Installation, Operation and Maintenance Manual IOM ACAQ

Group: Chiller
Part Number: 074640501
Effective: February 1998
Supersedes: None

Air-Cooled Condensers
Type ACS 010 Through ACS 100
Type ACD 045 Through ACD 210

Type AQS 020 Through AQS 085

Type AQD 040 Through AQD 170

© 1998 McQuay International

Table of Contents

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

Installation..............................................................................................................3
Unit Location...............................................................................................................................3
Sound Vibration ...........................................................................................................................3
Walls or Obstructions...................................................................................................................4
Multiple Units..............................................................................................................................5
Units in Pits .................................................................................................................................5
Decorative Fences ........................................................................................................................5
Refrigerant Piping..................................................................................................6
Refrigerant Piping........................................................................................................................7
Discharge Lines ...........................................................................................................................7
Electrical Wiring ....................................................................................................8

Operation..............................................................................................................17
Start-Up .....................................................................................................................................17
Discharge Gas Pulsation.............................................................................................................17
Low Ambient Operation Head Pressure Control .........................................................................17
Fan Cycling ...............................................................................................................................17
Fan Cycling Head Pressure Controls ..........................................................................................18
SpeedTrol ..................................................................................................................................18
Maintenance .........................................................................................................18
Cleaning Instructions .................................................................................................................18


1998 McQuay International
"Illustrations cover the general appearance of McQuay International products at the time of publication and we reserve the right to make changes in design and
construction at anytime without notice"

2 Air-Cooled Condensers IOM ACAQ

Introduction
Carefully check each shipment against the bill of lading and account for all items. Report any
shortage or damage to the delivering carrier.
Be careful when uncrating, to prevent damage. Heavy equipment should be left on units shipping
base until it has been moved to the final location.
This equipment must be installed in accordance with accepted industry standards. Failure to meet
the following conditions may void the warranty:
1. System piping must be installed following industry standards for good piping practices.
2. Inert gas must be charged into piping during welding.
3. System must be thoroughly leak checked and evacuated before initial charging. High vacuum
gauge capable of reading microns is mandatory. Dial indicating pressure gauges are not
acceptable.
4. Power supply to system must meet the following conditions:
§ Voltage for 208/230 motors not less than 195 volts or more than 253 volts.
§ All other voltages must be within 10% of nameplate ratings.
§ Phase imbalance not to exceed 2%.
5. All controls and safety switch circuits properly connected per wiring diagram.
6. Factory installed wiring must not be changed without written factory approval.
7. Relief valves must meet all code requirements.

Installation

Unit Location
Units are designed for outdoor application and may be mounted on a roof or concrete slab (ground
level installation). Install roof mounted units on steel channels or an I-beam frame to support the
unit above the roof. Use of vibration pads or isolators is recommended. The roof must be strong
enough to support the weight of the unit. For ground level installation, mount units on a one-piece
concrete slab with footings extending below the frost line. Be certain concrete slabs are installed
level and are properly supported to prevent settling. Locate the condenser far enough away from
any wall or other obstruction to provide sufficient clearance for air entrance. Do not attach
ductwork to the coil inlet or fan outlet. Avoid air recirculation conditions that may be caused by
sight screening, walls, etc. and keep unit fan discharge away from any building air intakes. Do not
install unit where exhaust or ventilation equipment will affect entering air temperature or foul coils.

Sound Vibration
Install units away from occupied spaces, utility areas, corridors and auxiliary spaces to reduce the
transmission of sound and vibration to occupied spaces. The refrigerant piping should be flexible
enough to prevent the transmission of noise and vibration from the unit into the building. If the
refrigerant lines are to be suspended from the structure of the building, use isolation hangers to
prevent the transmission of vibration. Where piping passes through a wall, pack fiberglass and
sealing compound around the lines to minimize vibration and retain flexibility. The unit must be
secured in its final location. Holes are provided in the base runner for this purpose.

IOM ACAQ Air-Cooled Condensers 3

 Figure 1, Unit Rigging

Walls or Obstructions
Locate the unit to ensure air may circulate freely and not be recirculated. For proper air flow and
access all sides of the unit must be at least the total width of condenser away from any wall or
obstruction. Increase this
distance whenever possible. Be
sure enough room is left for
maintenance through access
doors and panels. Overhead
obstructions are not permitted.
When enclosed by three walls
the unit must be installed as
indicated for units in a pit.

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 Multiple Units
For units placed side by side, the
minimum distance between units
is the width of the largest unit. If
units are placed end to end, the
minimum distance between units
is 4 feet.

Units in Pits
The top of the unit should be
level with the top of the pit, and
side distance increased to at least
twice the width of condenser. If
the top of the unit is not level
with the top of pit, discharge
cones or stacks must be used to raise discharge air to the top of the pit. This is a minimum
requirement.

Decorative Fences
Fences must have 50% free
area, with 1 foot undercut, at
least the width of condenser
minimum clearance, and must
not exceed the top of unit. If
these requirements are not
met, unit must be installed as
indicated for "Units in pits".

IOM ACAQ Air-Cooled Condensers 5

Refrigerant Piping
Figure 2 illustrates a typical piping arrangement involving a remote condenser located at a higher
elevation, as commonly encountered when the condenser is on a roof and the compressor and
receiver are on grade level or in a basement equipment room. In this case, the design of the
discharge line is very critical. If properly sized for full load condition, the gas velocity might be too
low at reduced loads to carry oil up through the discharge line and condenser coil. Reducing the
discharge line size would increase the gas velocity sufficiently at reduced load conditions; however,
when operating at full load, the line would be greatly undersized, and thereby create an excessive
refrigerant pressure drop. This condition can be overcome in one of two following ways:
1. The discharge line may be properly sized for the desired pressure drop at full load conditions
and an oil separator installed at the bottom of the trap in the discharge line from the
compressor.
2. A double riser discharge line may be used as shown in Figure 3. Line "A" should be sized to
carry the oil at minimum load conditions and the line "B" should be sized that at full load
conditions both lines would have sufficient flow velocity to carry the oil to the condenser.
For more complete information, see the ASHRAE Handbook on Systems.
Be aware of the following when fabricating piping:
• All oil traps are to be as short in radius as possible. The trap may be fabricated using three 90
degree ells.
• Use pressure relief valves at the condenser to protect the coil.
• Use a drain line check valve when the condenser is at a lower temperature than the receiver.

Figure 2, Typical Piping Arrangement

Figure 3, Double Riser Discharge Piping

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 Refrigerant Piping
Install piping according to standard accepted refrigeration practice. See Table 1 and Table 2 for
discharge and liquid drain line sizes for remote condenser connections. Use only refrigeration grade
copper tubing and put dry nitrogen through lines while brazing.

CAUTION
Do not use soft solder joints. Do not leave dehydrated piping or components open to the
atmosphere any longer than is absolutely necessary.

Discharge Lines
Design discharge lines to ensure refrigerant pressure drop is minimized (high pressure losses cause
increased compressor horsepower per ton of refrigerant) and a sufficiently high gas velocity to carry
oil through to the condenser coil and receiver at all loading conditions is maintained.

Table 1, Tons of Refrigeration

Line Size Discharge Line Drain Line
Type L R-22 R-404A, R-507 Velocity 100 FPM
Copper Sat. Suction Temp. (°F) Sat. Suction Temp. (°F) Refrigerant
OD -40 0 40 -40 0 40 R-22 R-502
1/2 0.75 0.8 0.85 0.56 0.63 0.7 2.3 1.5
5/8 1.4 1.5 1.6 1.0 1.2 1.3 3.7 2.3
7/8 3.7 4.0 4.2 2.7 3.1 3.4 7.8 4.9
1 1/8 7.5 8.0 8.5 5.5 6.3 7.0 13.2 8.3
1 3/8 13.1 14.0 14.8 9.6 10.9 12.1 20.2 12.6
1 5/8 20.7 22.0 23.4 15.2 17.2 19.1 28.5 17.9
2 1/8 42.8 45.7 48.5 31.4 35.6 39.5 49.6 31.1
2 5/8 75.4 80.4 85.4 55.3 62.8 69.5 76.5 48.0
3 1/8 120.2 128.2 136.2 87.9 99.8 110.5 109.2 68.4
3 5/8 178.4 190.3 202.1 130.5 148.1 164.0 147.8 92.6
4 1/8 251.1 267.8 284.4 183.7 208.4 230.9 192.1 120.3
Notes:
1. Source: ASHRAE Refrigeration Handbook:
2. Line sizes based on pressure drop equivalent to 1 'F per 100 equivalent feet
3. Values in Table are based on 1051F condensing temperature. Multiply Table capacities by the factors in Table 2 for other
condensing temperatures.
4. If subcooling is substantial or the line is short, a smaller line size may be used. Applications with very little subcooling or very
long lines may require larger sizes.

Table 2, Condensing Temperature Correction Factor

Condensing Discharge Line
Temperature R-22 R-404, R-507
90 0.88 0.91
100 0.95 -0.97
110 1.04 1.02
120 1.10 1.08
130 1.18 1.16

IOM ACAQ Air-Cooled Condensers 7

Electrical Wiring
All electrical wiring must be installed according to the National Electrical Code, local codes and
regulations. Use copper conductors only. Provide overcurrent protection for the fan motors. All
standard motors have internal inherent overload protectors, allowing contactors to be used instead of
starters requiring thermal protectors.

WARNING
There may be more than one source of electrical current in this unit. Do not service
before disconnecting all power supplies.

All condensers are furnished with either single-phase or three-phase fan motors which are identified
by the unit dataplate. Electrical leads from each motor terminate at the unit junction box. Field
connections must be made from these leads in accordance with local, state and national codes. The
motors are wired into a common junction box. Where fan cycling is furnished and factory installed,
the motors are completely wired through the control and to the contactors. Check motors for proper
rotation and be sure motor voltage and control voltage agree with electric services furnished.

8 Air-Cooled Condensers IOM ACAQ

 Figure 4, Typical Two - Four Fan Wiring With Fan Control

IOM ACAQ Air-Cooled Condensers 9

 Figure 5, Typical Four - Eight Fan Wiring With Fan Control

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 Figure 6, Typical Five Fan Wiring With Fan Control

IOM ACAQ Air-Cooled Condensers 11

 Figure 7, Typical Six Fan Wiring With Fan Control

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 Figure 8, Typical Ten Fan Wiring With Fan Control

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 Figure 9, Typical Twelve Fan Wiring With Fan Control

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 Figure 10, Typical Six Fan Wiring With Individual Contactor Control

IOM ACAQ Air-Cooled Condensers 15

 Figure 11, Typical Twelve Fan Wiring With Individual Contactor Control

16 Air-Cooled Condensers IOM ACAQ

Operation

Start-Up
Check for proper fan rotation. Air is drawn through the coil on all units. Be sure the fans turn
freely. Rotation of the motors and blades should be in a "clock-wise" direction looking at the unit
from the blade side. On three phase units, it may be necessary to reverse two of the three power
leads to the unit.

Discharge Gas Pulsation

Gas pulsations in a refrigeration system are most commonly associated with the compressor and
connecting discharge piping. Variations in the system piping configuration, line sizing, operating
pressures and compressor and component mounting all contribute to the presence and magnitude of
these pulsations. The vibration and movement of components caused by the pulsations may result in
line breakage or damage to the condenser. In order to eliminate discharge pulsations and the
potential for related condenser damage, install a discharge muffler in the refrigeration piping.
Follow the recommendations of the compressor or muffler manufacturer when selecting these
components.

Low Ambient Operation Head Pressure Control

The capacity of an air-cooled condenser varies with the difference between the entering air dry bulb
temperature and the condensing temperature of the refrigerant. Since air temperature in some
regions varies from summer to winter, the condensing temperature must be kept high enough to
ensure proper operation of the refrigerant expansion valve during low ambient operation, and also
allow enough capacity to ensure excessively high condensing temperatures do not occur during high
ambient conditions.
The low limit of the head pressure is dependent upon the required pressure drop across the
thermostatic expansion valve. For normal air conditioning applications, maintain head pressure
above a condensing temperature corresponding to 90° F. This corresponds to a normal lower limit of
about 60°F ambient air. When operation is required below 60°F ambient air temperature, additional
head pressure control will be required.

Fan Cycling
A decrease in ambient air temperature results in a capacity increase in the air-cooled condenser.
This capacity increase is directly proportional to the temperature difference between the condensing
temperature and the temperature of the ambient air entering the condenser. Air-cooled condensers
are often required to operate over a wide range of ambient air temperatures and variable loading
conditions, provisions must be made to maintain the overall system balance. Low head pressures
cause poor expansion valve operation and poor system operation.
The cycling of condenser fans provides an automatic means of maintaining head pressure
control, within reasonable limits, at lower ambient air temperatures. A fan cycling control system
allows fans to cycle in sequence by sensing condensing pressures. Short cycling is normally caused
by too close a differential in the control settings or set points. If flooding valves are used with fan
cycling, set valves to follow the fan cycling. Set pressure switches to at least 35 PSIG differential
setting.
Any fan cycle that is less than three minutes is considered short cycling, and could be
detrimental to the system. Adjust controls accordingly. Wire the fan closest to the header end of the
condenser to run continuously, whenever the compressor(s) is (are) operational. Cycling all of the
fans off will cause rapid, short cycling of the fans and erratic head pressure control.

IOM ACAQ Air-Cooled Condensers 17

 If additional head pressure control is necessary beyond letting the lead fan run, use variable
speed or flooding controls. If cycling the header fan is necessary for adequate head pressure control,
cycle on pressure. Fans must not cycle in multiples except on double wide single circuit condensers
where they may cycle in pairs (one motor on each side). Do not cycle more than two fans at a time
on double wide condensers and only one fan at a time on single wide condensers.

Fan Cycling Head Pressure Controls

Condenser fans are cycled to maintain adequate head pressure. Pressure fan cycling is available as
optional equipment.

Table 3, Factory Pressure Settings

Pressure fan cycling cycles fans in response to condenser pressure. This style of control is more
appropriate where the load on the condenser will vary due to multiple compressor operation or
stages of unloading or systems incorporating heat reclaim or hot gas defrost. Fan pressure and
differential settings may require adjustment to obtain stable operation.

SpeedTrol
Condenser head pressure control is provided by varying the air flow through the condenser by
changing the RPM of the condenser fan. This control package is offered in combination with
ambient fan cycling. The fan motor next to the header end of the condenser is the variable speed
fan. The remainder of the fans are constant speed and are cycled separately using pressure controls.
On condensers with two rows of fans, two variable speed fans are provided (one per unit) and the
remainder of the fans are constant speed.

Maintenance
Air-cooled condensing units require a minimum of maintenance. The unit coil will require a
periodic cleaning. Clean the unit using a brush, vacuum cleaner, pressurized air stream or a
commercially available coil cleaning foam. All of the condenser fan motors have sealed ball
bearings and do not need maintenance. If bearings fail, then replace bearings.

Cleaning Instructions
CAUTION
Never clean this unit with an acid-based cleaner.

Clean the finned surface at least every six months; more frequent cleaning may be required if
extreme conditions cause clogging or fouling of air passages through the finned surface.
Use Calgon Corporation's CalClean 41352 (or equal). Apply CalClean liberally to entering air
and leaving air surfaces of the finned area according to label directions and rinse thoroughly to
remove all cleaners..

18 Air-Cooled Condensers IOM ACAQ

Notes

IOM ACAQ Air-Cooled Condensers 19

Post Office Box 2510 Staunton, Virginia 24402-2510, USA, 540.248.0711