned Length ft. (mm) 80 x 208 (2032 x 5283) 80 x 208 (2032 x 5283) 160 x 104 (4064 x 2642) 80 x 208 (2032 x 5283) 80 x 208 (2032 x 5283) 160 x 104 (4064 x 2642) 80 x 208 (2032 x 5283) 80 x 208 (2032 x 5283) 160 x 104 (4064 x 2642) Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE No. of Fans -- Fan Diameter, in. (mm) (711) (711) (711) No. of Motors -- hp (kw) (1.1) (1.1) (1.1) Fan & Motor RPM, 60Hz Hz Fan Tip Speed, fpm Hz Total Unit Airflow, ft 3 /sec EVAPORATOR, DIRECT EXPANSION Shell Dia. -- Tube Length in.(mm) - in. (mm) ( ) ( ) ( ) Evaporator R-22 Charge lbs (kg) 47 (21.3) 47 (21.3) 47 (21.3) 47 (21.3) 47 (21.3) 47 (21.3) 52 (23.6) 52 (23.6) 52 (23.6) Water Volume, gallons (liters) 98 (371) 98 (371) 94 (356) Max. Water Pressure, psi (kpa) 152 (1048) 152 (1048) 152 (1048) Max. Refrigerant Pressure, psi (kpa) 300 (2068) 300 (2068) 300 (2068) Table 33, Physical Data, ALS 275C ALS 295C ALS MODEL NUMBER DATA 275C 295C Ckt. 1 Ckt. 2 Ckt. 3 Ckt. 1 Ckt. 2 Ckt. 3 BASIC DATA Unit ARI Conditions, tons (921) (964) (kw) Unit Operating Charge R-22, lbs (kg) 150 (68.1) 160 (72.6) 160 (72.6) 160 (72.6) 160 (72.6) 160 (72.6) Cabinet Dimensions, L x W x H, in. (mm) 355 x 83.4 x 94.5 (9017 x 2118 x 2400) 355 x 83.4 x 94.5 (9017 x 2118 x 2400) Unit Operating Weight, lbs. (kg) (6745) (6750) Unit Shipping Weight, lbs (kg) (6390) (6390) COMPRESSORS, SCREW, SEMI-HERMETIC Nominal Capacity, tons (kw) 80 (280) 95 (335) 95 (335) 95 (335) 95 (335) 95 (335) CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER Coil Face Area, ft. (m 2 ) (10.7) (10.7) (10.7) (10.7) (10.7) (10.7) Finned Height x Finned Length ft. (mm) 80 x 208 (2032 x 5283) 80 x 208 (2032 x 5283) 160 x 104 (4064 x 2642) 80 x 208 (2032 x 5283) 80 x 208 (2032 x 5283) 160 x 104 (4064 x 2642) Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE No. of Fans -- Fan Diameter, in. (mm) (711) (711) No. of Motors -- hp (kw) (1.1) (1.1) Fan & Motor RPM, 60Hz Hz Fan Tip Speed, fpm Hz Total Unit Airflow, ft 3 /sec EVAPORATOR, DIRECT EXPANSION Shell Dia. -- Tube Length in.(mm) - in. (mm) ( ) ( ) Evaporator R-22 Charge lbs (kg) 52 (23.6) 52 (23.6) 52 (23.6) 52 (23.6) 52 (23.6) 52 (23.6) Water Volume, gallons (liters) 94 (356) 94 (356) Max. Water Pressure, psi (kpa) 152 (1048) 152 (1048) Max. Refrigerant Pressure, psi (kpa) 300 (2068) 300 (2068) 48 ALS 141C 420C Product Manual ALS-4

49 Table 34, Physical Data, ALS 325C ALS 365C ALS MODEL NUMBER DATA 325C 335C 350C 365C Ckt 1 Ckt 2 Ckt 3 Ckt 4 Ckt 1 Ckt 2 Ckt 3 Ckt 4 Ckt 1 Ckt 2 Ckt 3 Ckt 4 Ckt 1 Ckt 2 Ckt 3 Ckt 4 BASIC DATA Unit ARI Conditions, tons (kw) (1038) (1080) (1130) (1162) Unit Operating Charge R-22, lbs (kg) Cabinet Dimensions, L x W x H, in. (mm) Operating Wt., lbs (kg) 155 (70.3) 155 (70.3) 160 (72.6) x 83.4 x 94.5 (11646 x 2118 x 2400) 160 (72.6) 155 (70.3) 160 (72.6) 160 (72.6) x 83.4 x 94.5 (11646 x 2118 x 2400) 160 (72.6) 160 (72.6) 160 (72.6) 160 (72.6) x 83.4 x 94.5 (11646 x 2118 x 2400) 160 (72.6) 160 (72.6) 160 (72.6) 160 (72.6) x 83.4 x 94.5 (11646 x 2118 x 2400) (8735) (8740) (8740) (8740) Shipping Wt., lbs (kg) (8300) (8305) (8305) (8310) COMPRESSORS, SCREW, SEMI-HERMETIC Nominal Capacity, tons (kw) 65 (230) 65 (230) 80 (280) 80 (280) 65 (230) 80 (280) 80 (280) 80 (280) CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER Coil Face Area, ft. (m 2) 96.3 (8.9) Finned Height x Finned Length ft. (mm) 80x173 (2032x 4394) 96.3 (8.9) 80x173 (2032x 4394) 96.3 (8.9) 80x173 (2032x 4394) 96.3 (8.9) 80x173 (2032x 4394) 96.3 (8.9) 80x173 (2032x 4394) 96.3 (8.9) 80x173 (2032x 4394) 96.3 (8.9) 80x173 (2032x 4394) 96.3 (8.9) 80x173 (2032x 4394) 80 (280) 96.3 (8.9) 80x173 (2032x 4394) 80 (280) 96.3 (8.9) 80x173 (2032x 4394) 80 (280) 96.3 (8.9) 80x173 (2032x 4394) 80 (280) 96.3 (8.9) 80x173 (2032x 4394) 80 (280) 96.3 (8.9) 80x173 (2032x 4394) 80 (280) 96.3 (8.9) 80x173 (2032x 4394) 80 (280) 96.3 (8.9) 80x173 (2032x 4394) 170 (77.1) 95 (335) 96.3 (8.9) 80x173 (2032x 4394) Fins Per Inch x Rows 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE Fan Qty., Dia. in (711) (711) (711) (711) (mm) No. of Motors, hp (1.5) (1.5) (1.5) (1.5) (kw) Fan & Motor RPM Fan Tip Speed, fpm Unit Airflow, ft 3 /sec EVAPORATOR, DIRECT EXPANSION Shell Dia. -- Tube Length in.(mm) - ft. (mm) Evaporator R-22 Charge lbs (kg) Water Volume, gallons (liters) Max. Water Pressure, psi (kpa) Max. Refrigerant Pressure, psi (kpa) 49 (22.2) ( ) 49 (22.2) 49 (22.2) 49 (22.2) 49 (22.2) ( ) 49 (22.2) 49 (22.2) 49 (22.2) 49 (22.2) ( ) 49 (22.2) 49 (22.2) 49 (22.2) 49 (22.2) ( ) 49 (22.2) 115 (435) 115 (435) 115 (435) 115 (435) 152 (1048) 152 (1048) 152 (1048) 152 (1048) 300 (2068) 300 (2068) 300 (2068) 300 (2068) 49 (22.2) 49 (22.2) Product Manual ALS-4 ALS 141C 420C 49

50 Table 35, Physical Data, ALS 375C ALS 420C ALS MODEL NUMBER DATA 375C 385C 400C 420C Ckt 1 Ckt 2 Ckt 3 Ckt 4 Ckt 1 Ckt 2 Ckt 3 Ckt 4 Ckt 1 Ckt 2 Ckt 3 Ckt 4 Ckt 1 Ckt 2 Ckt 3 Ckt 4 BASIC DATA Unit ARI Conditions, tons (kw) (1240) (1275) (1318) (1420) Unit Operating Charge R-22, lbs (kg) Cabinet Dimensions, L x W x H, in. (mm) Unit Operating Weight, lbs (kg) Unit Shipping Weight, lbs (kg) 175 (79.4) 175 (79.4) 180 (81.6) 180 (81.6) x 83.4 x 94.5 (11646 x 2118 x 2400) (8770) (8335) COMPRESSORS, SCREW, SEMI-HERMETIC Nominal Capacity, tons (kw) 80 (280) 80 (280) 95 (335) 95 (335) 175 (79.4) 80 (280) 180 (81.6) 180 (81.6) 180 (81.6) x 83.4 x 94.5 (11646 x 2118 x 2400) (8775) (8340) 95 (335) 95 (335) 95 (335) CONDENSERS, HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLER Coil Face Area, ft (m 2) (10.7) Finned Height x Finned Length, ft. (mm) Fins Per Inch x Rows Deep 80x208 (2032x 5283) (10.7) 80x208 (2032x 5283) (10.7) 80x208 (2032x 5283) (10.7) 80x208 (2032x 5283) (10.7) 80x208 (2032x 5283) (10.7) 80x208 (2032x 5283) (10.7) 80x208 (2032x 5283) (10.7) 80x208 (2032x 5283) 180 (81.6) 95 (335) (10.7) 80x208 (2032x 5283) 180 (81.6) 180 (81.6) 180 (81.6) x 83.4 x 94.5 (11646 x 2118 x 2400) (8775) (8340) 95 (335) (10.7) 80x208 (2032x 5283) 95 (335) (10.7) 80x208 (2032x 5283) 95 (335) (10.7) 80x208 (2032x 5283) 190 (86.2) 95 (335) (10.7) 80x208 (2032x 5283) 190 (86.2) 190 (86.2) 190 (86.2) x 83.4 x 94.5 (11646 x 2118 x 2400) (8800) (8385) 95 (335) (10.7) 80x208 (2032x 5283) 95 (335) (10.7) 80x208 (2032x 5283) 95 (335) (10.7) 80x208 (2032x 5283) 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE Fan Qty. Dia., in (711) (711) (711) (711) (mm) No. of Motors, hp (1.5) (1.5) (1.5) (1.5) (kw) Fan RPM, 60Hz Fan Tip Speed, fpm Unit Airflow, ft 3 /sec EVAPORATOR, DIRECT EXPANSION Shell Dia-Tube Length in.(mm) - in. (mm) Evaporator R-22 Charge lbs (kg) Water Volume, gallons (liters) Max. Water Pressure, psi (kpa) Max. Refrigerant Pressure, psi (kpa) 49 (22.2) ( ) 49 (22.2) 49 (22.2) 49 (22.2) 49 (22.2) ( ) 49 (22.2) 49 (22.2) 49 (22.2) 49 (22.2) ( ) 49 (22.2) 49 (22.2) 49 (22.2) 56 (25.4) ( ) 56 (25.4) 115 (435) 115 (435) 115 (435) 110 (416) 152 (1048) 152 (1048) 152 (1048) 152 (1048) 300 (2068) 300 (2068) 300 (2068) 300 (2068) 56 (25.4) 56 (25.4) 50 ALS 141C 420C Product Manual ALS-4

51 Dimensions, ALS Figure 8, Dimensions, ALS 141C ALS 218C Note: See page 54 for lifting locations, mounting locations, weights and mounting loads. Note: Remote evaporator connections in this location. Victaulic Connections Couplings by Others. B C Notes: 1. All dimensions in inches (mm). 2. Only water connections as shown are available. Control Center Power Center Control wiring entry knockouts for ½ (13) conduit both sides of unit. 6.0 (152) Compressor #1 Compressor #2 Inlet Power entry location this side only. 2 additional knockouts 6.0 (152) above and below this opening for multiple power supply. Outlet D 83.4 (2118) Standard Coil Guards Air Discharge 92.5 (2350) 48.6 (1234) 28.5 (724) E 8.1 (206) X A 6.50 (165) Y ALS Size A B Evaporator Center of Gravity C D E X Y Conn. Size In. 141C 150C 171C 186C 190C 200C 206C 218C Product Manual ALS-4 ALS 141C 420C 51

52 Figure 9, Dimensions, ALS 245C 295C Note: See page 55 for lifting locations, mounting locations, weights and mounting loads. Note: Remote evaporator connections in this location. 8.0 (203) Victaulic Connections Couplings by Others (5590) Control Center Compressor #1 Inlet Outlet Power Center Control wiring entry knockouts for ½ (13) conduit both sides of unit. 6.0 (152) Compressor #2 Power entry location this side only. 2 additional knockouts 6.0 (152) above and below this opening for multiple power supply (2400) 65.6 (1666) 10.0 (256) C/G 155 (3917) (9017) (3625) Compressor # (706) Notes: 1. All dimensions in inches (mm). 2. Only water connections as shown are available. Standard Coil Guards 28.5 (724) 6.50 (165) 52 ALS 141C 420C Product Manual ALS-4

53 Figure 10, Dimensions, ALS 325C 420C Note: See page 55 for lifting locations, mounting locations, weights and mounting loads. Product Manual ALS-4 ALS 141C 420C 53

54 Figure 11, ALS141C ALS186C Lifting and Mounting Locations L2 L4 36 (914) CONTROL BOX M2 46 (1168) M1 102 (2591) M4 161 (4089) M3 192 (4877) M6 M (2118) L1 L3 2 (51) Typical Spacing for Isolator Mounting (6) ALS Model Lifting Weight for Each Point lb (kg) Mounting Loads for Each Point lb. (kg) L1 & L2 L3 & L4 M1 & M2 M3 & M4 M5 & M6 Operating Wt lb. (kg) Shipping Wt. lb. (kg) Copper Fin Add (1171) 2125 (963) 1835 (831) 1785 (809) 1230 (557) 9700 (4394) 9420 (4267) 1370 (620) (1164) 2205 (999) 1830 (829) 1805 (818) 1305 (591) 9880 (4476) 9550 (4326) 1370 (620) (1164) 2210 (1001) 1830 (829) 1810 (820) 1305 (591) 9890 (4472) 9560 (4331) 1370 (620) (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 in. (25.4 mm) mounting holes at location "M" on bottom of base rail. Figure 12, ALS190C - ALS218C Lifting and Mounting Locations L2 L4 CONTROL BOX 36 (914) 46 (1168) M2 M1 123 (3124) 195 (4953) M4 M3 224 (5690) M6 M (2118) L1 L3 2 (51) Typical Spacing for Isolator Mounting (6) ALS Model Lifting Weight for Each Point lb (kg) Mounting Loads for Each Point lb. (kg) L1 & L2 L3 & L4 M1 & M2 M3 & M4 M5 & M6 Operating Wt lb. (kg) Shipping Wt. lb. (kg) Copper Fin Add (1320) 2230 (1010) 2010 (910) 2135 (967) 1165 (527) (4811) (4661) 1610 (730) (1323) 2230 (1010) 2015 (913) 2135 (967) 1165 (527) (4815) (4666) 1610 (730) (1332) 2310 (1046) 2000 (906) 2240 (1015) 1240 (562) (4965) (4756) 1610 (730) (1341) 2405 (1089) 1985 (899) 2425 (1098) 1365 (618) (5232) (4861) 1610 (730) 54 ALS 141C 420C Product Manual ALS-4

55 Figure 13, ALS245C - ALS295C Lifting and Mounting Locations 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) Model L1 & L2 L3 & L4 L5 L6 M1 & M2 M3 & M4 M5 & M6 M7 M8 Operating Wt lb. (kg) Shipping Wt. lb. (kg) Copper Fin Add (1289) 2445 (1108) 1420 (643) 2050 (928) 1745 (790) 2240 (1015) 2030 (920) 1150 (521) 1660 (752) (6722) (6356) 2020 (915) (1291) 2445 (1108) 1420 (643) 2050 (928) 1745 (790) 2245 (1017) 2030 (920) 1150 (521) 1660 (752) (6727) (6360) 2020 (915) (1289) 2455 (1112) 1430 (648) 2060 (933) 1750 (793) 2245 (1017) 2035 (922) 1155 (523) 1165 (528) (6741) (6383) 2020 (915) (1291) 2455 (1112) 1430 (648) 2060 (933) 1755 (793) 2245 (1017) 2035 (922) 1155 (523) 1665 (528) (6745) (6387) 2020 (915) (1298) 2455 (1112) 1430 (648) 2060 (933) 1755 (793) 2250 (1019) 2035 (922) 1155 (523) 1165(528) (6750) (6392) 2020 (915) NOTES: 1. 2 ½ in. (63.5 mm) lifting holes at location "L" on side of base rail in. (25.4 mm) mounting holes at location "M" on bottom of base rail. Figure 14, ALS325C - ALS420C Lifting and Mounting Locations 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) Model L1 & L2 L3 & L4 L5 & L6 L7 & L8 M1 & M2 M3 & M4 M5 & M6 M7 &M8 M9 & M10 Operating Wt lb. (kg) Shipping Wt. lb. (kg) Copper Fin Add (1189) 1895 (858) 2805 (1271) 1835 (831) 2060 (933) 1955 (886) 1485 (673) 2245 (1017) 1895 (858) (8734) (8299) 2750 (1246) (1189) 1895 (858) 2805 (1271) 1840 (833) 2065 (935)) 1955 (886) 1485 (673) 2245 (1017) 1895 (858) (8738) ( (1246) (1189) 1895 (858) 2805 (1271) 1840 (833) 2065 (935) 1955 (886) 1485 (673) 2245 (1017) 1895 (858) (8738) (8303) 2750 (1246) (1189) 1900 (861) 2805 (1271) 1840 (833) 2070 (938) 1955 (886) 1485 (673) 2245 (1017) 1895 (858) (8743) (8308) 2750 (1246) (1194) 1905 (863) 2815 ( (836) 2075 (940) 1960 (888) 1490 (675) 2255 (1021) 1900 (861) (8770) (8335) 2750 (1246) (1196) 1905 (863) 2815 ( (836) 2075 (940) 1965 (890) 1490 (675) 2255 (1021) 1900 (861) (8775) (8340) 2750 (1246) (1196) 1905 (863) 2815 ( (836) 2075 (940) 1965 (890) 1490 (675) 2255 (1021) 1900 (861) (8775) (8340) 2750 (1246) (1196) 1905 (863) 2815 ( (836) 2075 (940) 1965 (890) 1495 (677) 2260 (1024) 1920 (870) (8802) (8385) 2750 (1246) Product Manual ALS-4 ALS 141C 420C 55

56 Installation and Application 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. 56 ALS 141C 420C Product Manual ALS-4

57 Consult minimum clearance requirement drawings on the following pages for equipment space layout. Figure 15, Service Clearance Requirements, ALS 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 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. Product Manual ALS-4 ALS 141C 420C 57

58 Figure 16, Service Clearance Requirements, ALS 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 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. 58 ALS 141C 420C Product Manual ALS-4

59 Figure 17, Clearance Requirements, ALS 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 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. Product Manual ALS-4 ALS 141C 420C 59

60 Restricted Air Flow General The clearances required for design-life operation of ALS air-cooled condensers are described in the previous section. Occasionally, these clearances cannot be maintained due to site restrictions such as units being too close together or a fence or wall restricting airflow, or both. Fortunately the McQuay ALS chillers have several features that can mitigate the penalties attributable to restricted airflow. The condenser section is U shaped, as shown below. This allows inlet air for these coils to come in from either side. A vertical coil and its adjacent horizontal coil are manifolded together to serve one compressor circuit. Every compressor always has its own independent refrigerant circuit. The MicroTech control is proactive in response to off-design conditions. In the case of single or compounded influences restricting airflow to the unit, the microprocessor will act to keep the compressor(s) running (at reduced capacity) rather than allowing a shutoff on high discharge pressure. The MicroTech control can be programmed to sequence the compressors in the most advantageous way. For example, in the diagram shown below, it might be desirable to program circuit #1 to be the lag circuit (last circuit to reach full load) during periods of high ambient temperatures. Figure 18, Coil and Fan Arrangement 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. 60 ALS 141C 420C Product Manual ALS-4

61 Case 1, Building or Wall on One Side of One Unit The existence of a screening wall or the wall of a building in close proximity to an air-cooled chiller is common in both rooftop and ground level applications. Hot air recirculation on the coils adjoining the wall will increase compressor discharge pressure, decreasing capacity and increasing power consumption. Only the compressor(s) connected to these coils will be affected. Circuits opposite the wall are unaffected. When close to a wall, it is desirable to place chillers on the North or East side of them. It is also desirable to have prevailing winds blowing parallel to the unit s long axis. The worst case is to have wind blowing hot discharge air into the wall. Figure 19, Unit Adjacent to Wall Figure 20, Adjustment Factors Product Manual ALS-4 ALS 141C 420C 61

62 Case 2, Two Units Side By Side Two or more units sited side by side are common. If spaced closer than 12 feet (3.7 meters) it is necessary to adjust the performance of each unit; circuits adjoining each other are affected. NOTE: This case applies only to two units side by side. See Case 3 for three or more parallel units. If one of the two units also has a wall adjoining it, see Case 1. Add the two adjustment factors together and apply to the unit located between the wall and the other unit. Mounting units end to end will not necessitate adjusting performance. Depending on the actual arrangement, sufficient space must be left between the units for access to the control panel door opening and/or evaporator tube removal. See Clearance section of this guide for requirements for specific units. Pit or solid wall surrounds should not be used where the ambient air temperature exceeds 105 F (40 C). Figure 21, Two Units Side by Side Figure 22, Adjustment Factor 62 ALS 141C 420C Product Manual ALS-4

63 Case 3, Three or More Units Side By Side When three or more units are side by side, the outside chillers (1 and 3 in this case) are influenced by the middle unit only on their inside circuits. Their adjustment factors will be the same as Case 2. All inside units (only number 2 in this case) are influenced on both sides and must be adjusted by the factors shown below. Figure 23, Three or More Units Figure 24, Adjustment Factor Product Manual ALS-4 ALS 141C 420C 63

64 Case 4, Open Screening Walls Decorative screening walls are often used to help conceal a unit either on grade or on a rooftop. These walls should be designed such that the combination of their open area and distance from the unit do not require performance adjustment. It is assumed that the wall height is equal to or less than the unit height when mounted on its base support. This is usually satisfactory for concealment. If the wall height is greater than the unit height, see Case 5, Pit Installation The distance from the ends of the unit to the end walls should be sufficient for service, opening control panel doors, and pulling evaporator tubes, as applicable. If each side wall is a different distance from the unit, the distances can be averaged providing either wall is not less than 8 feet (2.4 meters) from the unit. For example, do not average 4 feet and 20 feet to equal 12 feet. Figure 25, Open Screening Walls Figure 26, Wall Free Area vs Distance 64 ALS 141C 420C Product Manual ALS-4

65 Case 5, Pit/Solid Wall Installation Pit installations can cause operating problems and great care should be exercised if they are to be used on an installation. Recirculation and restriction can both occur. A solid wall surrounding a unit is substantially the same as a pit and the data presented here should be used. Steel grating is sometimes used to cover a pit to prevent accidental falls or trips into the pit.. The grating material and installation design must be strong enough to prevent such accidents, yet provide abundant open area or serious recirculation problems will occur. Have any pit installation reviewed by McQuay application engineers prior to installation to make sure it has sufficient air-flow characteristics. The installation design engineer must approve the work to avoid an unreasonable risk of accident. Figure 27, Pit Installation Figure 28, Adjustment Factor Product Manual ALS-4 ALS 141C 420C 65

66 Chilled Water Systems McQuay requires that chilled water piping for its chillers be designed and installed in conformance with the system recommendations described in (American Society of Heating Refrigeration and Air-Conditioning Engineers, Inc.) ASHRAE Handbooks. Specifically the 1996 Edition, HVAC Systems & Equipment, Chapter 12. 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 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 Specifications and start-up procedures should: 1. Confirm that the chilled water piping system had been properly flushed out before being connected to the chiller vessel. 2. Confirm that the piping contains a) A cleanable strainer to remove impurities before they reach the chiller vessel b) An expansion tank in the piping, and c) An air vent located at the system high point to purge trapped air in the piping system. An air vent is also located at the top of the direct expansion chiller vessel and in the water head of a flooded vessel evaporator or condenser. Note: The evaporator will not provide venting and must not be the high point in the system. All water systems include air in solution with the water. The percentage of air that can be retained in solution is a function of the water temperature and water pressure. Since these two values change in both chilled and hot water systems, the presence of both b and c components listed above are vital to the successful operation of the system. 66 ALS 141C 420C Product Manual ALS-4

67 The presence of a cleanable filter or strainer (2a above) in a chilled water piping system is frequently taken for granted. The fact is that the filter or strainer may be inadequate for the installation or may be installed in the wrong location. 1. If the chilled water pump is located in the chilled water piping exiting the chiller vessel (down stream of the chiller), and the strainer is in its normal position ahead of the chilled water pump, then system impurities will be drawn, unfiltered through the chiller vessel. Severe reduction in chiller performance or damage to the evaporator tubes is the probable result. 2. Many chiller installations today are replacements for older less efficient machines or chillers with CFC refrigerants. Existing piping is drained down, opened to atmosphere, and reconnected to the new chiller vessel. Rust formed over the years and during the replacement process can break loose, pass through a conventional strainer, and settle in the chiller vessel that is frequently the lowest point in the piping system. Not only is a higher capacity filter required for these installations, but chemical treatment of the water is recommended immediately and should be maintained throughout the equipment life. Figure 29, Typical Chilled Water Piping Vent Outlet Drain Vibration Eliminator Valved pressure gauge Water strainer Vibration Eliminator Gate valve Flow Balancing Gate valve Switch valve Protect all field piping against freezing 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 Checking Water Flow The simplest method of checking water flow in a clean system (the chiller vessel has not been fouled nor is air bound), is to read the entering and leaving pressures and compare the actual pressure drop to the value published in the product catalog. Pressure drops at the job are read in psi or feet of water (kpa). Published values are displayed in feet of water. Use the following formula to convert from one to another x PSI = Feet of water or Feet of water x = PSI System Water Volume It is important to have adequate water volume in the system to provide an opportunity for the chiller to sense a load change, adjust to the change and stabilize. As the expected load change becomes more rapid, a greater water volume is needed. The system water volume is the total amount of water in the evaporator, air handling products and associated piping. If the water volume is too low, operational problems can occur including rapid compressor Product Manual ALS-4 ALS 141C 420C 67

68 cycling, rapid loading and unloading of compressors, erratic refrigerant flow in the chiller, improper motor cooling, shortened equipment life and other undesirable occurrences. For normal comfort cooling applications where the cooling load changes relatively slowly, we recommend a minimum system volume of seven minutes times the flow rate (GPM). For example, if the design chiller flow rate is 400 GPM, we recommend a minimum system volume of 2800 gallons (400 GPM x 7 minutes). For process applications where the cooling load can change rapidly, additional system water volume is needed. A process example would be the cooling of hot metal objects. The load would be very stable until the hot metal is dipped into the water tank. Then, the load would increase drastically. For this type of application, we recommend the normal comfort cooling recommendation addressed above plus three minutes of ballast for every 10% quick change in load. For example, if the hot metal example load changes from a stable 50% load to an immediate 100% load for metal cooling, the recommended system volume would increase to 8800 gallons. System volume = {400 GPM x 7 Minutes} + {(5 increment of 10% increase) x (3 Minutes) x 400 GPM} = 8800 Gallons Since there are many other factors that can influence performance, systems may successfully operate below these suggestions. However, as the water volume decreases below these suggestions, the possibility of problems increases. We believe that these guidelines should be an industry standard and not just recommendations from McQuay. 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. 68 ALS 141C 420C Product Manual ALS-4

69 Table 36, Freeze Protection Percent Volume Glycol Concentration Required Temperature For Freeze Protection For Burst Protection F ( C) Ethylene Glycol Propylene Glycol Ethylene Glycol Propylene Glycol 20 (6.7) (-12.2) (-17.8) (-23.3) (-28.9) (-34.4) (-40.0) (-45.6) (-51.1) Note: 1. These figures are examples only and may not be appropriate to every situation. Generally, for an extended margin of protection, select a temperature at least 5 F lower than the expected lowest ambient temperature. Inhibitor levels should be adjusted for solutions less than 30% glycol. 2. Glycol of less than 20% concentration is not recommended because of the potential for bacterial growth and loss of heat transfer efficiency. Variable Speed Pumping Variable water flow involves changing the water flow through the evaporator as the load changes. McQuay chillers are designed for this duty provided that the rate of change in water flow is slow and the minimum and maximum flow rates for the vessel are not exceeded. The recommended change in water flow is listed in the table below. As the number of stages of control increase, the slower the permissible rate of change in flow rate becomes. For the ALS control logic, there are timers that limit the rate of unloading or loading allowed. Slow changes allow the chiller the opportunity to sense a change, react to the change and stabilize preventing operational problems. ALS Size Number of Compressors Unloading Steps Maximum allowable % per minute of flow change 141 to to to 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. Product Manual ALS-4 ALS 141C 420C 69

70 Electrical Connections All wiring must be done in accordance with applicable local and national codes. ALS units may be ordered with internal power wiring for either single or multiple point power connections. If single point power connection is ordered, a single power terminal block is provided and wiring within the unit is sized in accordance with the U.S.A. National Electrical Code. A single field supplied disconnect is required or can be furnished as a factory option. If multiple point power wiring is ordered, two power connections are required for ALS 141C through ALS 218C and ALS 325C through ALS 420C. Three power connections are required for ALS 245C through ALS 295C. Wiring within the unit is sized in accordance with the U.S.A. National Electrical Code. Separate field supplied or factory supplied disconnects are required for each circuit. Disconnecting means are addressed by Article 440 of the U.S.A. National Electrical Code (NEC) which requires "disconnecting means capable of disconnecting air conditioning and refrigerating equipment including motor-compressors, and controllers from the circuit feeder." The disconnect switch should be selected and located within the NEC guidelines. Maximum recommended fuse sizes are given in the electrical data tables of this catalog for help in sizing the disconnect. Terminals are provided in the unit control center for optional field hookup of the control circuit to a separate fused 115 volt power supply. A control circuit transformer is factory installed to eliminate the requirement for a separate power supply to the control circuit. Terminals are provided in the unit control center for field hookup of the evaporator heater to either a separate 115 volt power supply or to control circuit power. 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 70 ALS 141C 420C Product Manual ALS-4

71 filter-driers, liquid line solenoid valves, electronic expansion valves, and sightglasses are already included on the ALS condensing unit. The evaporator is equipped with entering and leaving chilled water temperature sensor wells. The sensors are pre-wired to the ALS unit with 75 feet long sensor leads that must be field connected to the evaporator thermowells. Suction pressure transducers and temperature sensors must also be relocated to the evaporator. ALS units are shipped with an operating charge of refrigerant. Field piping must be leak tested, evacuated and charged during installation. Do not exceed 150 psig test pressure unless the unit is blanked off from the piping. Severe equipment damage or personal injury can result. Performance Derate Factors All performance tables and adjustment factors found in this catalog are applicable for remote evaporator installations, however, a performance derate must be applied to the R-22 performance data due to additional pressure drops in the suction and liquid lines which cause a loss of compressor performance. These derates are based on a suction line pressure drop equivalent of approximately 2 F (1 C) change in saturation temperature. For R-22 applications: Capacity = Tons (kw) x 0.97 Power = Compressor kw x 0.99 Refrigerant Line Sizes General Careful design of the refrigerant piping is necessary for efficient system operation. The refrigerant piping should be designed for a low pressure drop to obtain maximum capacity and efficiency while maintaining adequate velocity. Lines should slope in the direction of flow to provide good oil return to the compressors. Cost considerations favor keeping line sizes as small as possible while not exceeding acceptable pressure drops in order to maintain unit performance. NOTE All refrigerant piping must be reviewed by McQuay Application Engineers prior to order entry and will be verified by McQuay startup technicians. Suction line sizing Pressure drop in the suction line reduces system capacity and efficiency because it forces the compressor to operate at lower suction pressure. The suction line should be sized for a pressure drop approximately equivalent of 2 F (1 C) change in saturation temperature. For suction line sizing see Table 37 through Table 39. For applications with the evaporator below the ALS unit, the vertical section of the suction lines must be sized to return oil to the compressors at the minimum compressor capacity step. Example of Suction Line Size Calculation ALS 150C condensing unit with refrigerant R-22 Evaporator located 5 feet below the ALS compressor Lineal length of horizontal suction line is 25 feet Suction line requires 7 long radius (90 ) elbows; 3 in the horizontal, 4 in the riser Product Manual ALS-4 ALS 141C 420C 71

72 From Table 37, the nominal circuit capacities for circuit 1 and 2 are 65 and 80 tons respectively Total lineal suction line length = 30 feet each circuit (25 feet horizontal plus 5 feet vertical riser). For the first try, assume that the total equivalent suction line length is twice the lineal suction line length. Therefore the estimated total equivalent suction line length = 60 feet From Table 38 and Table 39, For nominal circuit capacities of 65 & 80 tons and equivalent line length of 60 ft, the suction line size = 2 5/8" for horizontal lines and 2 1/8" for vertical lines. From Table 42, Fitting loss for 2 5/8" long radius (90 ) elbow = 4.1 ft, and 3.3 ft for the 2 1/8 elbows. Therefore fitting loss in equivalent feet of pipe for (3) 2 5/8" long radius (90 ) elbow = 12.3 ft, and 13.2 ft for (4) 2 1/8" elbows. Therefore the actual equivalent suction line length = = 55.5 feet From Table 38 and Table 39, For nominal circuit capacities of 65 & 80 tons and equivalent line length of 55.5 ft the suction line size is correct. Table 37, ALS 141C-420C Nominal Circuit Capacities ALS Model Circuit 1 Tons (kw) Circuit 2 Tons (kw) Circuit 3 Tons (kw) Circuit 4 Tons (kw) 141C 65 (229) 65 (229) C 65 (229) 80 (262) C 80 (262) 80 (262) C 80 (262) 95 (334) C 80 (262) 95 (334) C 95 (334) 95 (334) C 95 (334) 95 (334) C 95 (334) 95 (334) C 65 (229) 80 (262) 80 (262) - 260C 80 (262) 80 (262) 80 (262) - 270C 80 (262) 80 (262) 95 (334) - 275C 80 (262) 95 (334) 95 (334) - 295C 95 (334) 95 (334) 95 (334) - 325C 65 (229) 65 (229) 80 (262) 80 (262) 335C 65 (229) 80 (262) 80 (262) 80 (262) 350C 80 (262) 80 (262) 80 (262) 80 (262) 365C 80 (262) 80 (262) 80 (262) 95 (334) 375C 80 (262) 80 (262) 95 (334) 95 (334) 285C 80 (262) 95 (334) 95 (334) 95 (334) 400C 95 (334) 95 (334) 95 (334) 95 (334) 420C 95 (334) 95 (334) 95 (334) 95 (334) Table 38, Vertical Upflow Suction Line Sizes Nominal Circuit Capacity Tons (kw) 65 (229) 80 (262) 95 (334) Vertical Upflow Suction Lines Equivalent Line Length Ft (m) Suction Line Size (in.) 40 (12) 2 1/8 75 (23) 2 1/8 40 (12) 2 1/8 75 (23) 2 1/8 40 (12) 2 5/8 75 (23) 2 5/8 72 ALS 141C 420C Product Manual ALS-4

73 Table 39, Horizontal and Vertical Downflow Suction Line Sizes Nominal Circuit Capacity Tons (kw) Vertical Downflow and Horizontal Suction Lines Equivalent Line Length Ft Suction Line Size, in. (m) 40 (12) 2 5/8 65 (229) 75 (23) 2 5/8 115 (35) 2 5/8 40 (12) 2 5/8 80 (262) 75 (23) 2 5/8 115 (35) 3 1/8 40 (12) 2 5/8 95 (334) 75 (23) 3 1/8 115 (35) 3 1/8 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. Table 40, Vertical Upflow Liquid-Vapor Line Sizes Nominal Circuit Capacity Tons (kw) 65 (229) 80 (262) 95 (334) Vertical Upflow Liquid-Vapor Lines Equivalent Line Length Ft (m) Liquid-Vapor Line Size o.d (in.) 40 (12) 1 3/8 75 (23) 1 3/8 40 (12) 1 3/8 75 (23) 1 3/8 40 (12) 1 5/8 75 (23) 1 5/8 Table 41, Horizontal and Vertical Downflow Liquid-Vapor Line Sizes Nominal Circuit Capacity Tons (kw) Vertical Downflow and Horizontal Liquid-Vapor Lines Equivalent Line Length Liquid-Vapor Line Size Ft (m) o.d (in.) 40 (12) 1 3/8 65 (229) 75 (23) 1 3/8 115 (35) 1 3/8 40 (12) 1 3/8 80 (262) 75 (23) 1 5/8 115 (35) 1 5/8 40 (12) 1 5/8 95 (334) 75 (23) 1 5/8 115 (35) 1 5/8 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 Product Manual ALS-4 ALS 141C 420C 73

74 lines at 40 F to 50 F (4.4 C to 10 C) operating temperatures. The liquid-vapor lines will operate at 40 F to 60 F (4.4 C to 15.6 C) and must also be insulated to prevent sweating and heat gain. Location and Arrangement Refrigerant lines should be as short and direct as possible to minimize tubing and fittings. Long radius elbows must be used (except for traps) to minimize the pressure drops. Traps should be as short as possible to minimize oil accumulation. Refrigerant piping should be arranged so that normal inspection of the equipment is not hindered. Adequate clearance should be provided between refrigerant piping and adjacent walls for insulation. Piping should be run so that it does not interfere with compressor service access, passages or obstruct headroom, windows and doors. Suction line hangers must be sized and located to support the weight of the piping in accordance with good piping practice. Horizontal portions of the suction lines must be downward sloping toward the compressors. Slope all piping in the direction of flow. Vertical portions of the suction lines must be sized for oil return at minimum compressor load. Note: Double section risers must not be utilized on any circuit. Traps must be provided as shown on Figure 30 and Figure 31. Table 42, Fitting Equivalent Feet of Pipe Line Size (in.) Angle Valve Globe Valve 90 Std. Radius Elbow 90 Long Radius Elbow 1 1/ / / / / / Equivalent Line Lengths Recommended refrigerant line sizes are based on equivalent line lengths of straight pipe, that is, a combination of straight pipe, fittings and valves. The pressure drop through valves and fittings is determined by establishing the equivalent straight length of pipe of the same size with the same friction loss. The "Total Equivalent Length" is the sum of the "Lineal Line Length" and the appropriate "Valve and Fitting Losses in Equivalent Feet of Pipe for Field Supplied Piping" given in Table 42. Figure 30, Evaporator Above ALS Unit 74 ALS 141C 420C Product Manual ALS-4

75 Figure 31, Evaporator Below ALS Unit 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. Table 43, Filter Drier Pressure Drop Percent Circuit Loading (%) Maximum Recommended Pressure Drop Across Filter Drier psig (kpa) (69.0) 75 8 (55.2) 50 5 (34.5) 25 4 (27.6) Refrigerant and Oil Charge The relative position of the ALS unit and the evaporator and the distance between them plays a critical role in determining suction and liquid line sizes and the field refrigerant and oil charges. ALS units with the remote evaporator option are shipped with an operating charge of refrigerant and oil. It will be necessary to evacuate the evaporator and field installed lines and field charge them. See Table 44 for refrigerant charge for suction and liquid-vapor lines. McQuay Service will supply and add additional oil as required. The correct oil is Planetelf ACD68AW, McQuay Part No (5 gal.), or (1 gal.). Charging Procedure The calculated refrigerant and oil charge must be added through the factory supplied charging valve located on the liquid-vapor line coming out of the compressor. Sufficient charge must be added to clear the liquid line sight glass located at the outlet of the condenser. Add an extra 10 lb. of refrigerant after the sight glass is clear. Note: Charge must never be added through the compressor suction line. Severe equipment damage can result. Product Manual ALS-4 ALS 141C 420C 75

76 Table 44, Refrigerant Charge for Suction and Liquid-Vapor Lines Lineal Tubing Length Ft (m) Suction Line Refrigerant Charge lb (kg) Liquid-Vapor Line Refrigerant Charge lb (kg) Line (in.) R-22 Line (in.) R / (0.15) 1 3/8 3.6 (1.6) 10 (3) 2 5/ (0.23) 1 5/8 5.0 (2.3) 3 1/ (0.32) 2 1/ (0.30) 1 3/8 7.2 (3.3) 20 (6) 2 5/ (0.46) 1 5/ (4.5) 3 1/ (0.64) 2 1/ (0.45) 1 3/ (4.9) 30 (9) 2 5/ (0.69) 1 5/ (6.8) 3 1/ (0.96) 2 1/ (0.60) 1 3/ (6.5) 40 (12) 2 5/ (0.92) 1 5/ (9.0) 3 1/ (1.29) 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 ALS 141C 420C Product Manual ALS-4

77 Dimensions, Remote Evaporator Figure 32, Evaporator for ALS ALS 200 OUTLET INLET ALS Model Evaporator Model Water Volume gal. (l) Refrigerant Volume Unit Weights lb. (kg) R-22 Operating Charge lb. (kg) cu.ft. (l) Operating Shipping Circuit 1 Circuit CDE (128) 1.4 (40.0) 934 (424) 635 (288) 34 (15.4) 34 (15.4) CDE (150) 1.8 (52.4) 1127 (512) 758 (343) 45 (20.4) 45 (20.4) ALS Overall Dimensions in. (mm) Model Length "K" Height "A" "B" "C" "D" "H" "J" Conn. "G" (2403) 17.8 (452) 11.0 (279) 10.2 (259) 12.8 (325) 6.4 (163) 85.2 (2164) 5 (152) (2426) 18.4 (467) 12.0 (305) 10.2 (259) 14.0 (356) 6.8 (173) 84.0 (2134) 8 (203) Product Manual ALS-4 ALS 141C 420C 77

78 Figure 33, Evaporator for ALS ALS OUTLET INLET ALS Model Evaporator Model Water Volume gal. (l) Refrig Volume cu. ft. (l) Weights lb. (kg) R-22 Opn Charge lb. (kg) Operating Shipping Circuit 1 Circuit CDE (208) 2.4 (67.9) 1464 (665) 943 (428) 57 (25.8) 57 (25.8) 218 CDE (373) 2.8 (79.2) 2028 (921) 1121 (509) 68 (30.9) 68 (30.9) ALS Dimensional Data Model A C D H J K (542) 12.1 (307) 16.0 (406) 6.9 (176) 84.5 (2149) 96.7 (2459) (601) 12.4 (315) 20.0 (508) 9.2 (235) 86.6 (2202) 99.7 (2533) 78 ALS 141C 420C Product Manual ALS-4

79 Figure 34, Evaporator for ALS ALS 295 ALS Model Evaporator Model Water Volume gal. (l) Refrig Weights lb. (kg) Volume cu. ft. (l) Operating Shipping R-22 Operating Charge lb. (kg) Circuit 1 Circuit 2 Circuit CDE (371) 2.91 (82.3) 2035 (924) 1130 (513) 47 (21) 47 (21) 47 (21) CDE (357) 3.3 (93.4) 2068 (939) 1174 (533) 53 (24) 53 (24) 53 (24) Product Manual ALS-4 ALS 141C 420C 79

80 Figure 35, ALS ALS 420 ALS Model Evaporator Model Water Vol. gal. (l) Refrig Vol. Weights lb. (kg) R-22 Operating Charge lb. (kg) cu. ft. (l) Operating Shipping Circuit 1 Circuit 2 Circuit 3 Circuit CDE (435) 4.1 (116) 2529 (1148) 1423 (646) 49 (22) 49 (22) 49 (22) 49 (22) 420 CDE (416) 4.7 (133( 2575 (1169) 1484 (674) 56 (25) 56 (25) 56 (25) 56 (25) 80 ALS 141C 420C Product Manual ALS-4

81 Standard Features Full Factory Testing Factory run tests with water hookups on all units prior to shipment help provide a trouble free start-up. Each unit is pressure tested, evacuated, and charged with a full operating charge of refrigerant and oil. McQuay does quality control checks and individual unit tests so that all controls are properly adjusted and operating correctly. Job site start-up and expenses are kept to a minimum as the unit is shipped ready to operate. Rigging Designed for easy handling and low installation costs, the ALS air-cooled screw chillers are assembled on a rugged galvanized steel channel base. The channel base distributes the unit weight for uniform low roof loading. Lifting holes are provided in the base of the unit to simplify installation. See dimension drawing for location. Cabinet Construction The unit casing and all structural members and rails are fabricated of continuous G90 galvanized steel and galvanized steel channel. The galvanized coating is applied to the base metal by the hot dip process and conforms to standard ASTM A525. The exterior casing is phosphatized and painted with a beige powder coated finish and passes the ASTM B hour salt spray test. Compressors All units feature multiple compressors with independent refrigerant circuits. The compressor is a direct drive, 3600 rpm, single-screw type with one main rotor that meshes with two diametrically opposed gaterotors. The two exactly opposed gaterotors create two exactly opposed compression cycles resulting in a well balanced compression cycle. The compressor has an internal economizer to enhance the unit's refrigeration effect and to allow the compressor to run at a more efficient operating point. During the economizer cycle vapor produced at the electronic expansion valve and motor cooling process is redirected to the rotor inlet, while the remaining liquid refrigerant flows to the evaporator. The electric motor is semi-hermetic, squirrel cage induction type and cooled by liquid refrigerant. This allows the motor to operate at lower temperatures enhancing system reliability and motor life when compared to suction gas cooled motors found on reciprocating and twin-screw compressors. Each compressor is equipped with suction and discharge service shutoff valves. Evaporator The evaporator is a direct expansion, shell-and-tube type with water flowing in the baffled shell and refrigerant flowing through the tubes. Independent refrigerant circuits within the evaporator serve each compressor. The evaporator is constructed with a carbon steel shell and seamless high efficiency copper tubes. Roll expansion anchors the refrigerant tubes in the heavy carbon steel tube sheets. Refrigerant heads are constructed of carbon steel and are removable to permit access to the tubes from either end. For easy draining and venting of the shell, 3/8 inch vent and drain plugs are provided on the top and bottom of the shell. Product Manual ALS-4 ALS 141C 420C 81

82 The evaporator is wrapped with an electric resistance heater cable and insulated with ¾ inch thick vinyl nitrate polymer sheet insulation to provide freeze protection down to -20 F (- 29 C) ambient air temperature. An ambient thermostat controls the heater cable. (Note: A water flow switch must be field installed to protect against evaporator freeze-up under low water flow conditions.) The evaporator insulation has a K factor of 0.28 at 75 F (24 C). The insulation is fitted and cemented in place, then painted with a resilient vinyl base paint to resist cracking. The tube side maximum working pressure is 300 psi (2068 kpa). The water side working pressure is 152 psi (1048 kpa). All evaporators are designed, constructed, inspected and stamped in accordance with the requirements of the ASME Boiler and Pressure Vessel Code. Condenser Fans and Motors Multiple direct-drive propeller fans operate in formed bell shaped orifices at low tip speeds for maximum static efficiency and minimum noise and vibration. Each fan is protected by a heavy-gauge, close meshed, PVC coated fan guard and is positioned within the unit cabinet for maximum protection against the elements. A heavy-duty, 3-phase motor with permanently lubricated ball bearings and inherent overload protection drives each condenser fan. Factory fusing provides positive protection from short circuiting. 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 keylocked 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. 82 ALS 141C 420C Product Manual ALS-4

83 Power Connections Standard power connection is to a single power block except for 208/230 volts on model ALS 245C and larger that have multipoint connection as standard (single point not available). Various options are available. Product Manual ALS-4 ALS 141C 420C 83

84 Optional Features Controls Low ambient head pressure control Optional SpeedTrol head pressure control permits unit operation down to 0 F (-18 C) ambient. However, since the actual minimum ambient can be dependent on wind conditions, wind baffles are also available. Under/over voltage protection Phone modem (Part Number ) An optional 9600 baud modem interface is available which allows the operator to control (or monitor) all chiller operations from a remote location through standard phone lines. 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. Water flow switch (Part Number ) A water flow switch is available for field installation in the chilled water piping to protect against evaporator freeze-up under low or no flow conditions. Terminals are provided in the unit control center for field hook up of the water flow detection switch. 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. Totally enclosed fan cooled condenser fan motors TEFC condenser fan motors are available as an option in lieu of the standard open drip-proof (ODP) fan motors when required by the application. When low ambient SpeedTrol is ordered the number 1 condenser fan motor on each refrigerant circuit will still be open dripproof. TEFC motors are standard on model ALS 218C and models ALS 325C to 420C. 84 ALS 141C 420C Product Manual ALS-4

85 Unit amps sensor package A unit amp sensor package can be provided which will display the percent of total unit amp draw at any given time. 115 volt convenience outlet A 10.0 amp, 115 volt convenience outlet mounted inside the control panel is available as an option on all units. Ground fault protection A ground fault interrupter can be provided to shut down the entire unit if a ground fault condition is sensed. 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. Baked epoxy condenser fin coating Electro Fin flexible dip and baked epoxy protective coating with hour salt spray resistance (ASTM B117-90) is available on the condenser coils and coil frames. Provides protection against adverse environments such as salt air as found on sea coast applications and many chemical environments. Consult the local McQuay sales office for complete specification and chemical resistance chart. Protective base guards Optional factory installed wire mesh lower base guards provide protection for ground level installations. Coil guards are standard. Wind baffles/hail guard The presence of wind will have an adverse affect on any air-cooled chiller. Wind across a condenser coil will not allow a chiller to operate as efficiently, or possibly not even start, at low ambient temperatures. Wind in effect raises the minimum ambient temperature in which the chiller can operate. The ALS air-cooled chillers are available with field installed wind baffles which allow the chiller to operate effectively down to the ambient temperature for which it was designed. Hail can have a damaging effect on the performance of an air-cooled condenser. As the finned area is flattened against the coil, restricting airflow, the efficiency of the coil is reduced. If desired, the wind/hail guards can be purchased for only one side of a unit in cases where an adjacent wall provides protection. 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. Product Manual ALS-4 ALS 141C 420C 85

86 Specifications The specification is available in MSWord from the local McQuay sales office. SECTION 15XXX AIR-COOLED ROTARY SCREW CHILLERS PART 1 - GENERAL 1.01 SUMMARY Section includes design, performance criteria, refrigerants, controls, and installation requirements for air-cooled rotary screw packaged chillers 1.02 REFERENCES Comply with applicable Standards/Codes of ARI 590, ANSI/ASHRAE 15, and ASME Section VIII SUBMITTALS A. Submit shop drawings and product data in accordance with specification requirements. B. Submittals shall include the following: 1. Dimensioned plan and elevation view drawings, required clearances, and location of all field connections. 2. Summary of all auxiliary utility requirements such as electricity, water, compressed air, etc. Summary shall indicate quality and quantity of each required utility. 3. Single line schematic drawing of the power field hookup requirements, indicating all items that are furnished. 4. Schematic diagram of control system indicating points for field connection. Diagram shall fully delineate field and factory wiring. 5. Certification of factory run test of chiller unit signed by company officer. 6. Installation manuals QUALITY ASSURANCE A. Qualifications; Equipment manufacturer must specialize in the manufacture of the products specified and have five years experience with the equipment and refrigerant offered. B. Regulatory Requirements: Comply with the codes and standards specified. 86 ALS 141C 420C Product Manual ALS-4

87 C. Chiller manufacturer must be ISO registered DELIVERY AND HANDLING A. Chillers shall be delivered to the job site completely assembled and charged with refrigerant and oil by the manufacturer. B. Comply with the manufacturers instructions for rigging and handling equipment WARRANTY The refrigeration equipment manufacturer s warranty shall be for a period of one year from date of equipment start up but not more than 18 months from shipment. It shall cover defects in material and workmanship having proven defective within the above period. PART 2--PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS A. McQuay International B. (Approved Equal) 2.02 UNIT DESCRIPTION Provide and install as shown on the plans factory assembled, factory 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 DESIGN REQUIREMENTS A. General: Provide a complete rotary screw packaged chiller as specified herein and as shown on the drawings. The unit shall be in accordance with the standards referenced in section 1.02 and any local codes in effect. B. Performance: Refer to the schedule of performance on the drawings. The chiller shall be capable of stable operation to a minimum of 25 percent of full load without hot gas bypass. The unit shall be capable of operating to 40 F (4.4 C) or 0 F (-18 F) ambient if the low ambient option is specified. Performance shall be in accordance with ARI Standard 550/ Product Manual ALS-4 ALS 141C 420C 87

88 C. Acoustics: Sound pressure levels for the units shall meet or be lower than dba on the overall A weighted sound pressure level. Measurements to be taken at full load at a distance of 30 feet (9.14 meters) from the side of the unit CHILLER COMPONENTS A. Compressors: The compressors shall be field serviceable, semi-hermetic, single-screw type with one main helical rotor meshing with two opposed gaterotors. If a twin-screw compressor is used, the manufacturer shall provide an extended 5-year parts and labor warranty covering all moving parts due to the large bearing loads inherent with this design. The gaterotors contact elements shall be constructed of a composite material designed for extended life. Electric motors shall be two pole, semi-hermetic, squirrel cage induction type and cooled by circulating liquid refrigerant. Suction gas cooled designs shall include an extended 5-year compressor warranty including parts and labor. Full load power factor shall be a minimum of The compressor shall be provided with an internal economizer cycle to improve system efficiency by subcooling the refrigerant flowing to the evaporator. Units without an internal compressor economizer shall be equipped with an external economizer of the flash type to provide an equivalent degree of subcooling. B. Evaporator: The evaporator shall be direct expansion type with carbon steel shell, water baffles, and high efficiency internally finned copper tubes rolled into a steel tubesheet. The evaporator shall be insulated with 3/4 inch (19mm) closed cell polyurethane insulation and heated with an electric heater to provide freeze protection to -20 F (-29 C) ambient temperature. The evaporator shall be designed, inspected, and stamped in accordance with ASME Section VIII requirements. C. Condenser: The condenser coils shall have seamless copper tubes mechanically bonded into plate type fins. The fins shall have full drawn collars to completely cover the tubes. A subcooling coil shall be an integral part of the main condenser coil. Condenser fans shall be propeller type 88 ALS 141C 420C Product Manual ALS-4

89 arranged for vertical air discharge and individually driven by direct drive fan motors. Each fan shall be in its own compartment to eliminate cross flow of condenser air during fan cycling and shall be equipped with a heavy-gauge fan guard. Fan motors shall be weather protected, three-phase, direct-drive, 1140 rpm, open drip-proof type. Coils shall be protected by a vinyl coated, wire mesh guard. D. Refrigerant Circuit: The unit must have refrigerant circuits completely independent of each other with one compressor per circuit. Each circuit shall include an electronic expansion valve, compressor suction and discharge shutoff valves, a liquid line shutoff valve, replaceable core filterdrier, sight glass with moisture indicator, liquid line solenoid valve (no exceptions), and insulated suction line. E. Unit casing and all structural members and rails shall be fabricated of continuous G90 galvanized steel and meet ASTM B hour salt spray test. The galvanized coating shall be applied to the base metal by the hot dip process and shall conform to ASTM A525. The control enclosure and unit panels shall be powder coat painted before assembly. F. The compressor starters shall be solid state and contain, at least, the following functions: controlled acceleration and deceleration, phase rotation protection, electronic thermal overload, over/under current protection, stalled motor protection, single phase protection, high load current, and current unbalance protection. G. Microprocessor based control system: A weatherproof control panel shall contain the field power connection points, control interlock terminals, and control system. Power and starting components shall include factory fusing of fan motors and control circuit; individual contactors for each fan motor, inherent fan motor overload protection and unit power terminal blocks for connection to remote disconnect switch. Terminals shall also be provided for power supply to the evaporator heater circuit. Hinged access doors shall be lockable. Barrier panels are required to protect against accidental contact with line voltage when accessing the control system. The system shall stage the unit based on the leaving water temperature. Safeties controlled by the microprocessor include motor protection, high discharge pressure, loss of refrigerant, loss of water flow, freeze protection, Product Manual ALS-4 ALS 141C 420C 89

90 and low refrigerant pressure. Controls shall include auto/stop switch, chilled water setpoint adjustment, anti-recycle timer, and digital display with water temperature and setpoint, operating temperatures and pressures, and diagnostic messages. The following features and functions shall be included: 1. The LCD type display shall have a minimum of 32 characters with all messages in English. Units of measure will be I-P. Coded messages and LED displays are not acceptable. 2. Critical parameters shall have their own section of control and be password protected. 3. Resetting chilled water temperature by either controlling the return water temperature or by a remote 4-20mA DC signal. 4. A soft load function to prevent the system from operating at full load during the chilled fluid pulldown period. 5. An electronic time clock to allow programming of a yearly start-stop schedule accommodating weekends and holidays. 6. Auto restart after a power failure without an external battery backup or auxiliary power for maintaining program memory. 7. Safety shutdowns shall be date and time stamped with system temperatures and pressures recorded. A minimum of six previous occurrences shall be kept in a revolving memory. 8. Start-to-start and stop-to-start timers to provide minimum compressor off-time with maximum motor protection. 9. Capability of communication with a PC or remote monitoring through a twisted pair RS-232 interface. 10. Lead-lag by manual selection or automatically by circuit run hours. 11. Discharge pressure control through intelligent cycling of condenser fans. 12. Pro-active compressor unloading in response to high discharge pressure or low evaporator pressure. 13. Continuous diagnostic checks of unit operation to provide a prealarm signal in advance of a shutdown allowing time for remedial action to be taken. 90 ALS 141C 420C Product Manual ALS-4

91 2.05 OPTIONS AND ACCESSORIES The following options are to be included: Nonfused service disconnect switch, factory mounted Ground fault protection, factory installed Low ambient head pressure control to 0 F (18 C), factory mounted Copper fin condenser coils Baked epoxy condenser coating Black fin - precoated fin option Totally enclosed air-over condenser fan motors Chilled water flow switch to be field mounted by contractor in the chilled water line and field wired to terminals in the control panel. Spring vibration isolators for field installation Protective welded wire lower base guards on compressor section 115 volt convenience outlet mounted in control panel Wind baffles and hail guards for field installation by installing contractor PART 3 - EXECUTION 3.01 INSTALLATION A. Install in strict accordance with manufacturer s requirements, shop drawings, and contract documents. B. Adjust and level chiller in alignment on supports. C. Coordinate electrical installation with electrical contractor. D. Coordinate controls with control contractor. E. Provide all appurtenances required to insure a fully operational and functional chiller START-UP A. Provide proper charge of refrigerant and oil. B. Provide Authorized Factory starting of chillers, and instruction to the owner on proper operation and maintenance. Product Manual ALS-4 ALS 141C 420C 91

92 Post Office Box 2510, Staunton, Virginia (800)