Heatcraft Refrigeration Products Condensing Units H Im Cu Users Manual

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H-IM-CU August 2008 Part No. 25008101

H-IM-CU-0808 | Version 000

Condensing

Units

Installation and

Operations Manual

Table of Contents

General Safety Information...............................................................................2

Inspection ...............................................................................................................2

Warranty Statement ............................................................................................2

Space and Location Requirements ...............................................................3

Remote and Water Cooled Condensing Units Requirements ..............4

City & Tower Water Connections .....................................................................4

Condensing Unit Rigging and Mounting ....................................................5

Head Pressure Control ........................................................................................6

Refrigerant Oils ......................................................................................................7

Phase Loss Monitor ..............................................................................................8

Recommended Refrigerant Piping Practices .............................................8

Refrigeration Pipe Supports ............................................................................8

Suction Lines ..........................................................................................................8

Liquid Lines ............................................................................................................9

Hot Gas Defrost Systems ...................................................................................9

Unit Cooler Piping .............................................................................................10

Line Sizing Tables ........................................................................................10-13

Evacuation and Leak Detection ...................................................................14

Refrigerant Charging Instructions ...............................................................14

Field Wiring .......................................................................................................... 14

Check Out and Start Up .................................................................................. 15

Operational Check Out .................................................................................... 16

System Balancing - Compressor Superheat ............................................. 16

General Sequence of Operation ..................................................................17

Electric Defrost Troubleshooting ................................................................. 17

System Troubleshooting Guide .................................................................... 18

Preventive Maintenance Guidelines ...........................................................19

Typical Wiring Diagrams ...........................................................................20-23

InterLink™ Replacement Parts ...................................................................... 24

Replaces None. Information formerly included in H-IM-64L.

General Safety Information

Installation and maintenance to be performed only by qualied

personnel who are familiar with this type of equipment.

Some units are pressurized with dry air or inert gas.

All units must be evacuated before charging the system with refrigerant.

WARNING: Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly.

Failure to follow this warning may result in personal injury or death.

Inspection

Responsibility should be assigned to a dependable individual at the job site

to receive material. Each shipment should be carefully checked against the

bill of lading. The shipping receipt should not be signed until all items listed

on the bill of lading have been accounted. Check carefully for concealed

damage. Any shortage or damages should be reported to the delivering

carrier. Damaged material becomes the delivering carrier’s responsibility,

and should not be returned to the manufacturer unless prior approval is

given to do so. When uncrating, care should be taken to prevent damage.

Heavy equipment should be left on its shipping base until it has been

moved to the nal location. Check the serial tag information with invoice.

Report any discrepancies to your Heatcraft Refrigeration Products Sales

Representative.

Warranty Statement

Seller warrants to its direct purchasers that products, including Service Parts,

manufactured by SELLER shall be of a merchantable quality, free of defects in

material or workmanship, under normal use and service for a period of one

(1) year from date of original installation, or eighteen (18) months from

date of shipment by SELLER, whichever rst occurs. Any product covered by

this order found to Seller’s satisfaction to be defective upon examination at

Seller’s factory will at SELLER’s option, be repaired or replaced and returned

to Buyer via lowest common carrier, or SELLER may at its option grant Buyer

a credit for the purchase price of the defective article. Upon return of a

defective product to SELLER’s plant, freight prepaid, by Buyer, correction of

such defect by repair or replacement, and return freight via lowest common

carrier, shall constitute full performance by SELLER of its obligations

hereunder.

SELLER shall have no liability for expenses incurred for repairs made by

Buyer except by prior, written authorization. Every claim on account of

breach of warranty shall be made to SELLER in writing within the warranty

period specied above – otherwise such claim shall be deemed waived.

Seller shall have no warranty obligation whatsoever if its products have

been subjected to alteration, misuse, negligence, free chemicals in system,

corrosive atmosphere, accident, or if operation is contrary to SELLER’s or

manufacturer’s recommendations, or if the serial number has been altered,

defaced, or removed.

MOTOR COMPRESSORS:

Motor compressors furnished by SELLER are subject to the standard

warranty terms set forth above, except that motor compressor replacements

or exchanges shall be made through the nearest authorized wholesaler

of the motor compressor manufacturer (not at SELLER’s factory) and no

freight shall be allowed for transportation of the motor compressor to and

from the wholesaler. The replacement motor compressor shall be identical

to the model of the motor compressor being replaced. Additional charges

which may be incurred throughout the substitution of other than identical

replacements are not covered by this warranty. An optional, non assignable,

four (4) year extended compressor warranty may be purchased within the

boundaries of the United Sates of America, its territories and possessions,

and Canada. With this extended compressor warranty, replacements are

administered by an authorized compressor distributor only. Replacements

within the rst year of the warranty area available through the distributor;

the second through fth years, the purchaser must submit a proof-of-

purchase of a compressor and supply it to Heatcraft Refrigeration Products

Warranty Claims for reimbursement.

Seller makes no express warranties except as noted above. All implied

warranties are limited to the duration of the Express Warranty. Liability for

incidental and consequential damages is excluded.

The forgoing is in lieu of all other warranties, express or implied,

notwithstanding the provisions of the uniform commercial code, the

Magnuson-Moss Warranty - Federal Trade Commission Improvement Act, or

any other statutory or common law, federal or state.

SELLER makes no warranty, express or implied, of tness for any particular

purpose, or of any nature whatsoever, with respect to products manufactures

or sold by seller hereunder, except as specically set forth above and on

the face hereof. It is expressly understood and agreed that SELLER shall not

be liable to buyer, or any customer of buyer, for direct or indirect, special,

incidental, consequential or penal damages, or for any expenses incurred by

reason of the use or misuse by buyer or third parties of said products. To the

extent said products may be considered "consumer products," As dened

in Sec. 101 of the Magnuson-Moss Warranty - Federal Trade Commission

Improvement Act, SELLER makes no warranty of any kind, express or implied,

to "consumers," except as specically set forth above and on the face hereof.

The following conditions should be adhered to when installing this unit to

maintain the manufacturers warranty:

System piping must be in accordance with good refrigeration

practices.

Inert gas must be charged into the piping during brazing.

The power supply to the unit must meet the following conditions:

A. Three phase voltages must be +/- 10%

of nameplate ratings. Single phase must be

within +10% or -5% of nameplate ratings.

B. Phase imbalance cannot exceed 2%.

All control and safety switch circuits must be properly connected

according to the wiring diagram.

The factory installed wiring and piping must not be changed

without written factory approval.

All equipment is installed in accordance with

Heatcraft Refrigeration Products specied minimum clearances.

Make sure that all eld wiring conforms to the requirements

of the equipment and all applicable national and local codes.

Avoid contact with sharp edges and coil surfaces.

They are a potential injury hazard.

Make sure all power sources are disconnected before any

service work is done on units.

The most important consideration which must be taken into account when

deciding upon the location of air-cooled equipment is the provision for a

supply of ambient air to the condenser, and removal of heated air from the

condensing unit or remote condenser area. Where this essential requirement

is not adhered to, it will result in higher head pressures, which cause poor

operation and potential failure of equipment. Units must not be located

in the vicinity of steam, hot air or fume exhausts. Corrosive atmospheres

require custom designed condensers.

Another consideration which must be taken is that the unit should be

mounted away from noise sensitive spaces and must have adequate support

to avoid vibration and noise transmission into the building. Units should be

mounted over corridors, utility areas, rest rooms and other auxiliary areas

where high levels of sound are not an important factor. Sound and structural

consultants should be retained for recommendations.

Space and Location Requirements for

Air Cooled Condensing Units and Remote Condensers

Figure 1. Space and Location Requirements for Condensing Units

Units in Pits

The top of the unit should be level with the top of the pit, and side

distance increased to “2W”.

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, a “W”

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”.

Walls or Obstructions

The unit should be located so that air may circulate freely and not be

recirculated. For proper air ow and access all sides of the unit should be

a minimum of “W” away from any wall or obstruction. It is preferred that

this distance be increased whenever possible. Care should be taken to

see that ample room is left for maintenance work through access doors

and panels. Overhead obstructions are not permitted. When the unit is

in an area where it is enclosed by three walls the unit must be installed

as indicated for units in a pit.

Walls or Obstructions for Horizontal Air Flow

Multiple Units with Horizontal Air Flow

* “W” = Total width of the condensing unit

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.

MIN.

AIR FLOW

MIN.

AIR FLOW AIR FLOW

Clearance for multiple units placed side by side

AIR FLOW AIR FLOW

AIR FLOW

MIN. W

MIN.

1 FT. MIN.

Clearance for fence enclosures

AIR FLOW

MIN.

10 FT. MAX.

Clearance for units in pits

AIR FLOW

STACK

(SUPPLIED BY OTHERS)

MIN.

AIR FLOW

Clearance from walls or obstructions

AIR FLOW

NOT RECOMMENDED

AIR FLOW

AIR FLOW AIR FLOW

W W

AIR FLOW

Requirements for Remote and Water Cooled

Condensing Units

General Installation

The indoor compressor units are designed to be used with a remote

condenser. The water cooled units are similar, except that they have an

integral water cooled condenser. Inlet and outlet water connections are to

be made in the eld. On units having a compressor water jacket, incoming

water shall be routed through the jacket prior to entering the condenser. For

cleaning purposes, condenser end plates can be removed to give access to

the water tubes. Cleaning is accomplished by a simple spiral tool powered

by an ordinary electric drill. During installation, allow space for cleaning the

condenser. Commercial equipment of this type is intended for installation

by qualied refrigeration mechanics.

Typical Arrangements

Diagram 1 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 suciently at reduced

load conditions; however, when operating at full load, the line would be

greatly undersized, and thereby creating an excessive refrigerant pressure

drop. This condition can be overcome in one of two of the following ways:

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.

City & Tower Water Connections

In the refrigeration industry “City” and “Tower” are designations of

temperature and ow conditions, not applications. The term “City” refers

to operating conditions where incoming water is 75˚F, and condensing

temperature is 105˚F. “Tower” refers to a higher temperature relationship

which is normally 85˚F, incoming water and 105˚F condensing temperature.

Water circuits in some condenser models provide a center, or Tower, outlet

connection to allow divided inlet water ow. This extra water port reduces

water velocity, water pressure drop, and condenser wear in applications such

as cooling towers where higher inlet temperatures and water ows occur.

Water Connections for City

For City water (open system) high pressure applications, the Tower

connections is plugged.

Water Connections for Tower

For Tower usage and low pressure applications, both normal water

connections will be used as inlets and the tower connection as an outlet.

Diagram 1 Diagram 2

Figure 2. Water Connections

A double riser discharge line may be used as shown in

Diagram 2. Line “A” should be sized to carry the oil at minimum

load conditions and the line “B” should be sized so that at the

full load conditions both lines would have sucient ow velocity

to carry the oil to the condenser.

Water Regulating Valve

Using this control on the water cooled condensing units, the head pressure

can be maintained by adjusting the ow of water through the condenser

section. This type control is most often located on the water entering side of

the condenser and is regulated by the refrigerant condensing pressure.

Subcooler

Diagrams 1 and 2 below show typical subcooler piping. Diagram 1 is the

preferred connection with receiver as it provides maximum subcooling.

Diagram 2 may be used if the receiver is located far from the condenser.

Notes:

All oil traps are to be as short in radius as possible. Common practice is

to fabricate the trap using three 90 degree ells.

Pressure relief valves are recommended at the condenser for protection

of the coil.

A pressure valve at the high point in the discharge line is recommended

to aid in removing non-condensables.

The placement of a subcooler should be that it does not interfere with

normal airow of the condenser. Increased static of the unit could cause

a decrease in system capacity and fan motor damage.

Figure 3. Spring Mount

Figure 5. Spring Mount

Figure 4. Solid Mount for Mobile or Deep Sump Application

Condensing Unit Rigging and Mounting

Rigging holes are provided on all units. Caution should be exercised when

moving these units. To prevent damage to the unit housing during rigging,

cables or chains used must be held apart by spacer bars. The mounting

platform or base should be level and located so as to permit free access of

supply air.

Ground Mounting

Concrete slab raised six inches above ground level provides a suitable base.

Raising the base above ground level provides some protection from ground

water and wind blown matter. Before tightening mounting bolts, recheck

level of unit. The unit should in all cases be located with a clear space in all

directions that is at a minimum, equal to the height of the unit above the

mounting surface. A condensing unit mounted in a corner formed by two

walls, may result in discharge air recirculation with resulting loss of capacity.

Roof Mounting

Due to the weight of the units, a structural analysis by a qualied engineer

may be required before mounting. Roof mounted units should be installed

level on steel channels or an I-beam frame capable of supporting the weight

of the unit. Vibration absorbing pads or springs should be installed between

the condensing unit legs or frame and the roof mounting assembly.

Access

Provide adequate space at the compressor end of the unit for servicing.

Provide adequate space on the connection side to permit service of components.

Spring Mounted Compressor

Compressors are secured rigidly to make sure there is no transit damage.

Before operating the unit, it is necessary to follow these steps:

Remove the upper nuts and washers.

Discard the shipping spacers.

Install the neoprene spacers. (Spacers located in the electrical

panel or tied to compressor.)

Replace the upper mounting nuts and washers.

Allow 1/16 inch space between the mounting nut/washer and

rubber spacer. Mounting spring must not be fully compressed

when mounting nut is properly installed. See Figures 3 and 5.

Rigid Mounted Compressor

Some products use rigid mounted compressors. Check the compressor

mounting bolts to insure they have not vibrated loose during shipment. See

Figure 4.

CAUTION:

Under no circumstance should all condenser motors be allowed to cycle o on one control. At least one motor shall be wired to operate at all times.

Under most circumstances, the condenser motor nearest the inlet header should remain on whenever the compressor is operating.

CAUTION:

Fans closest to the headers should not be cycled on standard temperature or pressure controls. Dramatic temperature and pressure changes at the

headers as a result of fan action can result in possible tube failure. Fan motors are designed for continuous duty operation.

Fan cycling controls should be adjusted to maintain a minimum of (5) minutes on and (5) minutes o. Short cycling of fans may result in a

premature failure of motor and/or fan blade.

Compressors operating below +10°F SST must have air owing over the compressor at all times when the compressor is running.

Figure 6. Dual Valve Piping Arrangement

Figure 7. Single Valve Flooding Valve Piping Arrangement

Head Pressure Control

Several types of head pressure control systems are available on

condensing units:

Dual Valve System. (See section on operation and adjustment.)

Single Valve system. No adjustments are necessary.

(See section on operation.)

Ambient Fan Cycle Control. (See section on operation

and adjustment.)

A. Dual Valve System

The system employs an ORI (open on rise of inlet pressure) valve and an ORD

( open on rise of dierential pressure) valve. The high pressure discharge gas

is introduced above the liquid in the receiver tank. The receiver discharge is

regulated by the ORI valve.

The discharge pressure of the ORI valve must be adjusted to regulate the unit

for proper operating conditions. Adjust the ORI valve shown on the following

diagram to maintain a discharge pressure of 160 to 180 PSIG.

Table 1. Ambient Fan Cycle Thermostat Settings

Models Design Thermostat Settings

T.D. T1 T2 T3

30 60

2-fan units: 25 65

20 70

4-fan units: 15 75

30 60 40

3-fan units: 25 65 55

20 70 60

6-fan units: 15 75 65

30 60 50 30

8-fan units: 25 65 55 40

20 70 65 50

15 75 70 60

NOTE: Cycle pairs of fans on double wide units.

Operation and Adjustment

Condensing units with dual valves require sucient charge to partially ood

the condenser during low ambient conditions.

Valve adjustment should be made with gauges connected to the discharge

port of the compressor. Adjustments should be made during mild or

low ambient conditions. Turning the valve stem “clockwise” on the ORI

valve will increase the discharge pressure, while turning the valve stem

“counterclockwise” will decrease the discharge pressure.

If adjustments are made during warm ambient conditions, it may not be

possible to adjust the regulator valve as low as desired. Readjustment may

be necessary once cooler conditions prevail.

B. Single Valve System

The standard valve used on high pressure refrigerant systems controls

the head pressure at approximately 180 PSIG. There is no adjustment for

this valve. On low pressure refrigerant systems the valve controls pressure

at approximately 100 PSIG. For energy eciency, the 100 PSIG valve is

sometimes used on high pressure refrigerant systems.

At condensing pressures above the valve setting, ow enters Port C and

leaves Port R. When the condensing pressure falls below the valve setting,

the valve modulates to permit discharge gas to enter Port D. Metering

discharge gas into the refrigerant ow leaving the condenser produces a

higher pressure at the condenser outlet, reduces the ow, and causes the

level of liquid refrigerant to rise in the condenser. This “ooding” of the

condenser with liquid refrigerant reduces the available condensing surface,

holding the condensing pressure at the valve setting.

C. Ambient Fan Cycle Control

This is an automatic winter control method which will maintain a condensing

pressure within reasonable limits by cycling fan motors in response to

outside air temperature. The thermostat(s) should be eld adjusted to shut

o the fan when the condensing temperature is reduced to approximately

90˚F. Table 1 lists approximate settings for several system T.D.’s. These settings

are approximate as they do not take into account variations in load.

Refrigeration Oils*

With the changes that have taken place in our industry due to the CFC

issue, we have reevaluated our lubricants to ensure compatibility with the

new HFC refrigerants and HCFC interim blends oered by several chemical

producers. As a secondary criteria, it is also desirable that any new lubricant

be compatible with the traditional refrigerants such as HCFC-22 or R502. This

“backward compatibility” has been achieved with the introduction of the

Polyol ester lubricants.

Polyol Ester Lubricants

Hygroscopicity

Ester lubricants (POE) have the characteristic of quickly absorbing moisture

from the ambient surroundings. This is shown graphically in Figure 8 where

it can be seen that such lubricants absorb moisture faster and in greater

quantity than conventional mineral oils. Since moisture levels greater

than 100 ppm will results in system corrosion and ultimate failure, it is

imperative that compressors, components, containers and the entire system

be kept sealed as much as possible. Lubricants will be packaged in specially

designed, sealed containers. After opening, all the lubricant in a container

should be used at once since it will readily absorb moisture if left exposed to

the ambient. Any unused lubricant should be properly disposed of. Similarly,

work on systems and compressors must be carried out with the open time as

short as possible. Leaving the system or compressor open during breaks or

overnight MUST BE AVOIDED!

Figure 8.

Color

As received, the POE lubricant will be clear or straw colored. After use, it may

acquire a darker color. This does not indicate a problem as the darker color

merely reects the activity of the lubricant's protective additive.

Oil Level

During Copeland's testing of Polyol ester oil, it was found that this lubricant

exhibits a greater tendency to introduce oil into the cylinder during ooded

start conditions. If allowed to continue, this condition will cause mechanical

failure of the compressor.

A crankcase heater is required with condensing units and it must be turned

on several hours before start-up.

Oil level must not exceed 1/4 sight glass.

Oil Types

Table 2 below summarizes which oils/lubricants are approved for use in

Copeland compressors.

Mineral Oils

The BR and Scroll compressors use Sontex 200, a “white oil”. This oil is

not suitable for low temperature applications nor is it available through

the normal refrigeration wholesalers. For eld “top-o” the use of 3GS or

equivalent, or Zerol 200TD is permissible, as long as at least 50% of the total

oil charge remains Sontex 200.

Suniso 3GS, Texaco WF32 and Calumet R015 (yellow oils) are available

through normal refrigeration wholesalers. These oils are compatible if mixed

and can be used on both high and low temperature systems.

Polyol Ester Lubricants

The Mobil EAL ARCTIC 22 CC is the preferred Polyol ester due to unique

additives included in this lubricant. ICI Emkarate RL 32S is an acceptable

Polyol ester lubricant approved for use when Mobil is not available. These

POE’s must be used if HFC refrigerants are used in the system. They are

also acceptable for use with any of the traditional refrigerants or interim

blends and are compatible with mineral oils. They can therefore be mixed

with mineral oils when used in systems with CFC or HCFC refrigerants when

Copeland compressors are used. These lubricants are compatible with one

another and can be mixed.

Alkyl Benzenes

Zerol 200TD is an alkyl benzene (AB) lubricant. Copeland recommends this

lubricant for use as a mixture with mineral oil (MO) when using the interim

blends such as R-401A, R-401B and R-402A (MP39, MP66 and HP80). A

minimum of 50% AB is required in these mixtures to assure proper oil return.

Shell MS 2212 is a 70/30 mixture of AB/MO. If this lubricant is used in a

retrot situation virtually all of the existing MO must be drained prior to

relling with the MS 2212 to assure a minimum 50% AB content.

Table 2. Refrigeration Oils

Refrigeration Oils Traditional Refrigerants

HCFC-22

Interims

R401A, R401B, R402A

(MP-39, MP-66, HP-80)

HFC's

HFC-134a, R404A, R507

POE's Mobil EAL ARCTIC 22 CC A A P

ICI (Virginia KMP) EMKARATE RL 32CF A A P

Mineral Oils Suniso 3GS P PM NOT ACCEPTABLE

Texaco WF32 P PM

Calumet RO15 (Witco) P PM

Sontex 200-LT (White Oil) (BR & Scroll Only)

Witco LP-200 P

A/B Zerol 200TD AM PM NOT ACCEPTABLE

Soltex Type AB-200 PM

P = Preferred Lubricant Choice A = Acceptable Alternative M = Mixture of Mineral Oil and Alkyl Benzene (AB) with minimum 50% AB.

*(Reprinted by permission from Copeland Corporation)

Figure 9. Example of Pipe Support Figure 10. Condensing Unit / Compressor to Wall Support

Suction Lines

Horizontal suction lines should slope away from the evaporator toward

the compressor at the rate of 1/4 inch per 10 feet for good oil return. When

multiple evaporators are connected in series using a common suction line,

the branch suction lines must enter the top of the common suction line.

For dual or multiple evaporator systems, the branch lines to each evaporator

should be sized for the evaporator capacity. The main common line should

be sized for the total system capacity.

Suction lines that are outside of refrigerated space must be insulated. See

the Line Insulation section on page 14 for more information.

Phase Loss Monitor

The combination phase sequence and loss monitor relay protects the system

against phase loss (single phasing), phase reversal (improper sequence) and

low voltage (brownout). When phase sequence is correct and full line voltage

is present on all three phases, the relay is energized as the normal condition

indicator light glows.

Note: If compressor fails to operate and the normal condition indicator light

on the phase monitor does not glow, then the supplied electrical current

is not in phase with the monitor. This problem is easily corrected by the

following steps:

Turn power o at disconnect switch.

Swap any two of the three power input wires.

Turn power on. Indicator light should glow and compressor

should start.

Observe motors for correct rotation.

Recommended Refrigerant Piping Practices

The system as supplied by Heatcraft Refrigeration Products, was

thoroughly cleaned and dehydrated at the factory. Foreign matter may enter

the system by way of the evaporator to condensing unit piping. Therefore,

care must be used during installation of the piping to prevent entrance of

foreign matter.

Install all refrigeration system components in accordance with applicable

local and national codes and in conformance with good practice required for

the proper operation of the system.

The refrigerant pipe size should be selected from the Line Sizing Tables. The

interconnecting pipe size is not necessarily the same size as the stub-out on

the condensing unit or the evaporator.

The following procedures should be followed:

Do not leave dehydrated compressors or lter-driers on

condensing units open to the atmosphere any longer than is

absolutely necessary.

Use only refrigeration grade copper tubing, properly sealed

against contamination.

Suction lines should slope 1/4" per 10 feet towards

the compressor.

Suitable P-type oil traps should be located at the base of each

suction riser to enhance oil return to the compressor.

For desired method of superheat measurement, a pressure tap

should be installed in each evaporator suction line in

the proximity of the expansion valve bulb.

When brazing refrigerant lines, an inert gas should be passed

through the line at low pressure to prevent scaling and

oxidation inside the tubing. Dry nitrogen is preferred.

Use only a suitable silver solder alloy on suction and liquid lines.

Limit the soldering paste or ux to the minimum required to

prevent contamination of the solder joint internally. Flux only the

male portion of the connection, never the female. After brazing,

remove excess ux.

See Table 6 for discharge and liquid drain line sizes for remote

condenser connections.

If isolation valves are installed at the evaporator, full port ball

valves should be used.

Refrigerant Pipe Support

Normally, any straight run of tubing must be supported in at least two

locations near each end of the run. Long runs require additional

supports. The refrigerant lines should be supported and fastened

properly. As a guide, 3/8 to 7/8 should be supported every 5 feet; 1-1/8

and 1-3/8 every 7 feet; and 1-5/8 and 2-1/8 every 9 to 10 feet.

When changing directions in a run of tubing, no corner should be left

unsupported. Supports should be placed a maximum of 2 feet in each

direction from the corner.

Piping attached to a vibrating object (such as a compressor or

compressor base) must be supported in such a manner that will not

restrict the movement of the vibrating object. Rigid mounting will

fatigue the copper tubing.

Do not use short radius ells. Short radius elbows have points of excessive

stress concentration and are subject to breakage at these points.

Thoroughly inspect all piping after the equipment is in operation and

add supports wherever line vibration is signicantly greater than most

of the other piping. Extra supports are relatively inexpensive as

compared to refrigerant loss.

Figure 11. Suction P-Traps

Slope 1/4"

per 10 ft.

toward

compressor

Figure 12. Double Suction Riser Construction

Sized for

Minimum

Load

Sized

for Full

Load

Sized for

Minimum

Load

Sized

for Full

Load

Suction Line Risers

Prefabricated wrought copper traps are available, or a trap can be made

by using two street ells and one regular ell. The suction trap must be the

same size as the suction line. For long vertical risers, additional traps may

be necessary. Generally, one trap is recommended for each length of pipe

(approximately 20 feet) to insure proper oil movement. See Figure 11 for

methods of constructing proper suction line P-traps.

NOTE:

A suction line trap must be installed at the point where piping changes the direction of refrigerant ow from any horizontal run to an upward vertical run.

Liquid Lines

Liquid lines should be sized for a minimum pressure drop to prevent

“ashing”. Flashing in the liquid lines would create additional pressure drop

and poor expansion valve operation. If a system requires long liquid lines

from the receiver to the evaporator or if the liquid has to rise vertically

upward any distance, the losses should be calculated to determine whether

or not a heat exchanger is required. The use of a suction to liquid heat

exchanger may be used to subcool the liquid to prevent ashing. This

method of subcooling will normally provide no more than 20˚F subcooling

on high pressure systems. The amount of subcooling will depend on the

design and size of the heat exchanger and on the operating suction and

discharge pressures. An additional benet from the use of the suction to

liquid type heat exchanger is that it can help raise the superheat in the

suction line to prevent liquid return to the compressor via the suction line.

Generally, heat exchangers are not recommended on R-22 low temperature

systems. However, they have proved necessary on short, well insulated

suction line runs to provide superheat at the compressor.

Hot Gas Defrost Systems

Hot Gas Defrost systems can be described as reverse cycle, re-evap., or

alternating evaporator. Please see manual H-IM-HGD for Mohave™ systems.

Refrigerant Piping

Install all refrigerant components in accordance with applicable local and

national codes and in accordance with good practice for proper system

operation. The thermostatic expansion valve must be the externally

equalized type. It can be mounted inside the unit end compartment. Mount

the expansion valve bulb on a horizontal run of suction line as close as

possible to the suction header. Use the clamps provided with the valve to

fasten the bulb securely so there is a tight line-to-line contact between the

bulb and the suction line. Suction and hot gas connections are made on the

outside of the unit.

Suction lines should be sloped towards the compressor at the rate of one

(1) inch per ten (10) feet for good oil return. Vertical risers of more than four

(4) feet should be trapped at the bottom with a P-trap. If a P-trap is used, the

expansion valve bulb should be installed between the unit and the trap.

Reverse Cycle System

The hot gas unit coolers can be used in reverse cycle hot gas defrost systems

using multiple evaporators connected to one condensing unit. Generally, not

more than one-third of the system defrosts at one time. During the reverse

cycle defrost, the reversing valve, located in the compressor discharge line,

diverts hot gas through the suction line to the evaporator.

See the piping view in the Reverse Cycle Defrost Piping diagram. The suction

line check valve directs the hot gas through the drain pan loop which

prevents condensate in the pan from freezing. The hot gas exits the loop at

the pan loop outlet header and enters the evaporator through the check

valve assembly. As the hot gas defrosts the coil, heat is removed from the

hot gas and eventually it condenses into a liquid and exits the coil at the

distributor side port. The liquid then ows through the check valve of the

thermostatic expansion valve bypass assembly, around the thermostatic

expansion valve, and into the system liquid line. The liquid refrigerant then

feeds other evaporators on the cooling cycle, evaporates, and returns to the

compressor through their suction lines.

Hot gas line sizes for R-22, R404A and R507

System Capacity

BTU/Hr

Equivalent Discharge Length (Ft.)

25 50 75 100 150

4,000 1/2 1/2 1/2 1/2 1/2

5,000 1/2 1/2 1/2 1/2 1/2

6,000 1/2 1/2 1/2 5/8 5/8

7,000 1/2 1/2 5/8 5/8 5/8

8,000 1/2 5/8 5/8 5/8 5/8

9,000 1/2 5/8 5/8 5/8 5/8

10,000 1/2 5/8 5/8 5/8 5/8

12,000 5/8 5/8 5/8 7/8 7/8

14,000 5/8 5/8 7/8 7/8 7/8

16,000 5/8 5/8 7/8 7/8 7/8

18,000 5/8 7/8 7/8 7/8 7/8

20,000 5/8 7/8 7/8 7/8 7/8

25,000 7/8 7/8 7/8 7/8 1-1/8

30,000 7/8 7/8 7/8 1-1/8 1-1/8

35,000 7/8 7/8 1-1/8 1-1/8 1-1/8

40,000 7/8 1-1/8 1-1/8 1-1/8 1-1/8

45,000 7/8 1-1/8 1-1/8 1-1/8 1-1/8

50,000 7/8 1-1/8 1-1/8 1-1/8 1-1/8

60,000 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8

70,000 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8

80,000 1-1/8 1-1/8 1-3/8 1-3/8 1-5/8

90,000 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8

100,000 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8

Note: Use next larger hot gas line size for -200F. and lower suction temperatures.

EVAP. COIL

TXV

PAN LOOP

THREE-PIPE DEFROST PIPING

CHECK

VALVE

HOT GAS LINE

LIQUID LINE

SUCTION LINE

HEAT – X

EVAP. COIL

TXV

PAN LOOP

CHECK VALVE

REVERSE CYCLE DEFROST PIPING

CHECK VALVE

CHECK

VALVE

LIQUID

LINE

SUCTION

LINE

HEAT – X

IMPORTANT:

It is imperative that with the alternating evaporator hot

gas defrost system, no more that 25% of the operating

refrigeration load be in defrost at any time.

Three Pipe System

The three pipe system (sometimes called re-evap.) uses three pipes: one for

liquid line, one for suction line, and one for hot gas line. In addition, a re-

evaporator accumulator is used at the suction outlet of the evaporator. The

hot gas is taken from the discharge line between the compressor and the

condenser, through a hot gas solenoid valve, then to the evaporator drain

pan circuit, distributor tee, through the coil. See the Three-Pipe Defrost

Piping Diagram for typical piping at the evaporator coil.

Alternating Evaporator System

In the alternating evaporator hot gas defrost system, a third line is taken

o the compressor discharge line as the re-evap system. It is piped with

solenoids at each evaporator, so that hot gas defrost is accomplished on one

or more evaporators while the remaining evaporators continue to function

in a normal manner. The liquid from defrosting evaporators is reintroduced

to the main liquid line and it is necessary that 75% or greater capacity be

retained in the normal refrigeration cycle to oset the capacity that is being

removed by the units on the hot gas defrost.

Pipe size example:

Given: -10°F Freezer with one system having (2) evaporators

• One condensing unit rated at 24,000 BTUH’s @ -20°F SST R404A

refrigerant.

• Two evaporators each rated at 12,000 BTUH’s @ 10°F TD.

• 100 feet of actual line run between condensing unit to rst evaporator

and 20 feet of actual line run between the rst evaporator and the

second evaporator (see gure below).

How to gure line sizes:

Determine equivalent line run = actual run + valves and tting allowances.

Use Line Sizing Tables to size lines.

Note any special considerations.

Fittings in this system:

• (6) 90° elbows in main line plus a 90° turn through a tee.

• (5) addtional 90° elbows to rst evaporator.

• (4) additional 90° elbows to second evaporator.

Determine line size 1 (main line from condensing unit):

Main line from the condensing unit to be sized for the total capacity

(balance) of the whole system of 24,000 BTUH’s (Table 8).

Refer to 24,000 @100 feet at -20°F SST R404A on the chart.

You will nd the suction line to be 1-3/8" and 1/2" liquid line.

Refer to Table 5. For every 1-3/8" 90° elbow you must add 4 equivalent

feet of pipe and 2.5 equivalent feet of pipe for each 1-3/8" tee.

Therefore, total equivalent line run =

Actual line run 100 feet

+ (6) 1-3/8" elbows @ 4' 24 feet

+ (1) 1-3/8" tee @ 2.5' 2.5 feet

Total equivalent line run 126.5 feet

Refer to Table 8. For 126.5 total equivalent feet, the suction

line size should be 1-3/8" and the liquid line stays at 1/2" line.

Note: The gray shaded areas on Table 8. For 24,000 BTUH’s, the maximum

suction riser is 1-1/8" to insure proper oil return and pressure drop from the

bottom p-trap to the top p-trap.

Determine line size 2 (evaporators):

Line sizing to each evaporator is based on 12,000 BTUH’s and

equivalent run from condensing unit. First evaporator has an 105 ft.

run and the second evaporator has a 120 ft. run.

Table 8 indicates 1-1/8" suction for the rst evaporator and indicates

1-1/8" suction for the second evaporator.

Refer to Table 5. Each 1-1/8" 90° elbow adds 3 equivalent feet of pipe.

Each 90° turn through a 1-1/8" tee adds 6 equivalent feet.

Actual line run (evap 1) 105 feet

+ (5) 1-1/8" elbows @ 3' 15 feet

+ (1) 90° turn through tee @ 6' 6 feet

Total equivalent line run 126 feet

Actual line run (evap 2) 120 feet

+ (4) 1-1/8" elbows @ 3' 12 feet

Total equivalent line run 132 feet

Table 8 indicates 1-1/8" suction line and 3/8" liquid line from

main line to both evaporators.

Unit Cooler Piping

Evap. 1

Evap. 2

Table 3. Weight of Refrigerants in Copper Lines During Operation (Pounds per 100 lineal feet of type "L" tubing)

Line Size O.D.

(Inches) Refrigerant Liquid Line Hot Gas Line Suction Line at Suction Temperature

-40˚F -20˚F 0˚F +20˚F +40˚F

3/8 22 3.9 0.22 0.02 0.03 0.04 0.06 0.08

R507, 404A 3.4 0.31 0.03 0.04 0.06 0.09 0.13

1/2 22 7.4 0.41 0.03 0.05 0.07 0.11 0.15

R507, 404A 6.4 0.58 0.04 0.07 0.13 0.16 0.24

5/8 22 11.8 0.65 0.05 0.08 0.12 0.17 0.25

R507, 404A 10.3 0.93 0.07 0.11 0.17 0.25 0.35

7/8 22 24.4 1.35 0.10 0.16 0.24 0.36 0.51

R507, 404A 21.2 1.92 0.15 0.23 0.37 0.51 0.72

1-1/8 22 41.6 2.30 0.17 0.28 0.42 0.61 0.87

R507, 404A 36.1 3.27 0.26 0.39 0.63 0.86 1.24

1-3/8 22 63.5 3.50 0.27 0.42 0.64 0.93 1.33

R507, 404A 55.0 4.98 0.40 0.58 0.95 1.32 1.87

1-5/8 22 90.0 4.96 0.37 0.59 0.90 1.33 1.88

R507, 404A 78.0 7.07 0.56 0.82 1.35 1.86 2.64

2-1/8 22 156 8.61 0.65 1.03 1.57 2.30 3.26

R507, 404A 134 12.25 0.98 1.43 2.35 3.23 4.58

2-5/8 22 241 13.70 1.01 1.59 2.42 3.54 5.03

R507, 404A 209 18.92 1.51 2.21 3.62 5.00 7.07

3-1/8 22 344 18.95 1.44 2.28 3.45 5.05 7.18

R507, 404A 298 27.05 2.16 3.15 5.17 7.14 9.95

3-5/8 22 465 25.60 1.94 3.08 4.67 6.83 9.74

R507, 404A 403 36.50 2.92 4.25 6.97 19.65 13.67

4-1/8 22 605 33.40 2.53 4.01 6.08 8.90 12.70

R507, 404A 526 47.57 3.80 5.55 9.09 12.58 17.80

Line Sizing

The following Tables 7 and 8 indicate liquid lines and suction lines for all

condensing units for R22, R404A, and R507.

When determining the refrigerant line length, be sure to add an allowance

for ttings. See Table 5. Total equivalent length of refrigerant lines is the sum

of the actual linear footage and the allowance for ttings.

Table 4. Pressure Loss of Liquid Refrigerants in Liquid Line Risers (Expressed in Pressure Drop, PSIG, and Subcooling Loss, ˚F)

Refrigerant

Liquid Line Rise in Feet

10' 15' 20' 25' 30' 40' 50' 75' 100'

PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F

R22 4.8 1.6 7.3 2.3 9.7 3.1 12.1 3.8 14.5 4.7 19.4 6.2 24.2 8.0 36.3 12.1 48.4 16.5

R507, R404A 4.1 1.1 6.1 1.6 8.2 2.1 10.2 2.7 12.2 3.3 16.3 4.1 20.4 5.6 30.6 8.3 40.8 11.8

Based on 110˚F liquid temperature at bottom of riser.

Table 5. Equivalent Feet of Pipe Due to Valve and Fitting Friction

Copper Tube, O.D., Type “L” 1/2 5/8 7/8 1-1/8 1-3/8 1-5/8 2-1/8 2-5/8 3-1/8 3-5/8 4-1/8 5-1/8 6-1/8

Globe Valve (Open) 14 16 22 28 36 42 57 69 83 99 118 138 168

Angle Valve (Open) 7 9 12 15 18 21 28 34 42 49 57 70 83

90˚ Turn Through Tee 3 4 5 6 8 9 12 14 17 20 22 28 34

Tee (Straight Through) or Sweep Below .75 1 1.5 2 2.5 3 3.5 4 5 6 7 9 11

90˚ Elbow or Reducing Tee (Straight Through)

1 2 2 3 4 4 5 7 8 10 12 14 16

Table 6. Recommended Remote Condenser Line Sizes

Net Evaporator

Capacity

Total Equiv.

Length

R-22 R507 & R-404A

Discharge Line (O.D.) Liquid Line Cond. to

Receiver (O.D.) Discharge Line (O.D.) Liquid Line Cond. to

Receiver (O.D.)

3,000 50 3/8 3/8 3/8 3/8

100 3/8 3/8 3/8 3/8

6,000 50 3/8 3/8 1/2 3/8

100 1/2 3/8 1/2 3/8

9,000 50 1/2 3/8 1/2 3/8

100 1/2 3/8 1/2 3/8

12,000 50 1/2 3/8 1/2 3/8

100 5/8 3/8 5/8 1/2

18,000 50 5/8 3/8 5/8 1/2

100 5/8 3/8 7/8 1/2

24,000 50 5/8 3/8 5/8 1/2

100 7/8 1/2 7/8 5/8

36,000 50 7/8 1/2 7/8 5/8

100 7/8 5/8 7/8 7/8

48,000 50 7/8 5/8 7/8 5/8

100 7/8 7/8 1-1/8 7/8

60,000 50 7/8 5/8 7/8 7/8

100 1-1/8 7/8 1-1/8 7/8

72,000 50 7/8 7/8 1-1/8 7/8

100 1-1/8 7/8 1-1/8 1-1/8

90,000 50 1-1/8 7/8 1-1/8 7/8

100 1-1/8 7/8 1-1/8 1-1/8

120,000 50 1-1/8 7/8 1-1/8 1-1/8

100 1-3/8 1-1/8 1-3/8 1-3/8

180,000 50 1-3/8 1-1/8 1-3/8 1-3/8

100 1-5/8 1-3/8 1-5/8 1-5/8

240,000 50 1-3/8 1-3/8 1-5/8 1-3/8

100 1-5/8 1-3/8 2-1/8 1-5/8

300,000 50 1-5/8 1-3/8 1-5/8 1-5/8

100 2-1/8 1-5/8 2-1/8 2-1/8

360,000 50 1-5/8 1-5/8 2-1/8 1-5/8

100 2-1/8 2-1/8 2-1/8 2-1/8

480,000 50 2-1/8 1-5/8 2-1/8 2-1/8

100 2-1/8 2-1/8 2-1/8 2-5/8

600,000 50 2-1/8 2-1/8 2-1/8 2-1/8

100 2-5/8 2-5/8 2-5/8 2-5/8

720,000 50 2-1/8 2-1/8 2-1/8 2-5/8

100 2-5/8 2-5/8 2-5/8 3-1/8

840,000 50 2-1/8 2-1/8 2-5/8 2-5/8

100 2-5/8 2-5/8 2-5/8 3-1/8

960,000 50 2-5/8 2-5/8 2-5/8 2-5/8

100 2-5/8 3-1/8 3-1/8 3-5/8

1,080,000 50 2-5/8 2-5/8 2-5/8 3-1/8

100 3-1/8 3-1/8 3-1/8 3-5/8

1,200,000 50 2-5/8 2-5/8 2-5/8 3-1/8

100 3-1/8 3-1/8 3-5/8 4-1/8

1,440,000 50 2-5/8 3-1/8 3-1/8 3-5/8

100 3-1/8 3-5/8 3-5/8 4-1/8

1,680,000 50 3-1/8 3-1/8 3-1/8 3-5/8

100 3-5/8 3-5/8 3-5/8 4-1/8

Table 7. Recommended Line Sizes for R-22 *

Capacity

BTUH

Suction Line Size Liquid Line Size

Suction Temperature Receiver to

Expansion Valve

Equivalent

Lengths

+40˚F

Equivalent Lengths

+20˚F

Equivalent Lengths

+10˚F

Equivalent Lengths

0˚F

Equivalent Lengths

-10˚F

Equivalent Lengths

-20˚F

Equivalent Lengths

25' 50' 100' 150' 25' 50' 100' 150' 25' 50' 100' 150' 25' 50' 100' 150' 25' 50' 100' 150' 25' 50' 100' 150' 25' 50' 100' 150'

1,000 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 1/2 3/8 3/8 3/8 1/2 3/8 3/8 1/2 1/2 3/8 3/8 3/8 3/8

3,000 3/8 3/8 1/2 1/2 3/8 1/2 1/2 5/8 3/8 1/2 1/2 5/8 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 3/8 3/8 3/8 3/8

4,000 3/8 3/8 1/2 1/2 3/8 1/2 1/2 5/8 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 1/2 5/8 5/8 7/8 3/8 3/8 3/8 3/8

6,000 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 1/2 5/8 5/8 7/8 5/8 5/8 5/8 7/8 1/2 5/8 7/8 7/8 5/8 5/8 7/8 7/8 3/8 3/8 3/8 3/8

9,000 1/2 5/8 5/8 7/8 1/2 5/8 5/8 7/8 5/8 5/8 7/8 7/8 5/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 5/8 7/8 7/8 1-

1/8 3/8 3/8 3/8 3/8

12,000 5/8 5/8 7/8 7/8 5/8 5/8 7/8 7/8 5/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 7/8 1-

1/8 7/8 7/8 1-

1/8

1/8 3/8 3/8 3/8 3/8

15,000 5/8 5/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 7/8 1-

1/8 7/8 7/8 7/8 1-

1/8 7/8 7/8 1-

1/8

1/8 7/8 7/8 1-

1/8

1/8 3/8 3/8 3/8 3/8

18,000 5/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 7/8 1-

1/8 7/8 7/8 1-

1/8

1/8 7/8 7/8 1-

1/8

1/8 7/8 1-

1/8

1/8 3/8 3/8 3/8 1/2

24,000 5/8 7/8 7/8 1-

1/8 7/8 7/8 7/8 1-

1/8 7/8 7/8 1-

1/8

1/8 7/8 1-

1/8

1/8 7/8 1-

1/8

3/8 7/8 1-

1/8

3/8

3/8 3/8 3/8 1/2 1/2

30,000 7/8 7/8 1-

1/8

1/8 7/8 7/8 1-

1/8

1/8 7/8 1-

1/8

1/8 7/8 1-

1/8

3/8 7/8 1-

1/8

3/8

1/8

3/8

3/8 3/8 3/8 1/2 1/2

36,000 7/8 1-

1/8

1/8 7/8 1-

1/8

1/8 7/8 1-

1/8

3/8

1/8

3/8

1/8

3/8

1/8

3/8

5/8 3/8 1/2 1/2 1/2

42,000 7/8 1-

1/8

1/8 7/8 1-

1/8

3/8

1/8

3/8

1/8

3/8

1/8

3/8

5/8

1/8

3/8

5/8

5/8 3/8 1/2 1/2 1/2

48,000 7/8 1-

1/8

1/8 7/8 1-

1/8

3/8

1/8

3/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8

5/8 1/2 1/2 1/2 1/2

54,000 7/8 1-

1/8

3/8

1/8

3/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8

3/8

5/8

1/8 1/2 1/2 1/2 5/8

60,000 7/8 1-

1/8

3/8

1/8

3/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8

3/8

5/8

1/8 1/2 1/2 5/8 5/8

66,000 7/8 1-

1/8

3/8

1/8

3/8

1/8

3/8

5/8

1/8

3/8

5/8

3/8

5/8

3/8

5/8

1/8 1/2 1/2 5/8 5/8

72,000 1-

1/8

3/8

1/8

3/8

5/8

1/8

3/8

5/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

1/8 1/2 1/2 5/8 5/8

78,000 1-

1/8

3/8

1/8

3/8

5/8

1/8

3/8

5/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

1/8 1/2 1/2 5/8 5/8

84,000 1-

1/8

3/8

1/8

3/8

5/8

3/8

5/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

1/8 1/2 5/8 5/8 5/8

90,000 1-

1/8

3/8

5/8

1/8

3/8

5/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

1/8 1/2 5/8 5/8 7/8

120,000

1/8

3/8

5/8

3/8

5/8

1/8

3/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8 5/8 5/8 7/8 7/8

150,000

3/8

5/8

1/8

3/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

5/8 5/8 7/8 7/8 7/8

180,000

3/8

5/8

1/8

3/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

5/8 5/8 7/8 7/8 7/8

210,000

3/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8 7/8 7/8 7/8 7/8

240,000

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8 7/8 7/8 7/8 1-

1/8

300,000

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

1/8 7/8 7/8 1-

1/8

360,000

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8 7/8 7/8 1-

1/8

480,000

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

3/8

600,000

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

3/8

* NOTES:

Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size.

Properly placed suction traps must also be used for adequate oil return.

All sizes shown are for O.D. Type L copper tubing.

Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly.

Recommended liquid line size may increase with reverse cycle hot gas systems.

If system load drops below 40% of design, consideration to installing double suction risers should be made.

Table 8. Recommended Line Sizes for R-404A and R507*

Capacity

BTUH

Suction Line Size Liquid Line Size

Suction Temperature Receiver to

Expansion Valve

Equivalent

Lengths

+20˚F

Equivalent Lengths

+10˚F

Equivalent Lengths

-10˚F

Equivalent Lengths

-20˚F

Equivalent Lengths

-30˚F

Equivalent Lengths

-40˚F

Equivalent Lengths

25' 50' 100' 150' 25' 50' 100' 150' 25' 50' 100' 150' 25' 50' 100' 150' 25' 50' 100' 150' 25' 50' 100' 150' 25' 50' 100' 150'

1,000 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 1/2 1/2 3/8 3/8 1/2 1/2 3/8 3/8 1/2 1/2 3/8 1/2 1/2 5/8 3/8 3/8 3/8 3/8

3,000 3/8 3/8 1/2 1/2 3/8 1/2 1/2 5/8 1/2 1/2 5/8 5/8 1/2 1/2 5/8 7/8 1/2 1/2 5/8 7/8 1/2 1/2 5/8 7/8 3/8 3/8 3/8 3/8

4,000 3/8 1/2 1/2 5/8 1/2 1/2 5/8 5/8 1/2 5/8 5/8 7/8 1/2 5/8 7/8 7/8 5/8 5/8 7/8 7/8 1/2 5/8 7/8 7/8 3/8 3/8 3/8 3/8

6,000 1/2 1/2 5/8 7/8 1/2 1/2 5/8 7/8 1/2 5/8 7/8 7/8 5/8 5/8 7/8 7/8 5/8 5/8 7/8 7/8 5/8 5/8 7/8 7/8 3/8 3/8 3/8 3/8

9,000 5/8 5/8 7/8 7/8 5/8 5/8 7/8 7/8 5/8 7/8 7/8 7/8 5/8 7/8 7/8 1-

1/8 5/8 7/8 7/8 1-

1/8 3/8 3/8 3/8 3/8

12,000 5/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 7/8 1-

1/8 7/8 7/8 1-

1/8

1/8 7/8 7/8 1-

1/8

1/8 7/8 7/8 1-

1/8

1/8 3/8 3/8 3/8 3/8

15,000 5/8 7/8 7/8 7/8 7/8 7/8 7/8 1-

1/8 7/8 7/8 1-

1/8

1/8 7/8 7/8 1-

1/8

1/8 7/8 7/8 1-

1/8

1/8 7/8 7/8 1-

1/8

1/8 3/8 3/8 3/8 1/2

18,000 7/8 7/8 7/8 1-

1/8 7/8 7/8 1-

1/8

1/8 7/8 7/8 1-

1/8

1/8 7/8 1-

1/8

3/8 7/8 1-

1/8

3/8 7/8 1-

1/8

3/8 3/8 3/8 1/2 1/2

24,000 7/8 7/8 1-

1/8

1/8 7/8 1-

1/8

1/8 7/8 1-

1/8

3/8

1/8

3/8

1/8

3/8

1/8

3/8

3/8 3/8 3/8 1/2 1/2

30,000 7/8 7/8 1-

1/8

1/8 7/8 1-

1/8

3/8

1/8

3/8

1/8

3/8

1/8

3/8

1/8

3/8

3/8 3/8 1/2 1/2 1/2

36,000 7/8 1-

1/8

3/8

1/8

3/8

1/8

3/8

1/8

3/8

1/8

3/8

1/8

3/8

5/8 1/2 1/2 1/2 1/2

42,000 1-

1/8

3/8

1/8

3/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8 1/2 1/2 1/2 5/8

48,000 1-

1/8

3/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8

1/8

3/8

5/8 1/2 1/2 5/8 5/8

54,000 1-

1/8

3/8

1/8

3/8

5/8

3/8

5/8

3/8

5/8

3/8

5/8

3/8

5/8

5/8 1/2 1/2 5/8 5/8

60,000 1-

1/8

3/8

5/8

1/8

3/8

5/8

3/8

5/8

3/8

5/8

3/8

5/8

3/8

5/8

5/8 1/2 1/2 5/8 5/8

66,000 1-

1/8

3/8

5/8

1/8

3/8

5/8

3/8

5/8

3/8

5/8

3/8

5/8

3/8

5/8

5/8 1/2 1/2 5/8 5/8

72,000 1-

1/8

3/8

5/8

1/8

3/8

5/8

3/8

5/8

3/8

5/8

3/8

5/8

3/8

5/8

5/8 1/2 5/8 5/8 5/8

78,000 1-

1/8

3/8

5/8

3/8

5/8

3/8

5/8

1/8

5/8

1/8

5/8

1/8 5/8 5/8 5/8 5/8

84,000 1-

1/8

3/8

5/8

3/8

5/8

1/8

3/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

1/8 5/8 5/8 5/8 7/8

90,000 1-

3/8

5/8

1/8

3/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

1/8 5/8 5/8 7/8 7/8

120,000

3/8

5/8

1/8

3/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8 5/8 5/8 7/8 7/8

150,000

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

5/8 5/8 7/8 7/8 7/8

180,000

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

5/8 7/8 7/8 7/8 1-

1/8

210,000

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8 7/8 7/8 1-

1/8

240,000

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

1/8 7/8 7/8 1-

1/8

300,000

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

5/8 7/8 1-

1/8

3/8

360,000

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

3/8

480,000

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

3/8

5/8

600,000

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

5/8

1/8

3/8

5/8

* NOTES:

Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size.

Properly placed suction traps must also be used for adequate oil return.

All sizes shown are for O.D. Type L copper tubing.

Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly.

Recommended liquid line size may increase with reverse cycle hot gas systems.

If system load drops below 40% of design, consideration to installing double suction risers should be made.

Evacuation and Leak Detection

Due to the smaller molecule size of HFC’s, they will tend to leak more readily

than CFC’s. Consequently, it is of the utmost importance that proper system

evacuation and leak detection procedures be employed.

Copeland recommends a minimum evacuation to 500 microns. In addition,

a vacuum decay test is strongly recommended to assure there is not a

large pressure dierential between the system and vacuum pump. Good

evacuation processes include frequent vacuum pump oil changes and large

diameter, short hose connections to both high and low sides of the system

preferably using bronze braided hose.

Leak detection can be carried out in the conventional manner.

If HCFC or CFC tracer gas is used, care must be taken to completely remove

all traces of the gas prior to introducing HFC’s.

Electronic leak detectors are now available that will sense HFC’s. This is

considered preferable since it removes the possibility of chlorine remaining

in the system after leak testing with HCFC’s and/or CFC’s. There is a view that

even small quantities of chlorine may act as a catalyst encouraging copper

plating and/or corrosion and should therefore be avoided.

WARNING:

HFC-134a has been shown to be combustible at pressure as low as 5.5

psig (at 350˚F) when mixed with air at concentrations more than 60%

air by volume.

At lower temperature, higher pressures are required to support

combustion. Therefore, air should never be mixed with HFC-134a for

leak detection.

Within the last several years, manufacturers have developed uorescent dye

leak detection systems for use with refrigerants. These dyes mix with the

lubricant and, when exposed to an ultraviolet light “uoresce,” indicates the

location of leaks. Copeland has tested and approved the Rigid “System Safe”

dye and found it to be compatible with the compressor materials in systems.

Leak Testing

After all lines are connected, the entire system must be leak tested. The

complete system should be pressurized to not more than 150 psig with

refrigerant and dry nitrogen (or dry CO2). The use of an electronic type leak

detector is highly recommended because of its greater sensitivity to small

leaks. As a further check it is recommended that this pressure be held for a

minimum of 12 hours and then rechecked. For a satisfactory installation, the

system must be leak tight.

Line Insulation

After the nal leak test, refrigerant lines exposed to high ambient conditions

should be insulated to reduce heat pickup and prevent the formation of

ash gas in the liquid lines. Suction lines must always be insulated with 3/4"

wall Armstrong “Armaex” or equal. When required, Liquid lines should be

insulated with 1/2 inch wall insulation or better. The insulation located in

outdoor environments should be protected from UV exposure to prevent

deterioration of insulating value.

Evacuation

CAUTION:

Do not use the refrigeration compressor to evacuate the system. Do

not start the compressor while it is in a vacuum.

A good, deep vacuum pump should be connected to both the low and high

side evacuation valves with copper tube or high vacuum hoses (1/4" ID

minimum). If the compressor has service valves, they should remain closed.

A deep vacuum gauge capable of registering pressure in microns should be

attached to the system for pressure readings.

A shut o valve between the gauge connection and vacuum pump should

be provided to allow the system pressure to be checked after evacuation. Do

not turn o vacuum pump when connected to an evacuated system before

closing shut o valve.

The vacuum pump should be operated until a pressure of 1,500 microns

absolute pressure is reached — at which time the vacuum should be broken

with the refrigerant to be used in the system through a drier until the system

pressure rises above “0” psig.

NOTE:

Refrigerant used during evacuation cannot be vented. Reclaim all used

refrigerant. EPA regulations are constantly being updated. Ensure your

procedure follows correct regulations.

Repeat this operation a second time.

Open the compressor service valves and evacuate the entire system to 500

microns absolute pressure. Raise the pressure to 2 psig with the refrigerant

and remove the vacuum pump.

Refrigerant Charging Instructions

Install a liquid line drier in the refrigerant supply line between the

service gauge and the liquid service port of the receiver. This

extra drier will insure that all refrigerant supplied to the

system is clean and dry.

When initially charging a system that is in a vacuum, liquid

refrigerant can be added directly into the receiver tank.

Check equipment catalog for refrigerant capacity. System

refrigerant capacity is 90% of receiver capacity. Do not add more

refrigerant than the data tag indicates, unless the line run exceeds

25ft. Then, add additional refrigerant as per the chart on page 30.

Weigh the refrigerant drum before charging so an accurate record

can be kept of the weight of refrigerant put in the system.

Start the system and nish charging until the sight glass indicates

a full charge and the proper amount has been weighed in. If the

refrigerant must be added to the system through the

suction side of the compressor, charge in vapor form only. Liquid

charging must be done in the high side only or with

liquid metering devices to protect the compressor.

Low Head Pressure Systems

If you are charging the system by using a clear sight glass as an indication of

proper charge the following must be considered.

Check the condensing temperature. It must be above 105˚F. If not, it will be

necessary to reduce the amount of air going through the condenser from

fans still running. Simply reduce the eective condenser face area to raise the

discharge pressure above the equivalent 105˚F condensing temperature and

then proceed to charge to clear the sightglass. Adjust evaporator superheat

at this time. Return to full condenser face area and allow the system to

balance.

Field Wiring

WARNING:

All wiring must be done in accordance with applicable codes and local

ordinances.

The eld wiring should enter the areas as provided on the unit. The wiring

diagram for each unit is located on the inside of the electrical panel door.

All eld wiring should be done in a professional manner and in accordance

with all governing codes. Before operating unit, double check all wiring

connections, including the factory terminals. Factory connections can vibrate

loose during shipment.

The serial data tag on the unit is marked with the electrical characteristic

for wiring the unit.

Consult the wiring diagram in the unit cooler and in the condensing unit

for proper connections.

Wire type should be of copper conductor only and of the proper

size to handle the connected load.

The unit must be grounded.

For multiple evaporator systems, the defrost termination controls

should be wired in series. Follow the wiring diagrams for multiple

evaporator systems carefully. This will assure complete defrost of

all evaporators in the system.

Multiple evaporator systems should operate o of one thermostat.

If a remote defrost timer is to be used, the timer should be located

outside the refrigerated space.

For air cooled condensers, due to multiple low amp motors, we

recommend using time delay fuse protection instead

of circuit breakers.

Check Out and Start Up

After the installation has been completed, the following points should be

covered before the system is placed in operation:

Check all electrical and refrigerant connections.

Be sure they are all tight.

Observe compressor oil level before start-up. The

oil level should be at or slightly above the 1/4 level

of the sight glass. Refer to Table 3 for proper compressor oil.

Remove upper mounting nuts on the compressor feet.

Remove the shipping spacers. Install the neoprene washers onto

the compressor feet. Replace the upper mounting nuts

and washers, allowing 1/16" space between the mounting nut

and the neoprene spacer.

Check high and low pressure controls, pressure regulating valves,

oil pressure safety controls, and all other safety controls, and

adjust if necessary.

Check the room thermostat for normal operation

and adjust.

Wiring diagrams, instruction bulletins, etc. attached to the

condensing units should be read and led for future reference.

All fan motors should be checked for proper rotation. Fan

motor mounts should be carefully checked for tightness and

proper alignment.

Electric and hot gas evaporator fan motors should

be temporarily wired for continuous operation until

the room temperature has stabilized.

Observe system pressures during charging and initial operation.

Do not add oil while the system is short of refrigerant

unless oil level is dangerously low.

Continue charging until system has sucient refrigerant for

proper operation. Do not overcharge.

Remember that bubbles in a sight glass may be caused by

a restriction as well as a shortage of refrigerant.

Do not leave unit unattended until the system has

reached normal operating conditions and the oil

charge has been properly adjusted to maintain the oil

level between 1/4 and bottom of the sight glass.

Make sure all Schrader valve caps are in place and tight.

Make sure ALL service valves are properly back-seated and tighten

valve packing if necessary.

CAUTION:

Extreme care must be taken in starting compressors for the rst time

after system charging. At this time, all of the oil and most of the

refrigerant might be in the compressor creating a condition which could

cause compressor damage due to slugging. Activating the crankcase

heater for 24 hours prior to start-up is required. If no crankcase heater is

present, then directing a 500 watt heat lamp or other safe heat source on

the lower shell of the compressor for approximately thirty minutes will be

benecial in eliminating this condition which might never reoccur.

WARNING:

Scroll compressor is directional dependent. If noisy, change phase of

input wiring.

System Balancing - Compressor Superheat

IMPORTANT:

In order to obtain the maximum capacity from a system, and to ensure

trouble-free operation, it is necessary to balance each and every system.

This is extremely important with any refrigeration system.

The critical value which must be checked is suction superheat.

Suction superheat should be checked at the compressor as follows:

Measure the suction pressure at the suction service valve of the

compressor and determine the saturation temperature corresponding

to this pressure from a “Temperature-Pressure” chart.

Measure the suction temperature of the suction line about one

foot back from the compressor using an accurate thermometer.

Subtract the saturated temperature from the actual

suction line temperature. The dierence is superheat.

Too low a suction superheat can result in liquid being returned to the

compressor. This will cause dilution of the oil and eventual failure of the

bearings and rings or in the extreme case, valve failure.

Too high a suction superheat will result in excessive discharge temperatures

which cause a break down of the oil and results in piston ring wear, piston

and cylinder wall damage.

It should also be remembered that the system capacity decreases as the

suction superheat increases. For maximum system capacity, suction

superheat should be kept as low as is practical. Copeland mandates a

minimum superheat of 20˚F at the compressor. We recommend that the

superheat at the compressor be between 20˚F and 30˚F.

If adjustments to the suction superheat need to be made, the expansion

valve at the evaporator should be adjusted.

Operational Check Out

After the system has been charged and has operated for at least two hours at

normal operating conditions without any indication of malfunction, it should

be allowed to operate overnight on automatic controls. Then a thorough

recheck of the entire system operation should be made as follows:

Check compressor discharge and suction pressures.

If not within system design limits, determine why and

take corrective action.

Check liquid line sight glass and expansion valve operation. If

there are indications that more refrigerant is required, leak test

all connections and system components and repair any

leaks before adding refrigerant.

Observe oil level in compressor crankcase sight glass. Add oil as

necessary to bring level to bottom 1/4 of the sight glass.

Thermostatic expansion valves must be checked

for proper superheat settings. Feeler bulbs must be

in positive contact with the suction line and should

be insulated. Valves set at high superheat will lower

refrigeration capacity. Low superheat promotes

liquid slugging and compressor bearing washout.

Using suitable instruments, carefully check line voltage and

amperage at the compressor terminals. Voltage must be within

10% of that indicated on the condensing unit nameplate. If high

or low voltage is indicated, notify the power company.

If amperage draw is excessive, immediately determine the cause

and take corrective action. On three phase motor compressors,

check to see that a balanced load is drawn

by each phase.

The maximum approved settings for high pressure controls on

our air cooled condensing equipment is 425 psig. On air cooled

systems, check as follows:

Disconnect the fan motors or block the condenser inlet air. Watch

high pressure gauge for cutout point. Recheck all safety and

operating controls for proper operation and adjust if necessary.

Check defrost controls for initiation and termination settings, and

length of defrost period. Set fail safe at length of defrost + 25%.

Example: 20 minute defrost + 5 minutes

= 25 minute fail safe

Check drain pan for proper drainage.

Check winter head pressure controls for pressure setting.

Check crankcase heater operation if used.

Install instruction card and control system diagram for

use of building manager or owner.

NOTE:

All adjustable controls and valves must be eld adjusted to meet desired

operation. There are no factory preset controls or valve adjustments. This

includes low pressure, high pressure, adjustable head pressure systems

and expansion valves.

Table 9. Recommended Low Pressure Control Settings for Outdoor Air Cooled Condensing Units

*Minimum

Temp. ˚F

R-22 R-404A/R-507

Cut-In PSI Cut-Out PSI Cut-In PSI Cut-Out PSI

50 70 20 90 35

40 55 20 70 35

30 40 20 55 35

10 30 10 45 25

0 15 0 25 7

-10 15 0 20 1

-20 10 0 12 1

-30 6 0 8 1"Hg.

* Minimum ambient or box temperature anticipated, high pressure control setting: R-22, 360 PSI; R-404A, R-507, 400 PSI

* The standard preset low pressure switch used for pumpdown is set for 15 PSI cut in / 4 PSI cut out and is a good setting for most pumpdown systems

* ZB Scroll compressors should be set for 25 PSI cut in / 17 PSI cut out (R-404A / R-507)

Electric Defrost Troubleshooting

The electric defrost units are relatively simple and trouble-free in operation:

Timer

If the system does not go through its proper sequence , check timer

operation through a defrost cycle. Check for loose wires or terminals. Before

replacing timer, check other components.

Operation of Paragon Timer

To set time of day grasp knob which is in the center of the inner (fail-safe) dial

and rotate it in a counter-clockwise direction. This will cause the outer (24

hour) dial to revolve. Line up the correct time of day on the outer dial with

the time pointer. Do not try to set the time control by grasping the other (24

hour) dial. Place pins in the outer dial at the time of day that defrost

is required.

Operation of Grasslin Timer

To set the time, turn the minute hand clockwise until the time of day (and

AM or PM) on the outer dial is aligned with the triangle marker on the inner

dial. Do not rotate minute hand counter-clockwise. Move the white tab

(tripper) on the outer dial outward at each desired initiation time. Each white

tab (tripper) is a 15 minute interval and provides 15 minutes of defrost. For

longer defrost duration, move additional tabs (following in time) from the

initiation tab. For example, if a 45 minute defrost is to start at 7:00 AM, move

the tabs outward that lie between 7:00 - 7:15, 7:15 - 7:30 and 7:30 - 7:45 on

the AM side of the dial. The defrost will initiate at 7:00 AM and time terminate

at 7:45 AM (if temperature termination does not occur rst). For models with

plastic cover on timer assembly; re-install cover after adjustment.

NOTE:

After correcting faulty condition it is essential that the coil and unit be

free of ice before placing unit back on automatic operation.

NOTES:

1. Lockout relays or normally closed switch of auxiliary contact on the

compressor contactor may be wired to defrost contactor. Its purpose

is to prevent energizing of the defrost heaters until the compressor has

pumped down and stopped, thus keeping power demand to a minimum.

2. If the control voltage is to remain energized for any period of time with

the compressor disabled, remove the defrost clock pins to prevent the

defrost heaters from energizing.

3. A Preventative Maintenance schedule should be set up as soon as

possible after start-up to maintain equipment integrity.

General Sequence of Operation

Refrigeration Cycle

Power is supplied to the timer at terminals “1” and “N”.

The fan delay and the defrost termination thermostat is closed in the fan

delay position and open in the defrost termination position.

The unit cooler fans run continuously.

The defrost heaters are o.

The room thermostat closes when the temperature rises above the

desired setting.

The liquid line solenoid is energized and opens, which allows

liquid refrigerant to ow through the unit cooler.

The low pressure control closes when the suction pressure rises

above the cutin setting of the control.

On systems with oil pumps, the oil safety control is closed. If the

net oil pressure is less than 9 PSIG for more than 120

seconds, the oil safety opens, thus breaking the circuit

to the compressor contactor holding coil. The compressor will

not operate. This control is reset manually and must be

reset before the compressor can be restarted.

The compressor contactor closes. The compressor and condenser

fan start simultaneously.

The room temperature gradually decreases to the desired temperature.

Once the desired temperature is reached, the thermostat opens and the

liquid line solenoid closes, stopping refrigerant ow through

the evaporator.

Suction pressure decreases and the compressor contactor opens

when the pressure drops below the cutout setting on the low

pressure control. The compressor and condenser fan stop running.

This cycle is repeated as many times as necessary to satisfy the

room thermostat.

Frost starts to form on the evaporator coil and continues to form

until the defrost cycle is initiated.

Defrost Cycle

The defrost cycle starts automatically by the timer at predetermined

times. Typical settings are two to four defrost cycles per day for freezers.

For heavier frost loads additional settings may be required.

Switch “2” to “4” opens in the timer which breaks the circuit to the room

thermostat, liquid line solenoid, and evaporator fan motors, allowing

the compressor to pump down and shut o. Simultaneously

switch “1” to “3” closes in the timer allowing current to ow to one side

of the defrost heater contactor. When the compressor

shuts o, an auxiliary contact will send power to the contactor holding

coil; thus, energizing the defrost heaters.

The heaters raise the temperature of the coil to 32˚F causing the frost to

melt o the coil.

When the coil warms to 45˚F to 55˚F, the defrost termination thermostat

closes, which allows current to the switching solenoid in the timer

allowing the refrigeration cycle to begin again.

The evaporator heaters are o. If the termination thermostat fails to

close, the fail-safe set on the timer will terminate defrost.

The low pressure control closes and the compressor will start.

When the coil temperature reaches 23˚F to 30˚F, the fan

delay closes. This allows the current to ow to the fan

motors. The fan motors start running.

The system will now operate in the refrigeration cycle until another

defrost period is initiated by the timer.

10.

11.

12.

13.

Table 10. System Troubleshooting Chart

PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS

Compressor will not

run

1. Main switch open.

2. Fuse blown.

3. Thermal overloads tripped.

4. Defective contactor or coil.

5. System shut down by safety devices.

6. No cooling required.

7. Liquid line solenoid will not open.

8. Motor electrical trouble.

9. Loose wiring.

10. Phase loss monitor inoperative.

1. Close switch.

Check electrical circuits and motor winding for shorts or grounds.

Investigate for possible overloading. Replace fuse after fault is corrected.

3. Overloads are automatically reset. Check unit closely when unit

comes back on line.

4. Repair or replace.

5. Determine type and cause of shutdown and correct it before

resetting safety switch.

6. None. Wait until calls for cooling.

7. Repair or replace coil.

8. Check motor for open windings, short circuit or burn out.

9. Check all wire junctions. Tighten all terminal screws.

10. Refer to page 17.

Compressor noisy or

vibrating

1. Flooding of refrigerant into crankcase.

2. Improper piping support on suction or liquid line.

3. Worn compressor.

4. Scroll compressor rotation reversed.

1. Check setting of expansion valves.

2. Relocate, add or remove hangers.

3. Replace.

4. Rewire for phase change.

High discharge

pressure

1. Non-condensables in system.

2. System overcharges with refrigerant.

3. Discharge shutoff valve partially closed.

4. Fan not running.

5. Head pressure control setting.

6. Dirty condenser coil.

1. Remove the non-condensables.

2. Remove excess.

3. Open valve.

4. Check electrical circuit.

5. Adjust.

6. Clean.

Low discharge

pressure

1. Faulty condenser temperature regulation.

2. Suction shutoff valve partially closed.

3. Insufficient refrigerant in system.

4. Low suction pressure.

5. Variable head pressure valve.

1. Check condenser control operation.

2. Open valve.

3. Check for leaks. Repair and add charge.

4. See corrective steps for low suction pressure.

5. Check valve setting.

High suction

pressure

1. Excessive load.

2. Expansion valve overfeeding.

1. Reduce load or add additional equipment.

2. Check remote bulb. Regulate superheat.

Low suction pressure 1. Lack of refrigerant.

2. Evaporator dirty or iced.

3. Clogged liquid line filter drier.

4. Clogged suction line or compressor suction gas strainers.

5. Expansion valve malfunctioning.

6. Condensing temperature too low.

7. Improper TXV.

1. Check for leaks. Repair and add charge.

2. Clean.

3. Replace cartridge(s).

4. Clean strainers.

5. Check and reset for proper superheat.

6. Check means for regulating condensing temperature.

7. Check for proper sizing.

Little or no oil

pressure

1. Clogged suction oil strainer.

2. Excessive liquid in crankcase.

3. Low oil pressure safety switch defective.

4. Worn oil pump.

5. Oil pump reversing gear stuck in wrong position.

6. Worn bearings.

7. Low oil level.

8. Loose fitting on oil lines.

9. Pump housing gasket leaks.

1. Clean.

2. Check crankcase heater. Reset expansion valve for higher superheat.

Check liquid line solenoid valve operation.

3. Replace.

4. Replace.

5. Reverse direction of compressor rotation.

6. Replace compressor.

7. Add oil and/or through defrost.

8. Check and tighten system.

9. Replace gasket.

Compressor loses oil 1. Lack of refrigerant.

2. Excessive compression ring blow by.

3. Refrigerant flood back.

4. Improper piping or traps.

1. Check for leaks and repair. Add refrigerant.

2. Replace compressor.

3. Maintain proper superheat at compressor.

4. Correct piping.

Compressor thermal

protector switch

open

1. Operating beyond design conditions.

2. Discharge valve partially shut.

3. Blown valve plate gasket.

4. Dirty condenser coil.

5. Overcharged system.

1. Add components to bring conditions within acceptable limits (i.e.,

CPR/EPR valves, additional condenser surface, liquid injection, etc.).

2. Open valve.

3. Replace gasket.

4. Clean coil.

5. Reduce charge.

Air-Cooled Condensing Units

Quarterly

1) Visually inspect unit

• Look for signs of oil stains on interconnection piping and condenser

coil. Pay close attention to areas around solder joints, building

penetrations and pipe clamps. Check any suspect areas with an

electronic leak detector. Repair any leaks found and add refrigerant as

needed.

• Check condition of moisture indicator/sightglass in the sight glass if

so equipped. Replace liquid line drier if there is indication of slight

presence of moisture. Replace refrigerant, oil and drier if moisture

concentration is indicated to be high.

Unit Coolers

At every six month interval, or sooner if local conditions cause clogging

or fouling of air passages through the nned surface, the following items

should be checked.

1) Visually inspect unit

• Look for signs of corrosion on ns, cabinet, copper tubing and

solder joints.

• Look for excessive or unusual vibration for fan blades or sheet metal

panels when in operation. Identify fan cell(s) causing vibration and

check motor and blade carefully.

• Look for oil stains on headers, return bends, and coil ns. Check any

suspect areas with an electronic leak detector.

• Check drain pan to insure that drain is clear of debris,

obstructions or ice buildup and is free draining.

2) Clean evaporator coil and blades

• Periodic cleaning can be accomplished by using a brush, pressurized

water or a commercially available evaporator coil cleaner or mild

detergent. Never use an acid based cleaner. Follow label directions for

appropriate use. Be sure the product you use is approved for use in

your particular application.

• Flush and rinse coil until no residue remains.

• Pay close attention to drain pan, drain line and trap.

3) Check the operation of all fans and ensure airow is

unobstructed

• Check that each fan rotates freely and quietly. Replace any fan motor

that does not rotate smoothly or makes an unusual noise.

• Check all fan set screws and tighten if needed.

• Check all fan blades for signs of stress or wear.

Replace any blades that are worn, cracked or bent.

• Verify that all fan motors are securely fastened to the motor rail.

• Lubricate motors if applicable.

4) Inspect electrical wiring and components

• Visually inspect all wiring for wear, kinks, bare areas and discoloration.

Replace any wiring found to be damaged.

• Verify that all electrical and ground connections are secure, tighten

if necessary.

• Check operation/calibration of all fan cycle and defrost controls

when used.

• Look for abnormal accumulation of ice patterns and adjust defrost

cycles accordingly

• Compare actual defrost heater amp draw against unit data plate.

• Visually inspect heaters to ensure even surface contact with the coil. If

heaters have crept, decrease defrost termination temperature and be

sure you have even coil frost patterns. Re-align heaters as needed.

• Check drain line heat tape for proper operation (supplied and installed

by others).

5) Refrigeration Cycle

• Check unit cooler superheat and compare reading for your specic

application

• Visually inspect coil for even distribution

• Check moisture indicator/sightglass for ash gas. If found check

entire system for refrigerant leaks and add refrigerant as needed after

repairing any leaks.

• Check compressor sightglass (if equipped) for proper oil level.

• Check condition of condenser. Look for accumulation of dirt and debris

(clean as required).

• Check for unusual noise or vibration. Take corrective action as required.

• Inspect wiring for signs of wear or discoloration and repair if needed.

• Check and tighten all are connections.

Semi-Annually

2) Repeat all quarterly inspection items.

3) Clean condenser coil and blades

• Periodic cleaning can be accomplished by using a brush, pressurized

water and a commercially available foam coil cleaner. If foam cleaner is

used, it should not be an acid based cleaner. Follow label directions for

appropriate use.

• Rinse until no residue remains.

4) Check operation of condenser fans

• Check that each fan rotates freely and quietly. Replace any fan motor

that does not rotate smoothly or makes excessive noise.

• Check all fan blade set screws and tighten as required.

• Check all fan blades for signs of cracks, wear or stress. Pay close

attention to the hub and spider. Replace blades as required.

• Verify that all motors are mounted securely.

• Lubricate motors if applicable. Do not lubricate permanently sealed,

ball bearing motors.

5) Inspect electrical wiring and components

• Verify that all electrical and ground connections are secure, tighten as

required.

• Check condition of compressor and heater contactors. Look for

discoloration and pitting. Replace as required.

• Check operation and calibration of all timers, relays pressure controls

and safety controls.

• Clean electrical cabinet. Look for signs of moisture, dirt, debris, insects

and wildlife. Take corrective action as required.

• Verify operation of crankcase heater by measuring amp draw.

6) Check refrigeration cycle

• Check suction, discharge and net oil pressure readings. If abnormal take

appropriate action.

• Check operation of demand cooling, liquid injection or unloaders if so

equipped.

• Check pressure drop across all lters and driers. Replace as required.

• Verify that superheat at the compressor conforms to specication. (30°F

to 45°F)

• Check pressure and safety control settings and verify proper operation.

Annually

7) In addition to quarterly and semiannual maintenance checks, submit an

oil sample for analysis

• Look for high concentrations of acid or moisture. Change oil and driers

until test results read normal.

• Investigate source of high metal concentrations, which normally

are due to abnormal bearing wear. Look for liquid refrigerant in the

crankcase, low oil pressure or low superheat as a possible source.

8) Inspect suction accumulator (if equipped)

• If the accumulator is insulated remove insulation and inspect for leaks

and corrosion.

• Pay close attention to all copper to steel brazed connections

• Wire brush all corroded areas and peeling paint.

• Apply an anticorrosion primer and paint as required. Re-insulate if

applicable.

Preventive Maintenance

Diagram 3. Typical Wiring Diagram for Single Evaporator with and without Defrost Timer

Diagram 4. Typical Wiring Diagram for Single Evaporator with Defrost Timer Only

Diagram 5. Typical Wiring Diagram for Multiple Evaporators with Defrost Timer Only

Diagram 6. Typical Wiring Diagram for Single Evaporator / Single Phase Defrost and Evaporator Fan Contactors

Diagram 7. Typical Wiring Diagram for Single Evaporator Defrost and Evaporator Fan Contactors

Diagram 8. Typical Wiring Diagram for Multiple Evaporators with Evaporator Fan Contactors/without Heater Limit Defrost

Diagram 10. Typical Wiring Diagram for Multiple Evaporators Defrost and Evaporator Fan Contactors

with Unit Cooler Holdout Relay

Diagram 9. Typical Wiring Diagram for Multiple Evaporators with Heater Limit Defrost and Evaporator Fan Contactors

Since product improvement is a continuing eort, we reserve the right to make changes in

specications without notice.

CLIMATE

CONTROL

Commercial Refrigeration Parts

The name behind the brands you trust.™

H-IM-CU-0808

Commercial Refrigeration Parts

Replacement Parts by

InterLink™ Comercial Refrigeration Parts is your link to a complete line of dependable and certied commercial refrigeration parts, accessories

and innovative electronic controls for all Heatcraft Refrigeration Products (HRP) brands - including Bohn, Larkin, Climate Control and Chandler.

At InterLink, we provide our wholesalers with a comprehensive selection of product solutions and innovative technologies for the installed

customer base. And every product is built to ensure the same high performance standards with which all HRP brands are built — backed by

a dedicated team to serve every customer need, delivering at the best lead times in the industry.

Replacement parts should be obtained from your local InterLink wholesaler. Replacement parts, which are covered under the terms of

the warranty statement on page 2 of this manual, will be reimbursed for total part cost only. The original invoice from the parts supplier

must accompany all warranty claims for replacement part reimbursement. Heatcraft Refrigeration Products reserves the right to adjust the

compensation amount paid on any parts submitted for warranty reimbursement when a parts supplier's original invoice is not provided with

a claim. For more information, call 800-686-7278 or visit www.interlinkparts.com.

For our complete Refrigeration Systems Installation and Operations Manual (H-IM-64L),

please visit http://heatcraftrpd.com/service/publibrary.asp.

Heatcraft Refrigeration Products Condensing Units H Im Cu Users Manual

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