Packaged Air-Cooled Water Chiller -...

Installation Manual IM ALR

Group: Chiller

Part Number: 074653001

Effective: November 1997

Supersedes: IM 676

© 1997 McQuay International

Packaged Air-Cooled Water Chiller

ALR 110E - ALR 185ERefrigerant R-22, 60 Hertz

2 ALR 110E through 185E IM ALR

Table of Contents

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

General Description............................................................................................................................... 3Inspection .............................................................................................................................................. 3Installation ............................................................................................................................................. 3Handling ................................................................................................................................................ 3Location................................................................................................................................................. 4Service Access....................................................................................................................................... 5Vibration Isolators ................................................................................................................................. 6Water Piping .......................................................................................................................................... 7Flow Switch........................................................................................................................................... 8Water Connections................................................................................................................................. 8Refrigerant Charge ................................................................................................................................ 9Glycol Solutions .................................................................................................................................... 9Evaporator Water Flow and Pressure Drop ......................................................................................... 11

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

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

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

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

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

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

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

Pre Start-up.......................................................................................................................................... 27Start-up ................................................................................................................................................ 27Sequence of Operation ........................................................................................................................ 28

"McQuay" is a registered trademarks of McQuay International1997 McQuay International

"Illustrations cover the general appearance of McQuay International products at the time of publication and we reserve the right to make changes in design andconstruction at anytime without notice"

IM ALR ALR110E through 185E 3

Introduction

General DescriptionMcQuay air-cooled water chillers are complete, self-contained automatic refrigerating units. Everyunit is completely assembled, factory wired, charged, and tested. Each unit consists of twin air-cooledcondensers with integral subcooler sections, multiple accessible hermetic compressors, replaceabletube dual circuit shell-and-tube evaporator, and complete refrigerant piping. Liquid line componentsinclude manual liquid line shutoff valves, sight-glass/moisture indicators, solenoid valves, and doublediaphragm hydraulic element thermal expansion valves. Other features include compressor crankcaseheaters, an evaporator heater for chilled water freeze protection, limited pumpdown during “on” or“off” periods, compressor lead-lag switch to alternate the compressor starting sequence, andsequenced starting of compressors.

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

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

Note: Unit shipping and operating weights are available in the Physical Data tablesbeginning on page 12.

Installation

Note: Installation is to be performed by qualified personnel who are familiar with local codesand regulations.

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

HandlingBe careful to avoid rough handling of the unit. Do not push or pull the unit from anything other thanthe base. Block the pushing vehicle away from the unit to prevent damage to the sheet metal cabinetand end frame (see Figure 1).

To lift the unit, 2 1/2" (64mm) diameter lifting holes are provided in the base of the unit.Arrange spreader bars and cables to prevent damage to the condenser coils or cabinet (see Figure 2).


Figure 1, Suggested pushing arrangement

Figure 2, Suggested lifting arrangement

Location

Unit PlacementALR units are for outdoor applications and can be mounted on a roof or ground level. Set units on asolid and level foundation. For roof mounted applications, install the unit on a steel channel or I-beam frame to support the unit above the roof. For ground level applications, install the unit on asubstantial base that will not settle. A one piece concrete slab with footings extended below the frostline is recommended. Be sure the foundation is level (within 1/2” [13 mm] over its length and width).The foundation must support the operating weights listed in the Physical Data tables beginning onpage 12.

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

Blocking required

across full width

Spreader bars

recommended

(Use Caution)

Must use these rigging

holes. (Be aware of

control box location)

NOTE: Number of fans can vary

from this diagram. Lifting method

remains the same.


ClearancesThe flow of air to and from the condenser coil must not be limited. Restricting air flow or allowingair recirculation will result in a decrease in unit performance and efficiency. There must be noobstruction above the unit that would deflect discharge air downward where it could be recirculatedback to the inlet of the condenser coil. The condenser fans are propeller type and will not operatewith ductwork on the fan outlet.

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

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

Figure 3, Clearance requirements

Sound IsolationThe ultra-low sound levels of the ALR reciprocatingchiller is suitable for most applications. Whenadditional sound reduction is necessary, locate theunit away from sound sensitive areas. Avoidlocations beneath windows or between structureswhere normal operating sounds may beobjectionable. Reduce structurally transmitted soundby isolating water lines, electrical conduit and theunit itself. Use wall sleeves and rubber isolatedpiping hangers to reduce transmission of water orpump noise into occupied spaces. Use flexibleelectrical conduit to isolate sound through electricalconduit. Spring isolators are effective in reducing thelow amplitude sound generated by reciprocatingcompressors and for unit isolation in sound sensitiveareas.

Service AccessEach end of the unit must be accessible after installation for periodic service. Compressors, filter-driers, and manual liquid line shutoff valves are accessible on each side of the unit adjacent to thecontrol box. High pressure, low pressure, and motor protector controls are on the compressor.Freezestats and cooler barrel thermostats are near the cooler. Most other operational, safety andstarting controls are located in the unit control box.

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

5 ft. (1524mm) Clearance for

air inlet

4 Ft.

(1220mm)

clearance for

i

"10 feet (3048)

for evaporator

tube removal

5 Ft. (1524mm) clearance for

air inlet


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

Table 1, Isolator Loads and TypeALR ISOLATOR LOADS AND TYPE FOR EACH MOUNTING LOCATIONUNIT R S TSIZE TYPE LB KG TYPE LB KG TYPE LB KG110E CP-2-28 1339 607 CP-2-28 1364 619 CP-2-31 1697 770120E CP-2-31 1362 618 CP-2-31 1490 676 CP-2-32 1748 793130E CP-2-31 1492 677 CP-2-32 1570 712 CP-2-32 1838 834135E CP-2-31 1506 683 CP-2-32 1670 758 CP-2-32 1904 864140E CP-2-31 1556 706 CP-2-32 1752 795 CP-2-32 1912 867145E CP-2-31 1572 713 CP-2-32 1680 762 CP-4-27 2093 949150E CP-2-32 1601 726 CP-2-32 1704 773 CP-4-27 2120 962160E CP-4-27 1948 884 CP-2-32 1962 890 CP-2-32 1848 838170E CP-4-27 2052 931 CP-2-32 2002 908 CP-2-32 1849 839180E CP-4-27 2052 931 CP-2-32 2002 908 CP-2-32 1849 839185E CP-4-27 2052 931 CP-2-32 2002 908 CP-2-32 1849 839

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

Table 2, Spring Flex Isolator Part NumbersMax. Load

TYPE COLOR McQuay EachPart No. Lb. KG

CP1-25 Red 477927A-25 450 204CP1-26 Purple 477927A-26 600 272CP1-27 Orange 477927A-27 750 340CP1-28 Green 477927A-28 900 408CP1-31 Gray 477927A-31 1100 499CP1-32 White 477927A-32 1300 590CP2-25 Red 477929A-25 900 408CP2-26 Purple 477929A-26 1200 544CP2-27 Orange 477929A-27 1500 681CP2-28 Green 477929A-28 1800 817CP2-31 Gray 477929A-31 2200 998CP2-32 White 477929A-32 2600 1180CP4-26 Purple 580513A-26 2400 1089CP4-27 Orange 580513A-27 3000 1361CP4-28 Green 580513A-28 3600 1633CP4-31 Gray 580513A-31 4400 1996CP4-32 White 580513A-32 5200 2359


Water PipingLocal authorities can supply the installer with the proper building and safety codes required for safeand proper installation.

Install piping with minimum bends and changes in elevation to minimize pressure drop. Considerthe following when installing water piping:

1. Vibration eliminators to reduce vibration and noise transmission to the building.

2. Shutoff valves to isolate the unit from the piping system during unit servicing.

3. Manual or automatic air vent valves at the high points of the system. Install drains at the lowestpoints in the system.

4. A means of maintaining adequate system water pressure (expansion tank or regulating valve).

5. Temperature and pressure indicators located at the unit to aid in unit servicing.

6. A strainer or other means of removing foreign matter from the water before it enters the pump.Place the strainer far enough upstream to prevent cavitation at the pump inlet (consult pumpmanufacturer for recommendations). The use of a strainer will prolong pump life and keepsystem performance up.

7. Place a strainer in the water line just before the inlet of the evaporator. This will help preventforeign material from entering and decreasing the performance of the evaporator.

CAUTIONIf separate disconnect is used for the 110V supply to the evaporator heating cable, mark thedisconnect clearly to ensure disconnect is not accidentally shut off during cold seasons.

8. The shell-and-tube evaporator has a thermostat and heating cable to prevent freeze-up down to -20°F (-29°C). It is suggested that the heating cable be wired to a separate 110V supply circuit.As shipped from the factory, the heating cable is wired to the control circuit. All water piping tothe unit must also be protected to prevent freezing.

9. If the unit is used as a replacement chiller on a previously existing piping system, flush thesystem thoroughly before unit installation. Regular water analysis and chemical water treatmenton the evaporator is recommended immediately at equipment start-up.

10. The total water volume in the system should be sufficient to prevent frequent “on-off” cycling.Turnover rate should not be less than 15 minutes for normal variable cooling loads. Turnoverrate for process cooling or a constant load, should not be less than 6 minutes.

11. When glycol is added to the water system for freeze protection, the refrigerant suction pressurewill be lower, cooling performance less, and water side pressure drop greater. If the percentageof glycol is high, or if propylene is used instead of ethylene glycol, the added pressure drop andloss of performance could be substantial. Reset the freezestat and low leaving water alarmtemperatures. The freezestat is factory set to default at 36°F (2.2°C). Reset the freezestat settingto approximately 4 to 5 degrees F (2.3 to 2.8 degrees C) below the leaving chilled water setpointtemperature. See the section titled “Glycol Solutions” for additional information concerningglycol.

12. Perform a preliminary leak check before insulating the piping and filling the system.

13. Piping insulation should include a vapor barrier to prevent condensation and possible damage tothe building structure.


Figure 4, Typical field evaporator water piping

Flow SwitchMount a water flow switch in either the entering or leaving water line to shut down the unit whenwater flow is interrupted.

A flow switch is available from McQuay (part number 00175033-00). It is a “paddle” typeswitch and adaptable to any pipe size from 3” (76mm) to 8” (203mm) nominal. Certain minimumflow rates are required to close the switch and are listed in Table 3. Installation should be as shown inFigure 5. Connect the normally open contacts of the flow switch in the unit control center at terminals5 and 6. There is also a set of normally closed contacts on the switch that can be used for an indicatorlight or an alarm to indicate when a “no flow” condition exists. Freeze protect any flow switch that isinstalled outdoors.

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

Table 3, Flow switch minimum flow ratesNOMINAL PIPE SIZE MINIMUM REQUIRED FLOW TO

INCHES (MM) ACTIVATE SWITCH - GPM (L/s)1 (25.4) 6.00 (0.38)

11/4 (31.8) 9.80 (0.62)11/2 (38.1) 12.70 (0.80)

2 (50.8) 18.80 (1.20)21/2 (63.50) 24.30 (1.50)

3 (76.20) 30.00 (1.90)4 (101.6) 39.70 (2.50)5 (127.0) 58.70 (3.70)6 (152.4) 79.20 (5.00)

Figure 5, Flow switch installation

Flow direction markedon switch

1" (25mm) NPT flowswitch connection

Tee

5" (127mm) pipe dia.Min. before switch

5" (127mm) pipe dia.Min. after switch

Protect all field piping

against freezing

VibrationEliminator

VibrationEliminator

FlowSwitch

Balancingvalve

Gate valveValved

pressuregauge

Waterstrainer

Gate valve

Vent

Outlet

Drain


Water ConnectionsBring water piping to the Evaporator from the bottom of the unit or through the side between thevertical supports.

Note: On units sizes 160E through 185E there is a diagonal bracket off of a vertical supportwhich will interfere with the water connection if brought in from the side. This brace can beremoved, but only after the unit is in place.

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

Glycol SolutionsThe system glycol capacity, glycol solution flow rate in GPM, and pressure drop through the coolermay be calculated using the following formulas and table.

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

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

Glycol GPM (from table)=×

−×

24 capacity glycol

Delta TG

( )

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

Glycol L / s (from table)=× −

×kW

Delta TFlow

4.18

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

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

Test coolant with a clean, accurate glycol solution hydrometer (similar to that found in servicestations) to determine the freezing point. Obtain percent glycol from the freezing point table below.On glycol applications it is normally recommended by the supplier that a minimum of 25% solutionby weight be used for protection against corrosion.

Note: The proceduredoes not specify thetype of glycol. Usethe derate factorsfound in Table 4 forcorrections whenusing ethylene glycoland those in Table 5for propylene glycol.


CAUTIONDo not use an automotive grade antifreeze. Industrial grade glycols must be used.Automotive antifreeze contains inhibitors which will cause plating on the copper tubes withinthe chiller evaporator. The type and handling of glycol used must be consistent with localcodes.

Table 4, Ethylene glycol% Freeze Point

E.G. °F °C Cap. kW GPM PD10 26 -3 0.991 0.996 1.013 1.07020 18 -8 0.982 0.992 1.040 1.12930 7 -14 0.972 0.986 1.074 1.18140 -7 -22 0.961 0.976 1.121 1.26350 -28 -33 0.946 0.966 1.178 1.308

Table 5, Propylene glycol% Freeze Point

P.G. °F °C Cap. kW GPM PD10 26 -3 0.987 0.992 1.010 1.06820 19 -7 0.975 0.985 1.028 1.14730 9 -13 0.962 0.978 1.050 1.24840 -5 -21 0.946 0.971 1.078 1.36650 -27 -33 0.929 0.965 1.116 1.481

Table 6, Capacity and power deratesChilled Water Fouling Factor

Delta-T 0.00025 (0.044) 0.00075 (0.132) 0.00175 (0.308)ALTITUDE °F °C Cap. kW Cap. kW Cap. kW

6 3.3 0.992 0.995 0.996 0.982 0.911 0.9358 4.4 0.995 0.997 0.969 0.984 0.914 0.937

SEA 10 5.6 1.000 1.000 0.975 0.986 0.919 0.939LEVEL 12 6.7 1.005 1.002 0.980 0.989 0.923 0.941

14 6.8 1.010 1.005 0.985 0.991 0.928 0.94316 8.9 1.014 1.007 0.989 0.993 0.930 0.9446 3.3 0.978 1.005 0.957 0.990 0.903 0.9438 4.4 0.982 1.007 0.961 0.993 0.905 0.94510 5.6 0.986 1.009 0.965 0.995 0.909 0.947

2000 feet 12 6.7 0.992 1.011 0.970 0.998 0.914 0.94914 6.8 0.997 1.014 0.973 1.001 0.919 0.95216 8.9 1.000 1.016 0.975 1.002 0.921 0.9536 3.3 0.966 1.016 0.944 0.999 0.894 0.9518 4.4 0.969 1.018 0.947 1.001 0.896 0.95310 5.6 0.973 1.021 0.952 1.005 0.900 0.956

4000 feet 12 6.7 0.978 1.025 0.956 1.008 0.904 0.95814 6.8 0.982 1.027 0.959 1.011 0.909 0.96016 8.9 0.986 1.028 0.961 1.015 0.911 0.9616 3.3 0.953 1.025 0.930 1.009 0.884 0.9618 4.4 0.955 1.028 0.934 1.011 0.887 0.96210 5.6 0.959 1.031 0.939 1.013 0.890 0.964

6000 feet 12 6.7 0.963 1.034 0.942 1.017 0.895 0.96614 6.8 0.968 1.036 0.946 1.020 0.899 0.96816 8.9 0.972 1.037 0.949 1.024 0.902 0.969


Evaporator Water Flow and Pressure DropEvaporator flow rate must fall between the minimum and maximum values shown in the evaporatorpressure drop curve. Flow rates below the minimum values will result in laminar flow which willreduce efficiency, cause erratic operation of the expansion valve and could cause low temperaturecutouts. Flow rates exceeding the maximum values can cause erosion on the evaporator waterconnections and tubes.

Measure the chilled water pressure drop through the evaporator at field installed pressure taps. Itis important not to include the effect of valves or strainers in these readings.

Varying chilled water flow through the evaporator while the compressor(s) are operating is notrecommended.

Figure 6, Evaporator water pressure drop curve


Physical Data

Table 7 , Physical Data ALR 110E through 135EPHYSICAL DATA ALR MODEL NUMBER

110E 120E 130E 135E

BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2

Unit Capacity @ ARI Conditions (1), Tons (kW) 107.8 (379.0) 120.7 (424.4) 130.6 (459.2) 135.5 (476.4)

Number Of Refrigerant Circuits 2 2 2 2

Unit Operating Charge, R-22, Lb. 87 87 90 90 120 120 120 120

Unit Operating Charge, R-22, (kg) (36.3) (36.3) (36.3) (36.3) (38.6) (38.6) (38.6) (38.6)

Cabinet Dimensions, LxWxH, In. 229 x 83 x 89 229 x 83 x 89 229 x 83 x 93 229 x 83 x 93

Cabinet Dimensions, LxWxH, (mm) (5809 x 2118 x 2369) (5809 x 2118 x 2369) (5809 x 2118 x 2369) (5809 x 2118 x 2369)

Unit Operating Weight, Lbs. (kg) 8800 (3992) 9200 (4173) 9800 (4445) 10160 (4609)

Unit Shipping Weight, Lbs. (kg) 8505 (3858) 8760 (3974) 9350 (4241) 9735 (4416)

Add'l Weight If Copper Finned Coils, Lbs. (kg) 1105 (501) 1105 (501) 1652 (750) 1652 (750)

COMPRESSORS

Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Semi-Hermetic

Nominal Horsepower 30-30 30-35 30-35 35-35 35-35 35-35 35-40 35-40

Number Of Cylinders Per Compressor 6 - 6 6 - 6 6 - 6 6 - 6 6 - 6 6 - 6 6 - 6 6 - 6

Oil Charge Per Compressor, Oz. 140 - 140 140 - 140 140 - 140 140 - 140 140 - 140 140 - 140 140 - 255 140 - 255

Oil Charge Per Compressor, (g) (3969 -3969)

(3969 -3969)

(3969 -3969)

(3969 -3969)

(3969 -3969)

(3969 -3969)

(3969 -7229)

(3969 -7229)

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

Standard Staging - Circuit #1 in LeadStandard 6 Stages 0-16-32-40-48-71-100 0-15-32-39-48-74-100 0-17-33-42-50-75-100 0-16-32-40-48-74-100

Standard Staging - Circuit #2 in LeadStandard 6 Stages 0-16-32-40-48-76-100 0-17-32-41-48-76-100 0-17-33-42-50-75-100 0-16-32-40-48-74-100

Optional Staging - Circuit #1 in LeadOptional 8 Stages 0-16-32-40-48 0-15-32-39-48 0-17-33-42-50 0-16-32-40-48

-64-84-92-100 -67-84-91-100 -67-83-92-100 -66-84-92-100

Optional Staging - Circuit #2 in LeadOptional 8 Stages 0-16-32-40-48 0-17-32-41-48 0-17-33-42-50 0-16-32-40-48

-68-84-92-100 -65-84-91-100 -67-83-92-100 -66-84-92-100

CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING

Coil Face Area,Sq. Ft. 115.6 115.6 115.6 115.6 115.6 115.6 115.6 115.6

Coil Face Area, (M2) (10.3) (10.3) (10.3) (10.3) (10.3) (10.3) (10.3) (10.3)

Finned Height x Finned Length, In. 80 x 208 80 x 208 80 x 208 80 x 208 80 x 208 80 x 208 80 x 208 80 x 208

Finned Height x Finned Length, (mm) (2032 x5283)

(2032 x5283)

(2032 x5283)

(2032 x5283)

(2032 x5283)

(2032 x5283)

(2032 x5283)

(2032 x5283)

Fins Per Inch x Rows Deep 16 x 2 16 x 2 16 x 2 16 x 2 16 x 3 16 x 3 16 x 3 16 x 3

Maximum Relief Valve Pressure Setting, psig (kPa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)

CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE

Number Of Fans - Fan Diameter, In. (mm) 10 - 28 (711) 10 - 28 (711) 12 - 28 (711) 12 - 28 (711)

Number Of Motors - HP (kW) 10 - 1.5 (1.1) 10 - 1.5 (1.1) 12 - 1.5 (1.1) 12 - 1.5 (1.1)

Fan And Motor RPM, 60/50Hz 1100/915 1100/915 1100/915 1100/915

60 Hz Fan Tip Speed, FPM 8063 8063 8063 8063

60 Hz Total Unit Airflow, CFM 94710 94710 108240 108240

DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE

Diameter, in. - Length, Ft. 14 - 10 16 - 10 16 - 10 16 - 10

Diameter, (mm) - Length, (mm) (356 - 3048) (406 - 3048) (406 - 3048) (406 - 3048)

Water Volume, Gallons, (L) 36.10 (136.6) 43.6 (165) 43.6 (165) 43.6 (165)

Maximum Water Pressure, psig (kPa) 175 (1207) 175 (1207) 175 (1207) 175 (1207)

Maximum Refrigerant Working Pressure, psig (kPa) 225 (1552) 225 (1552) 225 (1552) 225 (1552)

Water Inlet / Outlet Victaulic Connections, In. (mm) 6 (152.4) 6 (152.4) 6 (152.4) 6 (152.4)

Drain - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5) .375 (9.5)

Vent - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5) .375 (9.5)

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

IM ALR ALR 110E through 185E 13

Table 8, Physical Data ALR 140E through 160EPHYSICAL DATA ALR MODEL NUMBER

140E 145E 150E 160E

BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2

Unit Capacity @ ARI Conditions (1), Tons (kW) 139.7 (491.2) 144.7 (508.8) 149.9 (527.0) 157.8 (554.8)

Number Of Refrigerant Circuits 2 2 2 2

Unit Operating Charge, R-22, Lbs 125 125 130 130 130 130 140 140

Unit Operating Charge, R-22, (kg) (45.4) (45.4) (45.4) (45.4) (45.4) (45.4) (49.9) (49.9)

Cabinet Dimensions, LxWxH, In. 229 x 83 x 93 229 x 83 x 93 229 x 83 x 93 263 x 83 x 93

Cabinet Dimensions, LxWxH, (mm) (5809 x 2118 x 2369) (5809 x 2118 x 2369) (5809 x 2118 x 2369) (6690 x 2118 x 2369)

Unit Operating Weight, Lbs. (kg) 10440 (4736) 10690 (4849) 10850 (4922) 11515 (5223)

Unit Shipping Weight, Lbs. (kg) 10040 (4554) 10290 (4668) 10450 (4740) 11115 (5042)

Add'l Weight If Copper Finned Coils, Lb. (kg) 1652 (750) 1652 (750) 1652 (750) 1930 (876)

COMPRESSORS

Type Semi-Hermetic Semi-Hermetic Semi-Hermetic Semi-Hermetic

Nominal Horsepower 40-40 40-40 40-40 40-40 40-40 40-50 40-50 40-50

Number Of Cylinders Per Compressor 6 - 6 6 - 6 6 - 6 6 - 6 6 - 6 6 - 8 6 - 8 6 - 8

Oil Charge Per Compressor, Oz. 255 - 255 255 - 255 255 - 255 255 - 255 255 - 255 255 - 255 255 - 255 255 - 255


(7229 -7229)

(7229 -7229)

(7229 -7229)

(7229 -7229)

(7229 -7229)

(7229 -7229)

(7229 -7229)


Standard Staging - Circuit #1 in LeadStandard 6 Stages (N/A on MicroTech Units) 0-17-33-42-50-75-100 0-17-33-42-50-75-100 0-15-32-40-48-72-100 0-17-33-42-50-77-100

Standard Staging - Circuit #2 in LeadStandard 6 Stages (N/A on MicroTech Units) 0-17-33-42-50-75-100 0-17-33-42-50-75-100 0-15-32-40-48-76-100 0-17-33-42-50-77-100

Optional Staging - Circuit #1 in LeadOptional 8 Stages (Std. on MicroTech Units) 0-17-33-42-50 0-17-33-42-50 0-15-32-40-64 0-17-33-42-50

-67-83-92-100 -67-83-92-100 -64-84-92-100 -63-71-86-100

Optional Staging - Circuit #2 in LeadOptional 8 Stages (Std. on MicroTech Units) 0-17-33-42-50 0-17-33-42-50 0-15-32-40-48 0-17-33-42-50

-67-83-92-100 -67-83-92-100 -68-84-92-100 -63-71-86-100


Coil Face Area,Sq. Ft. 115.6 115.6 115.6 115.6 115.6 115.6 135 135

Coil Face Area, (M2) (10.3) (10.3) (10.3) (10.3) (10.3) (10.3) (12.5) (12.5)

Finned Height x Finned Length, In. 80 x 208 80 x 208 80 x 208 80 x 208 80 x 208 80 x 208 80 x 243 80 x 243


(2032 x5283)

(2032 x5283)

(2032 x5283)

(2032 x5283)

(2032 x5283)

(2032 x6172)

(2032 x6172)

Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3

Maximum Relief Valve Pressure Setting, psig (kPa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)


Number Of Fans - Fan Diameter, In. (mm) 12 - 28 (711) 12 - 28 (711) 12 - 28 (711) 14 - 28 (711)

Number Of Motors - HP (kW) 12 - 1.5 (1.1) 12 - 1.5 (1.1) 12 - 1.5 (1.1) 14 - 1.5 (1.1)

Fan And Motor RPM, 60/50Hz 1100/915 1100/915 1100/915 1100/915

60 Hz Fan Tip Speed, FPM 8063 8063 8063 8063

60 Hz Total Unit Airflow, CFM 108240 108240 108240 126280


Diameter, in. - Length, Ft. 16 - 10 18 - 10 18 - 10 18 - 10

Diameter, (mm) - Length, (mm) (406 - 3048) (457 - 3048) (457 - 3048) (457 - 3048)

Water Volume, Gallons, (L) 43.6 (165) 57.30 (216.9) 57.30 (216.9) 57.30 (216.9)

Maximum Water Pressure, psig (kPa) 175 (1207) 175 (1207) 175 (1207) 175 (1207)

Maximum Refrigerant Working Pressure, psig (kPa) 225 (1552) 225 (1552) 225 (1552) 225 (1552)

Water Inlet / Outlet Victaulic Connections, In. (mm) 6 (152.4) 6 (152.4) 6 (152.4) 6 (152.4)

Drain - NPT int, In. (mm) 0.375 (9.5) 0.375 (9.5) 0.375 (9.5) 0.375 (9.5)

Vent - NPT int, In. (mm) 0.375 (9.5) 0.375 (9.5) 0.375 (9.5) 0.375 (9.5)



Table 9, Physical Data ALR 170E through 185EPHYSICAL DATA ALR MODEL NUMBER

170E 180E 185E

BASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ckt.2

Unit Capacity @ ARI Conditions (1), Tons (kW) 167.2 (587.9) 177.3 (623.4) 185.8 (653.3)

Number Of Refrigerant Circuits 2 2 2

Unit Operating Charge, R-22, Lb. 140 140 145 145 145 145

Unit Operating Charge, R-22, (kg) (52.2) (52.2) (54.4) (54.4) (54.4) (54.4)

Cabinet Dimensions, LxWxH, In. 263 x 83 x 93 263 x 83 x 93 263 x 83 x 93

Cabinet Dimensions, LxWxH, (mm) (6690 x 2118 x 2369) (6690 x 2118 x 2369) (6690 x 2118 x 2369)

Unit Operating Weight, Lbs. (kg) 11805 (5355) 11805 (5355) 11805 (5355)

Unit Shipping Weight, Lbs. (kg) 11405 (5174) 11405 (5174) 11405 (5174)

Add'l Weight If Copper Finned Coils, Lb. (kg) 1930 (876) 1930 (876) 1930 (876)

COMPRESSORS

Type Semi-Hermetic Semi-Hermetic Semi-Hermetic

Nominal Horsepower 50-50 50-50 50-60 50-60 60-60 60-60

Number Of Cylinders Per Compressor 8 - 8 8 - 8 8 - 8 8 - 8 8 - 8 8 - 8

Oil Charge Per Compressor, Oz. 255 - 255 255 - 255 255 - 255 255 - 255 255 - 255 255 - 255


(7229 -7229)

(7229 -7229)

(7229 -7229)

(7229 -7229)

(7229 -7229)


Standard Staging - Circuit #1 in LeadStandard 6 Stages (N/A on MicroTech Units) 0-19-37-44-50-75-100 0-17-34-40-46-73-100 0-19-37-44-50-75-100

Standard Staging - Circuit #2 in LeadStandard 6 Stages (N/A on MicroTech Units) 0-19-37-44-50-75-100 0-17-34-40-46-73-100 0-19-37-44-50-75-100

Optional Staging - Circuit #1 in LeadOptional 8 Stages (Std. on MicroTech Units) 0-19-37-44-50 0-17-34-40-46 0-19-37-44-50

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

Optional Staging - Circuit #2 in LeadOptional 8 Stages (Std. on MicroTech Units) 0-19-37-44-50 0-17-34-40-46 0-19-37-44-50

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


Coil Face Area,Sq. Ft. 135 135 135 135 135 135

Coil Face Area, (M2) (12.5) (12.5) (12.5) (12.5) (12.5) (12.5)

Finned Height x Finned Length, In. 80 x 243 80 x 243 80 x 243 80 x 243 80 x 243 80 x 243


(2032 x6172)

(2032 x6172)

(2032 x6172)

(2032 x6172)

(2032 x6172)

Fins Per Inch x Rows Deep 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3 16 x 3

Maximum Relief Valve Pressure Setting, psig (kPa) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)


Number Of Fans - Fan Diameter, In. (mm) 14 - 28 (711) 14 - 28 (711) 14 - 28 (711)

Number Of Motors - HP (kW) 14 - 1.5 (1.1) 14 - 1.5 (1.1) 14 - 1.5 (1.1)

Fan And Motor RPM, 60/50Hz 1100/915 1100/915 1100/915

60 Hz Fan Tip Speed, FPM 8063 8063 8063

60 Hz Total Unit Airflow, CFM 126280 126280 126280


Diameter, in. - Length, Ft. 18 - 10 18 - 10 18 - 10

Diameter, (mm) - Length, (mm) (457 - 3048) (457 - 3048) (457 - 3048)

Water Volume, Gallons, (L) 57.30 (216.9) 57.30 (216.9) 57.30 (216.9)

Maximum Water Pressure, psig (kPa) 175 (1207) 175 (1207) 175 (1207)

Maximum Refrigerant Working Pressure, psig (kPa) 225 (1552) 225 (1552) 225 (1552)

Water Inlet / Outlet Victaulic Connections, In. (mm) 6 (152.4) 6 (152.4) 6 (152.4)

Drain - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5)

Vent - NPT int, In. (mm) .375 (9.5) .375 (9.5) .375 (9.5)



Electrical Data

Field Wiring

CAUTIONInternal power wiring to the compressors for single and multiple point option are different.Field wiring must be installed according to unit wiring diagram.

Wiring must comply with all applicable codes and ordinances. Warranty is void if wiring is not inaccordance with specifications. Copper wire is required for all power lead terminations at the unit.Aluminum or copper can be used for all other wiring.

ALR units may be ordered with internal power wiring for either single or multiple point powerconnection. If single point power connection is ordered, a single large power terminal block isprovided and wiring within the unit is sized in accordance with the National Electrical Code. A singlefield supplied fused disconnect is required. An optional factory mounted transformer may beinstalled.

If multiple point power wiring is ordered, three power connections, one per compressor circuit,one for condenser fans, and control circuit, are required. Separate field supplied fused disconnectsare required for each of the three circuits. A single power block is provided for all of the condenserfans and the optional 115V control transformer.

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

Table 10, 110E - 135E Electrical Data Single PointMinimum POWER SUPPLY FIELD FUSE SIZE

ALR Circuit Field Wire Hub

Unit Volts HZ. Ampacity Wire Nominal Recommended MaximumSize (MCA) Quantity Gauge Quantity Size

208 494 6 350 1 4.00 (102) 600 600230 483 6 350 1 4.00 (102) 600 500

110E 460 60 244 3 250 1 2.50 (64) 300 300575 184 3 3/0 1 2.00 (51) 200 225

208 547 6 500 1 4.00 (102) 600 600230 517 6 400 1 4.00 (102) 600 600

120E 460 60 270 3 300 1 2.50 (64) 300 300575 196 3 3/0 1 2.00 (51) 225 225

208 584 6 500 1 4.00 (102) 700 700230 546 6 500 1 4.00 (102) 600 600

130E 460 60 289 3 350 1 2.50 (64) 300 300575 206 3 4/0 1 2.00 (51) 225 225

208 615 6 350 2 2.50 (64) 700 700230 579 6 350 2 2.50 (64) 700 700

135E 460 60 298 3 350 1 2.50 (64) 350 350575 220 3 300 1 2.00 (51) 250 250

Table continued next pageSee page 22 for all Electrical Data notes.


Table 10, 140E - 185E Electrical Data Single Point (Continued)Minimum POWER SUPPLY FIELD FUSE SIZE

ALR Circuit Field Wire Hub

Unit Volts HZ. Ampacity Wire Nominal Recommended MaximumSize (MCA) Quantity Gauge Quantity Size

208 643 6 500 2 3.00 (76) 700 700230 609 6 500 2 3.00 (76) 700 700

140E 460 60 306 3 350 1 2.50 (64) 350 350575 232 3 250 1 2.50 (64) 250 250

208 643 6 500 2 3.00 (76) 700 700230 609 6 500 2 3.00 (76) 700 700

145E 460 60 306 3 350 1 2.50 (64) 350 350575 232 3 250 1 2.50 (64) 250 250

208 677 6 500 2 3.00 (76) 800 800230 653 6 500 2 3.00 (76) 800 800

150E 460 60 328 3 400 1 3.00 (76) 350 450575 257 3 300 1 2.50 (64) 300 300

208 716 6 500 2 3.00 (76) 800 800230 700 6 500 2 3.00 (76) 800 800

160E 460 60 352 3 500 1 3.00 (76) 400 400575 281 3 300 1 2.50 (64) 300 300

208 770 6 600 2 3.00 (76) 800 800230 770 6 600 2 3.00 (76) 800 800

170E 460 60 388 3 600 1 3.00 (76) 450 450575 321 3 400 1 3.00 (76) 350 350

208 860 12 300 2 4.0 (102) 1000 1000230 860 12 300 2 4.0 (102) 1000 1000

180E 460 60 413 3 600 1 3.00 (76) 500 500575 337 3 500 1 3.00 (76) 400 400

208 940 12 350 2 4.0 (102) 1000 1000230 940 12 350 2 4.0 (102) 1000 1000

185E 460 60 435 6 300 1 3.00 (76) 500 500575 351 3 500 1 3.00 (76) 400 400

See page 22 for all Electrical Data notes.


Table 11, 110E - 135E Electrical Data Multiple PointElectrical Circuit #1 - Fans and Transformer Electrical Circuit #2 - Compressor Circuit #1 Electrical Circuit #3 - Compressor Circuit #2

ALR Min. Power Supply FieldFusing

Min. Power Supply Field Fusing Min. Power Supply Field Fusing

Unit Volts HZ.

Circuit Field Wire Hub Rec. Max. Circuit Field Wire Hub Rec. Max. Circuit Field Wire Hub Rec. Max.

Size Amps Wire Hub Fuse Fuse Amps Wire Hub Fuse Fuse Amps Wire Hub Fuse Fuse(MCA) Qty. Gauge Qty. Size Size Size (MCA) Qty. Gaug

eQty. Size Size Size (MCA) Qty. Gauge Qty. Size Size Size

208 60 3 6 1 1.50(38)

60 60 214 3 4/0 1 2.00(51)

250 300 247 3 250 1 2.50(64)

300 350

230 60 3 6 1 1.50(38)

60 60 214 3 4/0 1 2.00(51)

250 300 235 3 250 1 2.50(64)

300 300

110E 460 60 29 3 10 1 1.00(25)

30 30 106 3 2 1 1.25(32)

125 150 122 3 1 1 1.25(32)

150 150

575 24 3 10 1 1.00(25)

25 25 81 3 4 1 1.00(25)

100 110 89 3 3 1 1.25(32)

110 125

208 60 3 6 1 1.50(38)

60 60 247 3 250 1 2.50(64)

300 350 273 3 300 1 2.50(64)

350 350

230 60 3 6 1 1.50(38)

60 60 235 3 250 1 2.50(64)

300 300 252 3 250 1 2.50(64)

300 350

120E 460 60 29 3 10 1 1.00(25)

30 30 122 3 1 1 1.25(32)

150 150 135 3 1/0 1 1.50(38)

175 175

575 24 3 10 1 1.00(25)

25 25 89 3 3 1 1.25(32)

110 125 95 3 3 1 1.25(32)

110 125

208 71 3 4 1 2.00(51)

80 80 273 3 300 1 2.50(64)

350 350 273 3 300 1 2.50(64)

350 350

230 71 3 4 1 2.00(51)

80 80 252 3 250 1 2.50(64)

300 350 252 3 250 1 2.50(64)

300 350

130E 460 60 35 3 8 1 1.25(32)

35 35 135 3 1/0 1 1.50(38)

175 175 135 3 1/0 1 1.50(38)

175 175

575 28 3 10 1 1.00(25)

30 30 95 3 3 1 1.25(32)

110 125 95 3 3 1 1.25(32)

110 125

208 71 3 4 1 2.00(51)

80 80 290 3 350 1 2.50(64)

350 400 290 3 350 1 2.50(64)

350 400

230 71 3 4 1 2.00(51)

80 80 271 3 300 1 2.50(64)

350 350 271 3 300 1 2.50(64)

350 350

135E 460 60 35 3 8 1 1.25(32)

35 35 140 3 1/0 1 1.50(38)

175 200 140 3 1/0 1 1.50(38)

175 200

575 28 3 10 1 1.00(25)

30 30 102 3 2 1 1.25(32)

125 150 102 3 2 1 1.25(32)

125 150

208 71 3 4 1 2.00(51)

80 80 304 3 350 1 2.50(64)

400 304 3 350 1 2.50(64)

350 400

230 71 3 4 1 2.00(51)

80 80 286 3 350 1 2.50(64)

350350

400 286 3 350 1 2.50(64)

350 400

140E 460 60 35 3 8 1 1.25(32)

35 35 144 3 1/0 1 1.50(38)

175 200 144 3 1/0 1 1.50(38)

175 200

575 28 3 10 1 1.00(25)

30 30 108 3 2 1 1.25(32)

125 150 108 3 2 1 1.25(32)

125 150

208 71 3 4 1 2.00(51)

80 80 304 3 350 1 2.50(64)

350 400 304 3 350 1 2.50(64)

350 400

230 71 3 4 1 2.00(51)

80 80 286 3 350 1 2.50(64)

350 400 286 3 350 1 2.50(64)

350 400

145E 460 60 35 3 8 1 1.25(32)

35 35 144 3 1/0 1 1.50(38)

175 200 144 3 1/0 1 1.50(38)

175 200

575 28 3 10 1 1.00(25)

30 30 108 3 2 1 1.25(32)

125 150 108 3 2 1 1.25(32)

125 150

208 71 3 4 1 2.00(51)

80 80 304 3 350 1 2.50(64)

350 400 338 3 500 1 3.00(76)

400 400

230 71 3 4 1 2.00(51)

80 80 286 3 350 1 2.50(64)

350 400 330 3 400 1 3.00(76)

400 400

150E 460 60 35 3 8 1 1.25(32)

35 35 144 3 1/0 1 1.50(38)

175 200 167 3 2/0 1 2.00(51)

200 225

575 28 3 10 1 1.00(25)

30 30 108 3 2 1 1.25(32)

125 150 133 3 1/0 1 1.50(38)

175 200

208 83 3 4 1 2.00(51)

90 90 338 3 500 1 3.00(76)

400 400 338 3 500 1 3.00(76)

400 400

230 83 3 4 1 2.00(51)

90 90 330 3 400 1 3.00(76)

400 400 330 3 400 1 3.00(76)

400 400

160E 460 60 40 3 8 1 1.25(32)

40 40 167 3 2/0 1 2.00(51)

200 225 167 3 2/0 1 2.00(51)

200 225

575 33 3 10 1 1.00(25)

35 35 133 3 1/0 1 1.50(38)

175 200 133 3 1/0 1 1.50(38)

175 200

Continued next page


Table 11 , 170E - 185E Electrical Data Multiple Point (ContinuedElectrical Circuit #1 - Fans and Transformer Electrical Circuit #2 - Compressor Circuit #1 Electrical Circuit #3 - Compressor Circuit #2

ALR Min. Power Supply Field Fusing Min. Power Supply FieldFusing

Min. Power Supply FieldFusing

Unit Volts HZ.

Circuit Field Wire Hub Rec. Max. Circuit Field Wire Hub Rec. Max. Circuit Field Wire Hub Rec. Max.

Size Amps Wire Hub Fuse Fuse Amps Wire Hub Fuse Fuse Amps Wire Hub Fuse Fuse(MCA) Qty Gauge Qty Size Size Size (MCA) Qty Gauge Qty Size Size Size (MCA) Qt

yGauge Qty Size Size Size

208 83 3 4 1 2.00(51)

90 90 365 3 500 1 3.00(76)

450 500 365 3 500 1 3.00(76)

450 500

230 83 3 4 1 2.00(51)

90 90 365 3 500 1 3.00(76)

450 500 365 3 500 1 3.00(76)

450 500

170E 460 60 40 3 8 1 1.25(32)

40 40 185 3 3/0 1 2.00(51)

225 250 185 3 3/0 1 2.00(51)

225 250

575 33 3 10 1 1.00(25)

35 35 153 3 2/0 1 2.00(51)

175 200 153 3 2/0 1 2.00(51)

175 200

208 83 3 4 1 2.00(51)

90 90 415 6 300 1 3.00(76)

500 600 415 6 300 1 3.00(76)

500 600

230 83 3 4 1 2.00(51)

90 90 415 6 300 1 3.00(76)

500 600 415 6 300 1 3.00(76)

500 600

180E 460 60 40 3 8 1 1.25(32)

40 40 199 3 3/0 1 2.00(51)

225 250 199 3 3/0 1 2.00(51)

225 250

575 33 3 10 1 1.00(25)

35 35 162 3 2/0 1 2.00(51)

200 225 162 3 2/0 1 2.00(51)

200 225

208 83 3 4 1 2.00(51)

90 90 455 6 350 1 4.00(102)

600 600 455 6 350 1 4.00(102)

600 600

230 83 3 4 1 2.00(51)

90 90 455 6 350 1 4.00(102)

600 600 455 6 350 1 4.00(102)

600 600

185E 460 60 40 3 8 1 1.25(32)

40 40 210 3 4/0 1 2.00(51)

250 300 210 3 4/0 1 2.00(51)

250 300

575 33 3 10 1 1.00(25)

35 35 169 3 2/0 1 2.00(51)

200 225 169 3 2/0 1 2.00(51)

200 225


Table 12, 110E -135E Compressor And Condenser Fan Motor Amp DrawRated Load Amps Locked Rotor Amps

ALR Compressors Fan No. Of Fan Compressors

Unit Volts HZ. No. No. No. No. Motors Fan Motors Across-The-Line Reduced Inrush

Size 1 2 3 4 (Each) Motors (Each) No. 1 No. 2 No. 3 No. 4 No. 1 No. 2 No. 3 No. 4

208 95 95 95 121 5.8 10 23.7 565 565 565 650 340 340 340 400

230 95 95 95 112 5.8 10 21.4 565 565 565 594 340 340 340 340

110E 460 60 47 47 47 60 2.8 10 10.7 283 283 283 297 156 156 156 195

575 36 36 36 42 2.3 10 11.5 230 230 230 245 138 138 138 152

208 95 121 121 121 5.8 10 23.7 565 650 650 650 340 400 400 400

230 95 112 112 112 5.8 10 21.4 565 594 594 594 340 340 340 340

120E 460 60 47 60 60 60 2.8 10 10.7 283 297 297 297 156 195 195 195

575 36 42 42 42 2.3 10 11.5 230 245 245 245 138 152 152 152

208 121 121 121 121 5.8 12 23.7 650 650 650 650 400 400 400 400

230 112 112 112 112 5.8 12 21.4 594 594 594 594 340 340 340 340

130E 460 60 60 60 60 60 2.8 12 10.7 297 297 297 297 195 195 195 195

575 42 42 42 42 2.3 12 11.5 245 245 245 245 152 152 152 152

208 121 121 135 135 5.8 12 23.7 650 650 754 754 400 400 463 463

230 112 112 127 127 5.8 12 21.4 594 594 594 594 340 340 340 340

135E 460 60 60 60 64 64 2.8 12 10.7 297 297 297 297 195 195 195 195

575 42 42 48 48 2.3 12 11.5 245 245 245 245 152 152 152 152

Continued on next pageSee page 22 for all Electrical Data notes.


Table 12, 140E - 185E Compressor And Condenser Fan Motor Amp Draw (Continued)Rated Load Amps Locked Rotor Amps

ALR Compressors Fan No. Of Fan Compressors

Unit Volts HZ. No. No. No. No. Motors Fan Motors Across-The-Line Reduced Inrush

Size 1 2 3 4 (Each) Motors (Each) No. 1 No. 2 No. 3 No. 4 No. 1 No. 2 No. 3 No. 4

208 135 135 135 135 5.8 12 23.7 754 754 754 754 463 463 463 463

230 127 127 127 127 5.8 12 21.4 594 594 594 594 340 340 340 340

140E 460 60 64 64 64 64 2.8 12 10.7 297 297 297 297 195 195 195 195

575 48 48 48 48 2.3 12 11.5 245 245 245 245 152 152 152 152

208 135 135 135 135 5.8 12 23.7 754 754 754 754 463 463 463 463

230 127 127 127 127 5.8 12 21.4 594 594 594 594 340 340 340 340

145E 460 60 64 64 64 64 2.8 12 10.7 297 297 297 297 195 195 195 195

575 48 48 48 48 2.3 12 11.5 245 245 245 245 152 152 152 152

208 135 135 135 162 5.8 12 23.7 754 754 754 1070 463 463 463 654

230 127 127 127 162 5.8 12 21.4 594 594 594 1070 340 340 340 654

150E 460 60 64 64 64 82 2.8 12 10.7 297 297 297 510 195 195 195 330

575 48 48 48 68 2.3 12 11.5 245 245 245 405 152 152 152 262

208 135 135 162 162 5.8 14 23.7 754 754 1070 1070 463 463 654 654

230 127 127 162 162 5.8 14 21.4 594 594 1070 1070 340 340 654 654

160E 460 60 64 64 82 82 2.8 14 10.7 297 297 510 510 195 195 330 330

575 48 48 68 68 2.3 14 11.5 245 245 405 405 152 152 262 262

208 162 162 162 162 5.8 14 23.7 1070 1070 1070 1070 654 654 654 654

230 162 162 162 162 5.8 14 21.4 1070 1070 1070 1070 654 654 654 654

170E 460 60 82 82 82 82 2.8 14 10.7 510 510 510 510 330 330 330 330

575 68 68 68 68 2.3 14 11.5 405 405 405 405 262 262 262 262

208 162 162 202 202 5.8 14 23.7 1070 1070 1070 1070 654 654 654 654

230 162 162 202 202 5.8 14 21.4 1070 1070 1070 1070 654 654 654 654

180E 460 60 82 82 93 93 2.8 14 10.7 510 510 510 510 330 330 330 330

575 68 68 75 75 2.3 14 11.5 405 405 405 405 262 262 262 262

208 202 202 202 202 5.8 14 23.7 1070 1070 1070 1070 654 654 654 654

230 202 202 202 202 5.8 14 21.4 1070 1070 1070 1070 654 654 654 654

185E 460 60 93 93 93 93 2.8 14 10.7 510 510 510 510 330 330 330 330

575 75 75 75 75 2.3 14 11.5 405 405 405 405 262 262 262 262



Table 13, 110E - 185E Field Wiring Data ,Single Point PowerWiring to Wiring to

ALR Standard Power Block Optional Disconnect Switch

Unit Volts HZ. Terminal Connector Wire Range Terminal Connector Wire Range

Size Amps (Copper Wire Only) Amps (Copper Wire Only)

208 840 (2 qty.) 1/0 - 600 MCM 600 (2 qty.) 250 - 500 MCM

230 840 (2 qty.) 1/0 - 600 MCM 600 (2 qty.) 250 - 500 MCM

110E 460 60 335 (1 qty.) #4 - 400 MCM 400 (1 qty.) 250 - 500 MCM

575 335 (1 qty.) #4 - 400 MCM 250 (1qty.) #4 - 350 MCM

208 840 (2 qty.) 1/0 - 600 MCM 600 (2 qty.) 250 - 500 MCM

230 840 (2 qty.) 1/0 - 600 MCM 600 (2 qty.) 250 - 500 MCM

120E 460 60 335 (1 qty.) #4 - 400 MCM 400 (1 qty.) 250 - 500 MCM

575 335 (1 qty.) #4 - 400 MCM 250 (1qty.) #4 - 350 MCM

208 840 (2 qty.) 1/0 - 600 MCM N/A

230 840 (2 qty.) 1/0 - 600 MCM N/A

130E 460 60 335 (1 qty.) #4 - 400 MCM 400 (1 qty.) 250 - 500 MCM

575 335 (1 qty.) #4 - 400 MCM 250 (1qty.) #4 - 350 MCM

208 840 (2 qty.) 1/0 - 600 MCM N/A

230 840 (2 qty.) 1/0 - 600 MCM N/A

135E 460 60 335 (1 qty.) #4 - 400 MCM 400 (1 qty.) 250 - 500 MCM

575 335 (1 qty.) #4 - 400 MCM 250 (1qty.) #4 - 350 MCM

208 840 (2 qty.) 1/0 - 600 MCM N/A

230 840 (2 qty.) 1/0 - 600 MCM N/A

140E 460 60 335 (1 qty.) #4 - 400 MCM 400 (1 qty.) 250 - 500 MCM

575 335 (1 qty.) #4 - 400 MCM 400 (1 qty.) 250 - 500 MCM

208 840 (2 qty.) 1/0 - 600 MCM N/A

230 840 (2 qty.) 1/0 - 600 MCM N/A

145E 460 60 335 (1 qty.) #4 - 400 MCM 400 (1 qty.) 250 - 500 MCM

575 335 (1 qty.) #4 - 400 MCM 400 (1 qty.) 250 - 500 MCM

208 840 (4 qty.) 1/0 - 600 MCM N/A

230 840 (4 qty.) 1/0 - 600 MCM N/A

150E 460 60 840 (2 qty.) 1/0 - 600 MCM 400 (1 qty.) 250 - 500 MCM

575 840 (2 qty.) 1/0 - 600 MCM 400 (1 qty.) 250 - 500 MCM

208 840 (*) (4 qty.) 1/0 - 600 MCM N/A

230 840 (*) (4 qty.) 1/0 - 600 MCM N/A

160E 460 60 840 (2 qty.) 1/0 - 600 MCM 400 (1 qty.) 250 - 500 MCM

575 840 (2 qty.) 1/0 - 600 MCM 400 (1 qty.) 250 - 500 MCM

208 840 (*) (4 qty.) 1/0 - 600 MCM N/A

230 840 (*) (4 qty.) 1/0 - 600 MCM N/A

170E 460 60 840 (2 qty.) 1/0 - 600 MCM 600 (1 qty.) 250 - 500 MCM

575 840 (2 qty.) 1/0 - 600 MCM 400 (1 qty.) 250 - 500 MCM

208 840 (*) (4 qty.) 1/0 - 600 MCM N/A

230 840 (*) (4 qty.) 1/0 - 600 MCM N/A

180E 460 60 840 (2 qty.) 1/0 - 600 MCM 600 (1 qty.) 250 - 500 MCM

575 840 (2 qty.) 1/0 - 600 MCM 400 (1 qty.) 250 - 500 MCM

208 840 (*) (4 qty.) 1/0 - 600 MCM N/A

230 840 (*) (4 qty.) 1/0 - 600 MCM N/A

185E 460 60 840 (2 qty.) 1/0 - 600 MCM 600 (1 qty.) 250 - 500 MCM

575 840 (2 qty.) 1/0 - 600 MCM 400 (1 qty.) 250 - 500 MCM

Note:* There are 2 power blocks, each having 840 terminal amps. (1680 total terminal amps)See page 22 for all other Electrical Data notes.


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

ALR Wiring to Standard Power BlockUnit Volts HZ. Terminal Amps Connector Wire Range (Copper Wire Only)Size Circuit 1 Circuit 2 Circuit 3 Circuit 1 Circuit 2 Circuit 3

208 175 335 335 (1 qty.) #12 - 2/0 (1 qty.) #4 - 400 MCM (1 qty.) #4 - 400 MCM230 175 335 335 (1 qty.) #12 - 2/0 (1 qty.) #4 - 400 MCM (1 qty.) #4 - 400 MCM

110E 460 60 175 175 175 (1 qty.) #12 - 2/0 (1 qty.) #12 - 2/0 (1 qty.) #12 - 2/0575 175 175 175 (1 qty.) #12 - 2/0 (1 qty.) #12 - 2/0 (1 qty.) #12 - 2/0







208 175 840 840 (1 qty.) #12 - 2/0 (2 qty.) 1/0 - 600 MCM (2 qty.) 1/0 - 600 MCM230 175 840 840 (1 qty.) #12 - 2/0 (2 qty.) 1/0 - 600 MCM (2 qty.) 1/0 - 600 MCM

140E 460 60 175 335 335 (1 qty.) #12 - 2/0 (1 qty.) #4 - 400 MCM (1 qty.) #4 - 400 MCM575 175 335 335 (1 qty.) #12 - 2/0 (1 qty.) #4 - 400 MCM (1 qty.) #4 - 400 MCM















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

1. Unit wire size ampacity (MCA) is equal to 125% of the largest compressor-motor RLA plus100% of RLA of all other loads in the circuit including the control transformer.

2. If the control transformer option is furnished, no separate 115v power is required.

3. If a separate 115V power supply is used for the control circuit, then the wire sizing is 12 amps.

4. Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductorampacity in accordance with NEC. Wire sizes for 6 conductors per conduit are based on 80%conductor ampacity in accordance with NEC. Voltage drop has not been included. Therefore, itis recommended that power leads be kept short. All terminal block connections must be madewith copper (type THW) wire.

5. The unit power terminal block may have 2 lugs per phase. Single or parallel conductors shouldbe used for power connections as listed under “Recommended Power Lead Wire Size.”

6. “Recommended Fuse Sizes” are selected at approximately 150% of the largest compressor RLA,plus 100% of all other loads in the circuit.

7. “Maximum Fuse Sizes” are selected at approximately 225% of the largest compressor RLA, plus100% of all other loads in the circuit.

8. The recommended power lead wire sizes are based on an ambient temperature of 86° F.Ampacity correction factors must be applied for other ambient temperatures. Refer to theNational Electrical Code Handbook.

Voltage Limitations:

Unit Nameplate - 208V/60Hz/3Ph: 187V to 253V (except ALR110E through ALR155E: 187V to220V)

Unit Nameplate - 230V/60Hz/3Ph: 187V to 253V (except ALR110E through ALR155E: 207V to253V)

Unit Nameplate - 460V/60Hz/3Ph: 414V to 506V

Unit Nameplate - 575V/60Hz/3Ph: 517V to 633V

Notes for “Compressor and Condenser Fan Amp Draw”:

1. Compressor RLA values are for wiring sizing purposes only but do not reflect normal operatingcurrent draw at rated capacity. If unit is equipped with SpeedTrol condenser fan motors, the firstmotor on each refrigerant circuit is a single phase, 1hp motor, with a FLA of 2.8 amps at 460volts, 5.6 amps at 208, 230, and 575 volts.

2. Compressor LRA for reduced inrush start are for the first winding only. If the unit is equippedwith SpeedTrol motors, the first motor is a single phase, 1 hp motor, with a LRA of 7.3 amps at460 volts, 14.5 amps at 208, 230 and 575 volts.

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

1. Single point power supply requires a single disconnect to supply electrical power to the unit.This power must be fused.

2. Multiple point power supply requires two independent power circuits each with separatedisconnects and a separate control circuit.

3. All field wiring to unit power block or optional non-fused disconnect switch must be copper.

4. All field wire size values given in table apply to 75° C rated wire per NEC.


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

TO COMPRESSOR(S)

27

28

NB

CHILLER CONTROL

120V

24V

T2

TIMECLOCK

CONTACTAUTO

AMBIENTTHERMOSTAT

BI4

BI1

24VAC

OFF

ON

17

18

4

CHILLER FLOW

SWITCH CONTACT

THEMOSTAT TC2.

WH

S1

BK

1

2

WH

16

AND FAN MOTORS.

OPTIONAL FUSED

CONTROL CIRCUIT

TRANSFORMER

3 PHASE

POWER

SUPPLY

DISCONNECT

BY OTHERS TERMINAL BLOCK

F1

540

13 F2

COOLER HEATER

COOLER HEATER

SEPARTE 115V

POWER FOR COOLER

HEATER (SEE NOTE A)

SEE NOTE A

545

NOTE A :

IT MAY BE DESIRABLE TO HAVE THE UNIT

COOLER HEATER ON A SEPARATE DISCONNECT

SWITCH FROM THE MAIN UNIT POWER SUPPLY

SO THAT THE UNIT MAY BE SHUT DOWN WITH

OUT DEFEATING THE FREEZE PROTECTION

PROVIDED BY THE COOLER HEATER. TO AC-

COMPLISH THIS, REMOVE WIRES 540 AND 545

AND FIELD WIRE TERMINALS 13 AND 16 TO A

SEPARATE 115V POWER SOURCE.

LEGEND

FIELD CONNECTION TERMINAL

FACTORY WIRING

FIELD WIRING

5

CHILLER CONTROL

(CIRCUIT 1)

CHILLER CONTROL

(CIRCUIT 2)


Dimensional Data

Figure 8, 110E through 185E Dimensions

ALR EVAPORATOR CENTER OF GRAVITY ISOLATOR LOCATION NUMBER

UNIT "A" CONN. WATER CONNECTIONS X Y R S T OF

SIZE LENGTH SIZE (1) B C E FANS

110E 229 (5817) 6 (152.4) 117.6

(2987)

13.8 (351) 19.5 (495) 106.5

(2705)

41.7 (1059) 13 (330) 58 (1473) 215 (5461) 10

120E 229 (5817) 6 (152.4) 118.5

(3010)

12.9 (328) 19.5 (495) 106.5

(2705)

41.7 (1059) 13 (330) 58 (1473) 215 (5461) 10

130E 229 (5817) 6 (152.4) 118.5

(3010)

12.9 (328) 19.5 (495) 107.0

(2718)

41.7 (1059) 13 (330) 58 (1473) 215 (5461) 12

135E 229 (5817) 6 (152.4) 118.5

(3010)

12.9 (328) 19.5 (495) 105.0

(2667)

41.7 (1059) 13 (330) 58 (1473) 215 (5461) 12

140E 229 (5817) 6 (152.4) 118.5

(3010)

12.9 (328) 19.5 (495) 108.0

(2743)

41.7 (1059) 13 (330) 58 (1473) 215 (5461) 12

145E 229 (5817) 6 (152.4) 118.5

(3010)

12.9 (328) 20.5 (521) 103.0

(2616)

41.7 (1059) 13 (330) 58 (1473) 215 (5461) 12

150E 229 (5817) 6 (152.4) 118.5

(3010)

12.9 (328) 20.5 (521) 105.0

(2667)

41.7 (1059) 13 (330) 58 (1473) 215 (5461) 12

160E 263 (6680) 6 (152.4) 153.2

(3891)

47.6 (1209) 20.5 (521) 121.0

(3074)

41.7 (1059) 13 (330) 95 (2413) 250 (6350) 14

170E 263 (6680) 6 (152.4) 153.2

(3891)

47.6 (1209) 20.5 (521) 119.0

(3023)

41.7 (1059) 13 (330) 95 (2413) 250 (6350) 14

180E 263 (6680) 6 (152.4) 153.2

(3891)

47.6 (1209) 20.5 (521) 118.0

(2997)

41.7 (1059) 13 (330) 95 (2413) 250 (6350) 14

185E 263 (6680) 6 (152.4) 153.2

(3891)

47.6 (1209) 20.5 (521) 118.0

(2997)

41.7 (1059) 13 (330) 95 (2413) 250 (6350) 14


Unit Layout and Principles of Operation

Figure 9, Major Component LocationsThe figure below illustrates component locations for each unit size.

CondFan 11Cond

Fan 11Cond

Fan 12Cond

Fan 12Cond

Fan 13Cond

Fan 13Cond

Fan 14Cond

Fan 14Cond

Fan 15Cond

Fan 15

CondFan 21Cond

Fan 21Cond

Fan 22Cond

Fan 22Cond

Fan 23Cond

Fan 23Cond

Fan 24Cond

Fan 24Cond

Fan 25Cond

Fan 25

Comp#2

Comp#2

Cooler

Comp#1

Comp#1

CO

NT

RO

LB

OX

032E, 035E, 040E032E, 035E, 040E

045E, 050E,055E, 060E, 065E045E, 050E,055E, 060E, 065E

070E

CondFan 11Cond

Fan 11Cond

Fan 12Cond

Fan 12Cond

Fan 13Cond

Fan 13Cond

Fan 14Cond

Fan 14Cond

Fan 15Cond

Fan 15Cond

Fan 16Cond

Fan 16Cond

Fan 17Cond

Fan 17

CondFan 21Cond

Fan 21Cond

Fan 22Cond

Fan 22Cond

Fan 23Cond

Fan 23Cond

Fan 24Cond

Fan 24Cond

Fan 25Cond

Fan 25Cond

Fan 26Cond

Fan 26Cond

Fan 27Cond

Fan 27

CO

NT

RO

LB

OX

Comp#2

Comp#2

Comp#4

Comp#4

Cooler

Comp #3Comp #3

Comp#1

Comp#1

080E, 085E, 090E, 100E, 110E, 120E080E, 085E, 090E, 100E, 110E, 120E

130E, 135E, 140E, 145E, 150E130E, 135E, 140E, 145E, 150E

160E, 170E, 180E, 185E160E, 170E, 180E, 185E

075E

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

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

Control center layouts ALR 080E through 185E

Figure 10, Left Side, 115V ControlSection

Figure 11, Right Side, High VoltagePower Section


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

Figure 12,Recommended Field Installed Unit Disconnect Location

Note: Mount disconnect on stationary panel so it does not interfere with hinged doors or withair intake into coil.

Stationary Panel

Disconnect Switch

9.5"(241mm)

Min.

PowerIntoUnit

Hinged Doors onControl Center

6" (152mm) Min.


Start-up and Shutdown

Pre Start-up1. Open all electric disconnects and check all electric connections for tightness. Check all

compressor valve connections for tightness.

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

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

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

5. Check voltage of the unit power supply and make certain voltage is within ±10% of nameplaterating.

6. Check unit power supply wiring for proper ampacity and a minimum insulation temperature of75°C.

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

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

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

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

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

NOTE: If LWC1 is a Unit 33 Metasys control, the control must be energized before thechilled water flow switch is closed.

CAUTIONMost relays and terminals in the unit control center are energized with S1 and the controlcircuit disconnect on. Do not close S1 until start-up.

Start-up1. Verify compressor suction and discharge shutoff valves are backseated. Always replace valve

seal caps.

2. Open oil equalization line valve.

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

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

5. Start auxiliary equipment by turning on the following:

� Time clock

� Ambient thermostat and/or remote on/off switch

� Chilled water pump.

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


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

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

� Oil level in each compressor crankcase

� Rotation of fans

� Flashing in refrigerant sightglass.

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

10. After system performance has stabilized, complete the “Compressorized Equipment WarrantyForm” (Form No. 415415Y) to obtain full warranty benefits. Return the form to McQuayInternational through your sales representative.

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

Start - upWith the control circuit power on and the control stop switch S1 closed, 115V power is appliedthrough the control circuit fuse F1 to the compressor crankcase heaters HTR1, HTR2, HTR3, andHTR4, the compressor motor protections MP1, MP2, MP3 and MP4, and the primary of the 24Vcontrol circuit transformer. The 24V transformer provides power to the contacts of the low pressurecontrols LP1 and LP2 and the compressor lockout timer TD1 and TD2.

When the remote time clock or manual shutdown switch turns on the chilled water pump, theflow switch closes and 115V power is applied to the relay contacts on the leaving water controlLWC1. The unit will automatically operate in response to the LWC1 if the manual pumpdownswitches PS1 and PS2 are closed ( in the “auto” position); the compressor lockout time relays R5, R6,R7, and R8; and the freezestats FS1 and FS2, high pressure controls HP1 and HP2, and thecompressor motor protectors MP1, MP2, MP3, and MP4 do not sense failure conditions.

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

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

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


PumpdownAs the leaving water control is satisfied, it will unload the compressor(s) and then de-energize theliquid line solenoid valve(s) SV1 and SV2, causing the valve(s) to close. When the compressor haspumped most of the refrigerant out of the evaporator and into the condenser, the low pressurecontrol(s) LP1 and LP2 will open. If the refrigerant leaks into the low side causing the pressure toclose the low pressure controls LP1 and LP2, the compressor will start after a two-hour time delay.For normal temperature controlled operation, the timer is bypassed and the compressor will start on arefrigerant pressure rise.

Note: Do not shut the unit down without going through the pumpdown cycle. Flow switch,time clock, and ambient lockout thermostat must be wired to allow pumpdown when unit isturned off.

.

13600 Industrial Park Boulevard, P.O. Box 1551, Minneapolis, MN 55440 USA (612) 553-5330

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