TAFCO Walk In Cooler Freezer.pdf

THE GUIDE FOR

INSTALLING, STARTING - UP,

OPERATING and MAINTAINING

WITT CONDENSING UNITS AND REFRIGERATION SYSTEMS

TABLE OF CONTENTS

Safety Information and Guidelines.....................................................…… Receiving and Handling ................................................................……… Locating and Mounting Condensing Units ....................................……… Locating and Mounting Evaporators........................................……......….....4 - 5 Piping ...............................................................................................…….........6 - 7 Leak Testing .................................................................................…...…… Suction Line Design ...............................................................….….… Equivalent Feet of Tube ........................................................…….........… Weight of Refrigerant in Copper Tube.................................….......….… Recommended Line Sizes ..........................................................…….…....... 10 - 13 Field Wiring.....................................................................................…… Field Wiring Diagrams .................................................................……..…......14 - 16 Evacuation .................................................................................…….… Charging and Start-Up .................................................................…….… Charging Flooded Condenser Systems .................….....................………...19 Pressure Control Settings ...............................................................……… Indoor Condensing Unit Ventilation ................................................………...20 Defrosting Evaporators .....................................................................…...…...21 - 22 Product Loading and Air Circulation ................................................….… Operating Pressures and Temperatures .......................................……...…..23 System Start-Up Check List ...........................................................…...… System Service Check List ...........................................................……… Trouble-Shooting Systems ............................................................…….........26 - 27 System Maintenance .....................................................................…… Ordering Replacement Parts .......................................................………

SYSTEMS

IOM W550.0

January, 2002

201 Thomas French Dr. Scottsboro, AL. 35769 Phone 256-259-7400 Fax: 256-259-7478

SAFETY INFORMATION

READ THESE INSTRUCTIONS ALL THE WAY THROUGH BEFORE STARTING WORK!

Make sure all power sources are disconnected before doing any service work.

LOCK disconnects in the OFF position to prevent accidental turning on and injury.

Commercial refrigeration equipment should be installed, started-up, maintained, and serviced by trained and certified personnel having experience with this type of equipment.

All field wiring must conform to the requirements of the equipment, applicable local codes and the National Electrical Code. Always use correct size copper conductors.

Sheet metal and coil surface have sharp edges that are a potential injury hazard.

Handle carefully, using gloves and other protective safety wear to prevent injury.

COMPLY WITH SAFETY AND CAUTION LABELS ON THE EQUIPMENT

THINK SAFETY ! WORK SAFELY !

RECEIVING YOUR EQUIPMENT

INSPECTION

Check all items against the bill of lading to make sure all crates and cartons have been received.

If there are any shortages or damage, report it immediately to the carrier and file a freight claim.

Damaged equipment is the delivering carrier's responsibility. Take care not to damage equipment when uncrating. Check for concealed damage. Do not return damaged equipment to the factory without prior approval. A Return Material Authorization (RMA) must be obtained in advance.

Check the unit specplate. Verify that the specplate voltage agrees with the available power supply.

Large condensing units, remote condensers, and evaporators should be left on their shipping skid until at their final location. Do not use the shipping skid as a permanent base.

RIGGING and HANDLING Good rigging and handling practice must be used to protect units from damage. Having proper handling equipment at the jobsite is most important and should be planned in advance. Always use spreader bars when lifting with cable, chain, or slings. Do not hoist a crate from it's upper members.

If rigging is required, support the crate from the skid. All crates are blocked up for forklift handling.

Do not forklift against sheetmetal panels or coils. Always lift against a structural part of the skid or unit at the center of gravity. Secure units to a forklift to prevent slipping off.

Large condensing units have compressors mounted near one end that offsets the center of gravity.

Find the center of gravity near the compressor end to prevent tipping when lifting. Smaller, lighter units may be carefully manhandled for short distances. Observe the units for additional lifting and rigging decals.

« « « « Items returned without an RMA label will be refused . « «« «

LOCATING AND MOUNTING CONDENSING UNITS

Condensing units must be located where there is an unrestricted supply of clean, fresh air. Areas with corrosive vapors or materials should be avoided, as should areas with polluted air. Do not locate units where air discharge from one will enter into the air intake of others. Avoid locating units in restricted spaces where heat will build up and can enter the condenser. Condensing units with horizontal air flow should be positioned so that the direction of air flow through the condenser is the same as the prevailing wind. Make sure there is room around the unit for regular inspection and service. Mount all condensing units level.

Roof mounted condensing units must have adequate support for their operating weight plus a safety factor. They should be mounted above supporting walls, over hallways, storage areas, or auxillary areas that are not sensitive to noise or vibration. Mount them where sound levels are not an important factor.

Pad mounted condensing units should be mounted on smooth and level pads a minimum of 4 inches above ground level. They should be mounted away from windows, doors, and other areas sensitive to noise. The area surrounding a pad mounted unit preferably will be concrete, asphalt, or other smooth, hard, clean level surface. This will keep the condenser coil clean from grass, dirt, and weed clippings. A security fence also helps to keep leaves and other debris out of the coil.

Protecting the condensing unit also protects the product stored in the cooler or freezer!

Condensing units, piping and disconnects should not be accessible to unauthorized persons. To protect the equipment from tampering and vandalism and protect people from accidental injury, a security fence with locked access is highly recommended. Condensing units accessible to the general public often receive damage to the coil, piping, fans, or other components. Protect your equipment, your products in storage, and protect yourself from liability. Prevent accidents and loss.

Condensing units must be mounted to pads or structural rails with adequate size bolts to prevent the unit from shifting or changing postion.

Mounting holes are provided for proper size fasteners. Iso-pads are recommended to absorb vibration and reduce noise. Seismic isolators may be required in some localities. Follow the isolator manufacturers recommendation when selecting and applying isolators. Mount units level.

Condensing units with spring mounted compressors are shipped with blocks or retainers under the compressor feet to keep it from shaking during shipment. On Copeland H and K model compressors, remove the blocks and loosen the mounting nut to have 1/16 inch between the nut and rubber spacer. On 3 HP and larger models, mounting nuts must be removed to insert the rubber spacer. Remove the blocks, insert the rubber spacer over the mounting stud, replace the nuts and tighten to 1/16 inch from the spacer. Do not tighten mounting nuts tight against the rubber spacer or foot. Units with iso-pad mounted compressors are shipped with the mounting nuts tight and they should be checked to be sure they have not loosened in shipment.

Observe minimum clearance recommendations below. Do not locate any unit to be bordered by tall walls or obstructions on three or more sides, even when the clearance are observed. The minimum space between units is 2x dimensions shown.

Table 1

CONDENSING MINIMUM

UNIT DIMENSION (Inches)

DESCRIPTION A B C

Proline 1/2 thru 2 HP 60 24 36

Proline 3 thru 6 HP 72 24 36

WD Series 3 thru 22 HP 72 30 48

WV Series 20 thru 80 HP 48 48 48

B

CONDENSING UNIT

DISCHARGE AIR INTAKE AIR

A C

B

Drawing 1

12" 12" 12" 24" 60" 15" 15" 15" 30" 75" 18" 18" 18" 36" 90" 24" 24" 24" 48" 120" 30" 30" 30" 60" 150" 36" 36" 36" 72" 180" 42" 42" 42" 84" 210" 48" 48" 48" 96" 240"

* Critical Minimum Dimension H = Height of Evaporator ‡ Minimum walk-in height of 7'-0"

Air H

Front wall 5 x H Min.

12"

Air Product

Product Storage Area Door

* Refer to Table 2 for dimension H Floor

Drawings are not to scale

No doors at side or back of evaporators. Back wall H

H 2 x H H

Side Evaporator wall

Air Air

5 x H Side Alternate wall Door location

* Refer to Table 2 for dimension H Door Front wall

SIDE VIEW

TOP VIEW

Evaporator

126" 144"

3 x H

Evap.

Obstruction Free Area

60" ‡ 72" 90" 108"

60" ‡ 60" ‡

Unit to Front Wall

5 x H

Unit to Floor 3 x H

Unit to Unit 2 x H

LOCATING WALK-IN EVAPORATORS

AND EVAPORATOR PERFORMANCE

MINIMUM DIMENSION FOR GOOD AIR CIRCULATION

EVAPORATOR

HEIGHT (Key Dim.)

H

Unit to Back Wall *

1 x H

Unit to Side Wall

1 x H

Table 2

Locate evaporators for the air pattern to cover all of the piping, and personnel. Heavy zinc plated or stainless room. Do not restrict the inlet or outlet air stream. steel bolts should be used to mount evaporators. We Avoid placing evaporators above or close to doors. recommend a minimum 5/16" diameter for Super-Flo, Direct the air stream toward the door when possible Easy-Flo and Dual-Flo units. A minimum 3/8" diameter or arrange to blow down an aisle. Allow sufficient should be used with Inter-Flo and Polar-Flo units.

clearance for air circulation and servicing the unit. Use flat washers next to hanger bars and tighten all fasteners securely. Hang all unit coolers level to insure positive The ceiling structure must have adequate strength to condensate draining. All drain lines must be trapped.support all mechanical equipment, components, Drawing 4 Drawing 5

Air

Air

2 x H* 2 x H*

EVAP.

Air

EVAP.

Air

TOP VIEW - Large coolers or freezers where one wall will not accommodate all evaporators or desired air throw is excessive.

Drawing 6 Drawing 7

Air

A C

EVAP. B EVAP.

A A

C

Air Air D

Air Air

C Air

TOP VIEW - Single Centermount Unit

Min. Min. Max. Max. Min. Max.

1' 2' 16' 12' 8' 24'

Dimensions are in feet. One foot minimum between bottom of unit and top of product.

LOCATING AND MOUNTING WALK-IN EVAPORATORS

RECOMMENDED SPACING FOR CENTERMOUNT EVAPORATORS

*Refer to Table 2 for dimension H

D

EVAP.

See Table 3 See Table 3

TOP VIEW - Multiple Centermount Units

8' 3'

Table 3 Max. Min.

A B C

PIPING

Condensing Unit and Evaporator coils are thoroughly cleaned and dehydrated at the factory. Care must be taken when field piping to prevent foreign materials and moisture from entering the system. Do not leave units or piping open to the atmosphere any longer than necessary. Use ACR grade Copper tube, keeping it dry, clean, and capped. If type “L” tube is used, it should be thoroughly cleaned internally.

When brazing, always pass dry nitrogen through the tubing to prevent oxide and scale from forming. A suitable silver alloy solder should be used on suction and liquid lines. Use only Wrot Copper fittings. Long radius elbows should be used. Install all piping and components in accordance with local and national codes and in conformance with good refrigeration practice for proper operation of the systems.

The suction line and its components must be selected and installed with extreme care. The suction line must be sized for high enough refrigeration velocity to assure good oil return, and low enough pressure drop to prevent excessive system capacity loss. The optimum line size for a system will result in a reasonable velocity at minimum pressure drop. Total suction line pressure loss should not exceed 2°F equivalent loss.

Suction line risers must be carefully selected, have an oil trap at the bottom and at 15 foot intervals up the riser. The should be the same size as the vertical riser connected to its outlet. Riser should not be larger in diameter than horizontal runs.

Horizontal runs of suction line should slope 1 inch per 10 feet in the direction of flow. A 1/4 inch male flare Schrader fitting should be installed in the suction line at the evaporator outlet to obtain accurate evaporator pressure and superheat readings. Refer to pages 8 though 13 for line size recommendations and piping diagrams. Note the maximum size for suction line risers.

Liquid lines, both horizontal and vertical, are normally the same size. In vertical lines with upward flow there will be a pressure loss similar to that in water line riser, due to the lift involved. If ignored, this pres-sure loss can result in liquid line flash gas that will prevent good expansion valve and system performance. Sizing the liquid line too small will also result in flash gas. Sizing a liquid line larger than necessary will increase the system refrigerant charge.

Flash gas can be avoided by adding subcooling to the system, however, subcooling should not be considered as an acceptable alternative to properly sized liquid lines.

One method to obtain liquid subcooling and return gas superheat is to join the liquid and suction line together and then insulate them. This economical method is often used on vertical lines. Another alternative is to use a manufactured liquid-suction heat exchanger. This type of heat exchanger is usually located inside the cooler or freezer, near the evaporator. D series and V series condensing units include an integral liquid subcooling circuit in the condenser coil. Any one of these methods will normally provide enough subcooling to offset the liquid line pressure loss due to friction and lift. Liquid lines with more than 30 feet of vertical lift need special attention!

A liquid line solenoid should be installed near the expansion valve inlet. If there are multiple evaporators, locate the solenoid near the branch line to the first evaporator.

Before installing the expansion valve on the distributor, check the distributor to be sure it has a nozzle installed or is a venturi type. For optimum performance, the expansion valve outlet should be installed directly to the distributor. If reducing couplings or adapters are required keep them close coupled. Do not have elbows between the expansion valve and distributor. The expansion valve must be selected to match the system capacity. Follow the expansion valve manufacturers ratings when select-ing the valve and use the appropriate capacity multi-plier if liquid is subcooled below 70°F. If the amount of liquid subcooling may vary, a balanced port expan-sion valve should be used.

Evaporators with 1/2 inch flare nut (FN) inlet distributors can be converted to a sweat type inlet.

All distributors have room to remove the flare with a mini-cutter. The inlet would be 1/2 inch OD and an expansion valve with 1/2” ODF outlet would fit. Alco type HFS or Sporlan type EG, SBF or S expansion valves are available with 1/2” ODF extended Copper outlet connections. To protect the valve(s), wrap them with a wet rag while brazing. Disassembly of the valve is not required.

Expansion valves are supplied with clamps for securing the bulb to the suction line. The bulb must be secured at the evaporator outlet, on the side of a horizontal run of suction line, at the 4 o’clock or 8 o’clock position, before any traps. The bulb must be in uniform contact with clean Copper tube and must not bridge any fitting or uneven surface. A thermal mastic or heat transfer compound may be used with the expansion valve bulb and suction line for quicker expansion valve response. DO not overtighten bulb clamps or deform the bulb in any way.

Drain lines should be the size of the evaporator drain pan connection or larger. They should not be reduced in size. Plastic drain lines are often used in coolers, however, Copper or metal lines are recommended if room temperature is below 35°F. All drain lines must be protected from freezing. All drain lines must be trapped and run to an open drain.

Drain lines should be sloped 4 inches per foot to insure positive drainage. Never connect a condensate drain directly to a sewer line. Never drain onto a floor or walkway, creating a safety hazard. Traps must be in warm ambient or be protected from freezing. It may be necessary to run heat tape the entire length of the drain line and trap to prevent freezing. Insulating the drain line is recommended with the heat tape energized continuously. Drain properly and safely!

All piping must be adequately supported to prevent vibration and breaking. Tube clamps should have a gasketed surface to prevent abrasion. Inspect all piping while the equipment is operating and add supports to prevent stress and vibration. When the liquid solenoid opens and closes, the liquid line will tend to move forcefully. Without proper support the joints at the liquid solenoid, expansion valve, distributor, and distributor leads can fracture. Take care to secure the liquid line at the evaporator. Line supports are inexpensive compared to downtime and refrigerant loss. All piping must be protected where it passes through walls or ceilings. Precautions should be taken to see that the piping does not touch any structural members and is properly supported in order to prevent the transmission of vibration into the building. The piping chase must be thoroughly sealed to protect the tube and prevent ambient air from entering the refrigerated space. Seal around the drain line where it passes through the wall. Air leaks can cause equipment problems, damage the structure and product, increase load, increase operating cost, and can cause a safety hazard.

Eliminate all air leaks. See Table 11 for recommended line support spacing.

In low temperature application, or where proper oil circulation cannot be maintained, an oil separator may be required. When operating at evaporator temperatures of -20°F and lower, oil separators should be considered in order to minimize the amount of oil in circulation.

In addition to the critical nature of oil return, there is no better invitation to system difficulties than an excessive refrigerant charge. A reasonable pressure drop is far more preferable than oversized lines which can contain refrigerant far in excess of the systems needs. On systems with a larger refrigerant charge, or on systems where liquid floodback is likely to occur, a suction line accumulator is strongly recommended.

LEAK TESTING

After all refrigerant connections are made, have been visually inspected and secured, add proper system refrigerant until the pressure is 25 to 35 PSI. Then pressurize with dry nitrogen up to 120 to 140 PSI.

Always use a pressure reducing regulator. Wait 20 to 30 minutes for the refrigerant to reach all parts of the system. Using an electronic leak detector, check all connections and components, both factory and field installed. The compressor, evaporator coil, and condenser coil must be checked. Valves and controls must be checked. Repair any leaks found and re-check until no leaks are located and the pressure holds steady. Leave the system pressurized overnight to verify that the pressure remains unchanged.

Unlocated leaks can mean unprofitable call back, additional refrigerant cost, higher energy cost, and possible internal contamination and failure of the system. With highly hygroscopic polyol ester (POE) lubricants, leak detection is essential to prevent moisture from entering a system. The system installation must be leak free!

After leak testing has been completed, the system must be thoroughly evacuated before charging.

DOUBLE RISER

WHEN REQUIRED

LOOP TO PREVENT

LIQUID DRAINING

INTO COMPRESSOR

SLOPE

EVAPORATORS ABOVE

COMPRESSOR

DOUBLE RISER

WHEN REQUIRED

EVAPORATORS BELOW

COMPRESSOR

EVAPORATOR ABOVE

COMPRESSOR

EVAPORATOR BELOW

COMPRESSOR

SMALLER

DOUBLE RISERDOUBLE TRAP

15' MAX

ADD

TRAP

SLOPE

RISER

SLOPE

LARGER

RISER

SLOPE

SLOPE

EVAPORATORS ABOVE

COMPRESSOR

SLOPE

SUCTION LINE DESIGN

RECOMMENDED LINE SIZES - R-22

Table 6

SYSTEM +45°F SUCTION +35°F SUCTION +25°F SUCTION +15°F SUCTION

BTUH 30' 60' 100' 150' 30' 60' 100' 150' 30' 60' 100' 150' 30' 60' 100' 150'

3000 3/8 3/8 1/2 1/2 3/8 1/2 1/2 1/2 3/8 1/2 1/2 5/8 1/2 1/2 1/2 5/8

4000 3/8 1/2 1/2 1/2 1/2 1/2 1/2 5/8 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8

6000 1/2 1/2 1/2 5/8 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 1/2 5/8 5/8 5/8

9000 5/8 5/8 5/8 7/8 5/8 5/8 5/8 7/8 5/8 5/8 5/8 7/8 5/8 5/8 7/8 7/8

12000 5/8 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

15000 5/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 1 1/8

18000 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 1 1/8

24000 7/8 7/8 7/8 1 1/8 7/8 7/8 7/8 1 1/8 7/8 7/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8

30000 7/8 7/8 1 1/8 1 1/8 7/8 7/8 1 1/8 1 1/8 7/8 7/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8

36000 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8

42000 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8

48000 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8

60000 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 5/8

75000 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8

90000 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 1 5/8

120000 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8

150000 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8

180000 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 5/8

210000 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8

240000 1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8

300000 2 1/8 2 1/8 2 1/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8

360000 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 3 1/8

480000 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8 3 1/8 2 5/8 2 5/8 3 1/8 3 1/8

600000 2 5/8 2 5/8 2 5/8 3 1/8 2 5/8 2 5/8 3 1/8 3 1/8 2 5/8 3 1/8 3 1/8 3 5/8 2 5/8 3 1/8 3 1/8 3 5/8

All Line Sizes are for O.D. Type L, ACR, or RS copper tube. All Lengths are "Equivalent Feet."

Shading indicates Maximum Suction Riser Size. Diameter of riser must not be larger than horizontal run.

Consider double suction risers if capacity control can reduce capacity 35% or more below design.

All line sizes selected for 2°F equivalent pressure loss maximum.

Suction traps must be used for proper oil return.

RECOMMENDED LINE SIZES - R-22

Table 7

+5°F SUCTION -10°F SUCTION -20°F SUCTION LIQUID LINE SYSTEM

30' 60' 100' 150' 30' 60' 100' 150' 30' 60' 100' 150' 30' 60' 100' 150' BTUH

1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 1/2 5/8 5/8 5/8 1/4 1/4 1/4 3/8 3000

1/2 1/2 5/8 5/8 1/2 5/8 5/8 5/8 5/8 5/8 5/8 7/8 1/4 1/4 1/4 3/8 4000

5/8 5/8 5/8 7/8 5/8 5/8 7/8 7/8 5/8 7/8 7/8 7/8 1/4 1/4 3/8 3/8 6000

5/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 1 1/8 1/4 3/8 3/8 3/8 9000

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 1/8 3/8 3/8 3/8 3/8 12000

7/8 7/8 7/8 1 1/8 7/8 7/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 3/8 3/8 3/8 3/8 15000

7/8 7/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 3/8 3/8 3/8 3/8 18000

7/8 1 1/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 3/8 3/8 3/8 1/2 24000

7/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 3/8 3/8 3/8 1/2 1/2 30000

1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 5/8 3/8 1/2 1/2 1/2 36000

1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 3/8 1/2 1/2 1/2 42000

1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1 5/8 1 5/8 1 5/8 1/2 1/2 1/2 5/8 48000

1 1/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 2 1/8 1/2 1/2 5/8 5/8 60000

1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8 1/2 1/2 5/8 5/8 75000

1 3/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 1/2 5/8 7/8 7/8 90000

1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 5/8 5/8 7/8 7/8 120000

1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 5/8 7/8 7/8 7/8 150000

1 5/8 2 1/8 2 1/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 7/8 7/8 7/8 7/8 180000

2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 3 1/8 7/8 7/8 7/8 1 1/8 210000

2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 3 1/8 7/8 7/8 1 1/8 1 1/8 240000

2 1/8 2 5/8 2 5/8 3 1/8 2 1/8 2 5/8 2 5/8 3 1/8 2 5/8 3 1/8 3 1/8 3 1/8 7/8 1 1/8 1 1/8 1 1/8 300000

2 1/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 3 1/8 3 1/8 2 5/8 3 1/8 3 1/8 3 5/8 1 1/8 1 1/8 1 1/8 1 1/8 360000

2 5/8 2 5/8 3 1/8 3 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 1/8 3 5/8 3 5/8 3 5/8 1 1/8 1 1/8 1 1/8 1 3/8 480000

2 5/8 3 1/8 3 5/8 3 5/8 3 1/8 3 1/8 3 5/8 3 5/8 3 1/8 3 5/8 3 5/8 4 1/8 1 1/8 1 1/8 1 3/8 1 3/8 600000

Table 8

10' 15' 20' 25' 30' 40'

2° 3° 4° 4° 5° 7°

2° 2° 3° 3° 4° 5°

R - 22

R - 404A or R - 507

MINIMUM LIQUID SUBCOOLING (°F)

TO OFFSET PRESSURE LOSS IN RISERS

RISE IN FEET

REFRIGERANT

RECOMMENDED LINE SIZES - R-404A, R-507

Table 9

SYSTEM +30°F SUCTION +20°F SUCTION +10°F SUCTION -10°F SUCTION

BTUH 30' 60' 100' 150' 30' 60' 100' 150' 30' 60' 100' 150' 30' 60' 100' 150'

3000 3/8 3/8 1/2 1/2 3/8 1/2 1/2 1/2 1/2 1/2 1/2 5/8 1/2 5/8 5/8 5/8

4000 3/8 1/2 1/2 1/2 1/2 1/2 1/2 5/8 1/2 1/2 5/8 5/8 1/2 5/8 5/8 7/8

6000 1/2 1/2 5/8 5/8 1/2 5/8 5/8 7/8 1/2 5/8 5/8 7/8 5/8 5/8 7/8 7/8

9000 1/2 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 7/8

12000 1/2 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

15000 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 1 1/8 1 1/8

18000 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 1/8 7/8 7/8 1 1/8 1 1/8

24000 5/8 7/8 7/8 7/8 7/8 7/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8

30000 7/8 7/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8

36000 7/8 7/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8

42000 7/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8

48000 7/8 1 1/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 3/8 1 5/8

60000 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 1 5/8

75000 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8

90000 1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8

120000 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8

150000 1 5/8 1 5/8 1 5/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8

180000 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8

210000 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 3 1/8

240000 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8 3 1/8

300000 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 3 1/8 2 5/8 2 5/8 3 1/8 3 1/8

360000 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 3 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 5/8 3 1/8 3 1/8 3 5/8

480000 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 5/8 2 5/8 3 1/8 3 5/8 3 1/8 3 1/8 3 5/8 3 5/8

600000 2 5/8 2 5/8 2 5/8 3 1/8 2 5/8 2 5/8 3 1/8 3 1/8 2 5/8 3 1/8 3 1/8 3 5/8 3 1/8 3 5/8 3 5/8 4 1/8

All Line Sizes are for O.D. Type L, ACR, or RS copper tube. All Lengths are "Equivalent Feet."

Shading indicates Maximum Suction Riser Size. Diameter of riser must not be larger than horizontal run.

Consider double suction risers if capacity control can reduce capacity 35% or more below design.

All line sizes selected for 2°F equivalent pressure loss maximum.

Suction traps must be used for proper oil return.

RECOMMENDED LINE SIZES - R-404A, R-507

Table 10

-20°F SUCTION -30°F SUCTION -40°F SUCTION LIQUID LINE SYSTEM

30' 60' 100' 150' 30' 60' 100' 150' 30' 60' 100' 150' 30' 60' 100' 150' BTUH

1/2 5/8 5/8 5/8 1/2 5/8 5/8 7/8 5/8 5/8 7/8 7/8 1/4 1/4 1/4 1/4 3000

1/2 5/8 5/8 5/8 5/8 5/8 7/8 7/8 5/8 5/8 7/8 7/8 1/4 1/4 1/4 1/4 4000

5/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 1 1/8 1 1/8 1/4 1/4 1/4 3/8 6000

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 1/8 1/4 3/8 3/8 3/8 9000

7/8 7/8 1 1/8 1 1/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 3/8 3/8 3/8 3/8 12000

7/8 1 1/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 3/8 3/8 3/8 1/2 15000

7/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 3/8 3/8 1/2 1/2 18000

1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 3/8 1 5/8 1 5/8 3/8 1/2 1/2 1/2 24000

1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 3/8 1 5/8 1 5/8 1/2 1/2 1/2 5/8 30000

1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1/2 1/2 1/2 5/8 36000

1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1/2 1/2 5/8 5/8 42000

1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1/2 1/2 5/8 5/8 48000

1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1/2 5/8 5/8 5/8 60000

1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 5/8 5/8 5/8 7/8 75000

1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 5/8 5/8 7/8 7/8 90000

2 1/8 2 1/8 2 1/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 1/8 2 5/8 2 5/8 3 1/8 5/8 7/8 7/8 7/8 120000

2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 7/8 7/8 7/8 7/8 150000

2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8 3 1/8 3 5/8 7/8 7/8 1 1/8 1 1/8 180000

2 1/8 2 5/8 2 5/8 3 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 5/8 3 1/8 3 1/8 3 5/8 7/8 1 1/8 1 1/8 1 1/8 210000

2 5/8 2 5/8 2 5/8 3 1/8 2 5/8 2 5/8 3 1/8 3 1/8 3 1/8 3 1/8 3 5/8 3 5/8 7/8 1 1/8 1 1/8 1 1/8 240000

2 5/8 2 5/8 3 1/8 3 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 1/8 3 1/8 3 5/8 4 1/8 1 1/8 1 1/8 1 1/8 1 3/8 300000

2 5/8 3 1/8 3 5/8 3 5/8 3 1/8 3 1/8 3 5/8 3 5/8 3 1/8 3 5/8 4 1/8 5 1/8 1 1/8 1 1/8 1 1/8 1 3/8 360000

3 1/8 3 5/8 3 5/8 4 1/8 3 5/8 3 5/8 4 1/8 4 1/8 3 5/8 4 1/8 5 1/8 5 1/8 1 1/8 1 1/8 1 3/8 1 3/8 480000

3 1/8 3 5/8 4 1/8 4 1/8 3 5/8 4 1/8 4 1/8 5 1/8 4 1/8 4 1/8 5 1/8 5 1/8 1 1/8 1 3/8 1 3/8 1 5/8 600000

Table 11

Support all lines securely using cushioned clamps.

Clamps should be a minimum of 12 inches from elbows.

MAXIMUM DISTANCE BETWEEN

TYPE "L" COPPER TUBE LINE SUPPORTS

3/8 - 1/2 5/8 - 7/8

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

TUBE O.D. (INCHES) MAXIMUM FEET

All field wiring must be in compliance with local and System wiring diagrams are located inside the condensing national codes. Use only copper conductors of the unit control panel door. Wire components as shown on the appropriate size. The equipment specplates are marked wiring diagrams. All equipment must be grounded. To aid with the electrical characteristics. All field wiring should the evacuation and provide additional compressor protection enter the equipment control panels through bushings. during charging and start-up, the crankcase heater should be energized 24 hours before charging begins. After start- Disconnect switches and evaporator branch circuit up, any vibrating armored cable should be secured and protection are supplied by the installer and must comply must not contact refrigerant tubing.

with the governing electrical codes.

The room thermostat and liquid line solenoid should be Be sure the power is disconnected and tighten all wired in series per the diagrams. The pumpdown cycle is connections before starting equipment. If any electrical mandatory to maintain compressor warranty. Carefully components are located outdoors, use the appropriate follow the diagrams of multiple evaporator systems to outdoor fixture, fittings, and conduit. ensure proper defrosting of all units.

208/230/3 or 460/3 POWER SUPPLY FAN MOTOR POWER

FROM FIELD SUPPLIED DISCONNECT 120 or 208/230 VOLTS

O O

O O O O O LLS

O O O EVAP ROOM T'STAT

CIRCUIT BREAKER FANS

or TERMINAL BLOCK

TB1 ALL UNITS MUST BE GROUNDED

44 38 2 (N) Volts & phase to O O O match evap fans For factory wiring refer to the diagram in the unit.

O O O O O If liquid line solenoid (LLS) is factory mounted or LLS EVAP if unit has low ambient flooded condenser option, ROOM T'STAT FANS connection to TB1 - 38 terminal must be made.

208/230/ POWER SUPPLY 208/230 or 460 POWER SUPPLY

FROM FIELD SUPPLIED DISCONNECT FROM FIELD SUPPLIED DISCONNECT

O O O O O O O O O O O O

CIRCUIT BREAKER CIRCUIT BREAKER

or TERMINAL BLOCK or TERMINAL BLOCK

TB1 TB2 TB1 TB2

44 38 2 N X 4 3 44 38 2 N X 4 3

O O O O O O O O O O O O O O

O O O O

LLS LLS

ROOM T'STAT O O O O TB - Terminal Block ROOM T'STAT O O O O

N X 4 3 LLS - Liquid Line Solenoid N X 4 3

EVAP EVAP

OFF-CYCLE AIR DEFROST

WITH OR WITHOUT TIMER

ALTERNATE UNIT COOLER WIRING

AIR DEFROST WITHOUT TIMER

CONDENSING

UNIT

CONDENSING

UNIT

GROUND

LUG

GROUND

LUG

FIELD WIRING

ELECTRIC DEFROST, 1Ø FANS & HEATERS HOT GAS DEFROST, 1Ø FANS

TYPICAL FIELD WIRING

GROUND

LUG

CONDENSING

UNIT

208/230/3 POWER SUPPLY

FROM FIELD SUPPLIED DISCONNECT

O O O

O O O ALL UNITS MUST BE GROUNDED

CIRCUIT BREAKER Provide jumper from N to 3 if or TERMINAL BLOCK heater safety (HS) is not used. For factory wiring refer to the diagram in the unit.

TB1 TB2 C6 C7 If liquid line solenoid (LLS) is factory mounted or 44 38 2 N X 4 3 if unit has low ambient flooded condenser option, O O O O O O O O O O O O O connection to TB1 - 38 terminal must be made.

O O

LLS

O O O O O O O O O O

T'STAT N X 4 3 H1 H2 H3 H1 H2 H3

TB - Terminal Block

C# - Contactor #

LLS - Liquid Line Solenoid

H - Heater terminal

208/230/3 POWER SUPPLY

FROM FIELD SUPPLIED DISCONNECT

O O O

O O O ALL UNITS MUST BE GROUNDED

CIRCUIT BREAKER

or TERMINAL BLOCK For factory wiring refer to the diagram in the unit.

TB1 TB2A TB2B TB2C If liquid line solenoid (LLS) is factory mounted or 44 38 2 N X 4 3 N X 4 3 N X 4 3 if unit has low ambient flooded condenser option, O O O O O O O O O O O O O O O connection to TB1 - 38 terminal must be made.

O O

LLS

O O O O O O O O O O O O

T'STAT N X 4 3 N X 4 3 N X 4 3

TB - Terminal Block

LLS - Liquid Line Solenoid

TYPICAL FIELD WIRING

GROUND

LUG

HEATER

CONDENSING

UNIT

ELECTRIC DEFROST, MULTIPLE EVAPORATOR, 1Ø FANS & HEATERS

ELECTRIC DEFROST, 1Ø FANS & 3Ø HEATERS

ROOM

EVAP

HEATER

ROOM

THE MOST POSITIVE AND DEPENDABLE MEANS OF KEEPING LIQUID REFRIGERANT

OUT OF THE COMPRESSOR CRANKCASE IS THE USE OF A PUMPDOWN CYCLE

GROUND

LUG

EVAP A EVAP B EVAP C

CONDENSING

UNIT

208/230/3 POWER SUPPLY

FROM FIELD SUPPLIED DISCONNECT

O O O CONDENSING UNIT

O O O CIRCUIT BREAKER Provide jumper from N to 3 if or TERMINAL BLOCK heater safety (HS) is not used.

TB1 TB2A C6 TB2B C7 TB2C C8

44 38 2 N X 4 3 N X 4 3 N X 4 3

O O O O O O O O O O O O O O O O O O O O O O O O

O O

LLS

O O O O O O O O O O O O O O O O O O O O O

T'STAT N X 4 3 H1 H2 H3 N X 4 3 H1 H2 H3 N X 4 3 H1 H2 H3

TB - Terminal Block

C# - Contactor #

LLS - Liquid Line Solenoid ALL UNITS MUST BE GROUNDED

H - Heater terminal

208/230/3 or 460/3 POWER SUPPLY

FROM FIELD SUPPLIED DISCONNECT

O O O CONDENSING UNIT

O O O CIRCUIT BREAKER Provide jumper from N to 3 if or TERMINAL BLOCK heater safety (HS) is not used.

TB1 TB2A C6 TB2B C7 TB2C C8 C5

44 38 2 N X 4 3 N X 4 3 N X 4 3

O O O O O O O O O O O O O O O O O O O O O O O O O O O

O O

LLS

ROOM O O O O O O O O O O O O O O O O O O O O O

T'STAT N X 4 3 H1 H2 H3 N X 4 3 H1 H2 H3 N X 4 3 H1 H2 H3

M1 M2 M3 M1 M2 M3 M1 M2 M3

TB - Terminal Block O O O O O O O O O

C# - Contactor #

LLS - Liquid Line Solenoid

H - Heater terminal

M - Motor terminal ALL UNITS MUST BE GROUNDED

For factory wiring refer to the diagram in the unit. If liquid line solenoid (LLS) is factory mounted or if condensing unit has low ambient flooded condenser option, connection to TB1 - 38 terminal must be made.

HEATER

EVAP C

ELECTRIC DEFROST, MULTIPLE EVAPORATOR, 3Ø FANS AND HEATERS

GROUND

LUG

EVAP A EVAP B

MOTORHEATER

TYPICAL FIELD WIRING

ROOM

ELECTRIC DEFROST, MULTIPLE EVAPORATOR, 1Ø FANS AND 3Ø HEATERS

GROUND

LUG

HEATER HEATER

HEATER

EVAP CEVAP BEVAP A

HEATER

EVACUATION

Proper installation procedures must include DEEP EVACUATION of the system. It takes both a deep vacuum and filter-drier in a system for proper protection. The filter-drier will pick up moisture, oxides, fibers, particles of metal, flux, and other materials that evacuation cannot remove. Removing the AIR and MOISTURE from a system by applying a DEEP VACUUM is an absolute necessity.

Only by using a rotary deep vacuum pump and an electronic deep vacuum gauge can the installer be sure a system is dehydrated sufficiently to prevent early breakdown. By using a rotary deep vacuum pump and the multiple evacuation method, an electronic deep vacuum gauge can indicate that the system has been adequately evacuated and if a leak exists. The installer must comply with government regulations and use appropriate procedures and equipment to avoid releasing refrigerants into the atmosphere.

A two-valve test manifold mounted on the vacuum pump is recommended. To shorten the evacuation time and to prevent erroneous gauge readings, install the largest diameter vacuum line feasible and as short as practical. A minimum 3/8 inch OD copper tube or seamless metal hose is recommended. The larger the system, the larger the vacuum line diameter should be.

Do not use neoprene hose for evacuation. Neoprene hose is not sufficiently vacuum tight for evacuation or testing. Using a deep vacuum sealant on all line connections and fittings is good practice.

Be prepared to frequently change the vacuum pump oil. Use oil that is specifically refined for rotary deep vacuum pumps. A vacuum pump cannot create a vacuum less than the vapor pressure of its sealing oil.

Clean and dry deep vacuum oil is essential for proper system evacuation and protection of the vacuum pump. If the vacuum pump cannot quickly pull down to a low blank-off vacuum reading the oil must be changed. If the pump and oil are in good condition it should quickly attain a 100 micron reading when blanked-off. We recommend checking the pump condition with this test before attempting to evacuate a refrigeration system.

Use an electronic deep vacuum gauge. The system must hold at 500 microns or less with R-22 systems and 400 microns or less on R-404A or R-507 systems after final evacuation. The vacuum gauge should hold very close to this reading for 10 minutes after the pump is closed off. Holding steady at or close to this micron reading indicates the system is dry and leak free. The compressor service valves must be open for the final evacuation so that the compressor and entire system is evacuated.

Pull a continuous vacuum for a minimum of 4 hours.

Longer is better. On systems over 5 horsepower pull the vacuum overnight. POE lubricants are much slower than mineral oils to release moisture. Proper evacuation of systems with POE lubricants can take more time. The vacuum decay test for 10 minutes described in paragraph 5 is strongly recommended.

Deep evacuation is an absolute necessity!

Make the charging line connection with a line purged of air and break the vacuum. Break the vacuum with the proper system refrigerant and pressurize the system to 5 to 10 PSI before removing the vacuum pump lines.

DO NOT START THE COMPRESSOR WHILE THE

SYSTEM IS UNDER VACUUM. Do not use the compressor as a vacuum pump. Do not allow the system to stand at deep vacuum more than one hour without the vacuum pump operating.

EVACUATION RECORD

System ID __________________________ HP_____

Start Vacuum: _______ AM / PM Date ___- ___- ___

________ microns after 4 hours

________ microns after 8 hours

________ microns after 12 hours

________ microns after 16 hours

Stop Vacuum: _______ AM / PM Date ___- ___- ___

________ microns after ______ hours of evacuation

________ microns 10 minutes after pump shut off

Evacuated by ________________________________

CHARGING and START-UP

The control circuit should be energized 24 hours before charging and start-up to open the liquid line solenoid and turn on the crankcase heater.

This will assist the evacuation and dehydration process and provide additional compressor protection during the charging and start-up.

Charge refrigerant into a system through a filter-drier in the charging line. This provides further assurance the refrigerant charge is clean and dry.

The system refrigerant capacity is approximately 80% of the condenser, receiver, and liquid line capacity. If the condenser volume or refrigerant capacity is unknown, the system refrigerant capacity is often calculated at 90% of the receiver and liquid line capacity. Be cautious if the calculated charge is exceeded. Weigh the refrigerant. The actual refrigerant charge should be less than the calculated capacity. DO NOT charge liquid refrigerant into the suction side of the compressor.

Be sure the compressor discharge valve is open.

The suction valve should be open 2 or 3 turns, with a valve stem wrench attached for quick throttle adjusting. High and low pressure gauges should be attached. Liquid charging is faster.

If R-404A or R-507 is used, liquid charging is mandatory. R-404A and R-507 refrigerant cylinders have a dip tube and liquid is charged with the cylinder upright. Break the final vacuum by charging liquid refrigerant into the receiver outlet valve access or the area of liquid line downstream from the receiver outlet.

Approximately 50 to 60% of the system charge can usually be injected into the receiver area before it is necessary to start the compressor for the system to accept more refrigerant . It may be necessary to throttle the compressor suction valve to keep suction pressures reasonable and prevent tripouts during charging and pull-down. If it is necessary to add liquid refrigerant to the suction side, a full control ball valve must be used in the charging line to slowly meter refrigerant vapor into the system.

If the condensing temperature is 105°F or greater, charge the system until the sight glass just clears, being careful not overcharge. If the condensing temperature is below 105°F, a part of the condenser coil can be blocked to raise the condensing temperature to 105°F. Be careful not to block the air blast against the compressor.

This procedure satisfies systems with floating head pressure control. Follow the same procedure for systems with low-ambient flooded condenser head pressure control.

With 105°F condensing temperature, charge until the sight glass just clears. Then accurately weigh in the additional pounds of refrigerant specified in the chart on page 19. There is also a charging tag on the unit. The pounds specified on the tag supercedes this IOM. This will provide adequate charge for all ambient operation. The actual charge should not exceed the calculated systems capacity. After system charging and room pull-down is complete , test the ability of the system to successfully pump down. Raise the room thermostat setting to close the liquid solenoid.

The system must pumpdown and shut off at the low pressure cutout setting. See Table 13.

Unblock the condenser coil and return the room thermostat to the desired setting.

The first two to three hours of operation after start-up is a critical time. Do not just start-up and walk away. Watch for floodback and adjust the expansion valve if necessary. Observe system pressures. Check all fans on the evaporator and condensing unit to be sure they are operational and turning the proper direction. Record the pounds of refrigerant charged into the system.

Check the compressor oil level frequently. On low temperature systems the fan delay control may cycle the evaporator fans. To keep the fans on until the room pulls down, it may be necessary to jumper the fan delay control.

Check voltage and amperage at the compressor.

Voltage must be within 10% of the specplate rating. Amperage should be approximately equal across all three lines. Check the piping for vibration and add supports if needed. Check electrical conduit for vibration and route to prevent contact with tubing.

Use the Start-Up Check List on page 24 to assist you. Don’t forget to remove the fan delay jumper if one was used. Also, fully open the suction valve. After the room has pulled down to design temperature and held for 24 hours, review the system guidelines on page 23 and complete a system service record on page 25.

POUNDS OF ADDITIONAL REFRIGERANT CHARGE

TO ADD FOR FLOODED HEAD PRESSURE CONTROL

Table 12

Proline 1/2 - 6 HP Proline 1/2 - 6 HP WD - Series 3 - 22 HP WV - Series 20 - 80 HP

Model Lbs. to Model Lbs. to Model Lbs. to Model Lbs. to PLH Add PLS Add WDLD Add WVLD Add

H051H22 2.5 S050H22 1.3 3L22 9.5 SINGLE

H050M44 2.2 S050M44 1.1 3L44 8.2 20H22 58 H050L44 2.2 S050L22 1.3 4L22 14.3 20M44 50 H075H22 2.5 S050L44 1.1 4L44 12.3 25H22 78 H075M44 3.2 S075H22 2.5 5H22 14.3 25M44 67 H075L44 3.2 S075L22 2.5 5M44 16.4 27L22 58 H100H22 3.8 S075L44 3.2 5L22 14.3 27L44 50 H100L44 3.2 S100H22 3.8 5L44 12.3 30H22 98 H101M44 4.3 S100M44 4.3 6M44 23.0 30M44 84 H150H22 5.0 S100L22 3.8 6L22 14.3 30L22 58 H150M44 4.3 S100L44 3.2 6L44 12.3 30L44 50 H150L44 4.3 S150H22 5.0 7H22 27.0 35H22 115 H200H22 7.5 S150L44 4.3 7M44 23.0 35M44 99 H201M44 8.6 S200H22 7.5 8H22 27.0 40H22 144 H200L44 6.5 S200M44 6.5 8M44 23.0 40M44 124 H250H22 7.5 S200L22 7.5 8L22 27.0 50H22 156 H300H22 12.4 S200L44 6.5 8L44 23.0 50M44 134 H300M44 10.6 S201L22 7.5 9L22 27.0 60H22 195

H300L44 10.6 S202L22 7.5 9L44 23.0 60M44 168 H400H22 12.4 S250L44 7.1 10H22 44.0

H400M44 10.6 S300H22 8.3 10M44 38.0 PARALLEL

H500H22 16.5 S300M44 7.1 10L22 27.0 17H22 58 H500M44 14.2 S300L22 8.3 10L44 23.0 17M44 50

PLD S300L44 7.1 12H22 44.0 21H22 78

D300L22 12.4 S400H22 12.4 12M44 38.0 21M44 67 D300L44 10.6 S400M22 12.4 12L22 27.0 24H22 98 D400L22 12.4 S400M44 10.6 12L44 23.0 24M44 84 D400L44 10.6 S500H22 16.5 15H22 54.0 31H22 86 D500H22 16.5 S500M22 16.5 15M44 46.0 31M44 74 D500M44 14.2 15L22 44.0 41H22 115 D500L22 12.4 15L44 38.0 41M44 99 D500L44 10.6 22L22 54.0 44L44 74

22L44 46.0 51H22 117 51M44 101 54L44 99

CHARGING STEPS - (See Page 18) 61H22 195

1. Charge as necessary to achieve a clear sight glass, with the air 61M44 168 intake to the condenser blocked, to maintain a minimum 200 psi 61L44 124 head pressure. This will prevent gas from by passing through the 71H22 173 flood valve. DO NOT OVERCHARGE! Just clear the glass. 71M44 149

2. Add the exact amount of refrigerant shown in this table of the 81H22 231 model being charged. This will provide the system the charge it 81H22 198 requires for all weather, flooded, operation.

RECOMMENDED INITIAL

LOW PRESSURE CONTROL SETTING - PSIG

Table 13

MINIMUM R-22 R-404A, R-507

SYSTEM * MAXIMUM CUT MAXIMUM CUT

TEMP. °F CUT IN OUT CUT IN OUT

50 75 25 85 35 40 60 20 70 35 30 45 20 55 35

20 40 15 50 30 10 30 10 45 25 0 20 5 25 5

-10 15 1 20 1 -20 10 0 12 1 -30 6 8" Vac. 8 8" Vac.

*Minimum System Temperature is the coldest point in the system, whether it is the outdoor ambient or the refrigerated room temperature. The Minimum System Temperature dictates the low pressure control setting. When possible, keep the low pressure cut out at positive pressure. Low pressure controls are factory set at 15 PSI cut in and 3 PSI cut out.

RECOMMENDED INITIAL

HIGH PRESSURE CONTROL SETTING - PSIG Table 14

R-22 R-404A, R-507

CUT IN CUT OUT CUT IN CUT OUT

270 - 275 350 - 360 315 - 320 390 - 400

ESTIMATING VENTILATION REQUIREMENTS

for INDOOR AIR COOLED CONDENSING UNITS Table 15

SATURATED SUCTION °F CFM PER HORSEPOWER

High temp. +28 to +45 2000

Med. temp. +1 to +27 1500

Low temp. -1 to -30 1000 These estimates are based on limiting the equipment room ventilation air temperature rise to 10°F above the make up air. The total fresh air CFM must be available to the condenser coil inlets at design ambient.

The temperature rise may be reduced by increasing the CFM.

High temperature CFM required = HT HP x 2000 = ____________________

Med. temperature CFM required = MT HP x 1500 = ____________________

Low temperature CFM required = L T HP x 1000 = ____________________

TOTAL estimated CFM required = (add above) _____________________

DEFROST

AIR DEFROST - An air defrost system, sometimes called off-cycle, is wired so that the evaporator fans run continuously, unless manually de-energized.

Whenever the compressor stops, the room air (minimum = 34°F) warms the coil to room temperature melting the frost. It is essential that the frost completely melts and drains each time the compressor cycles off. If it does not, a partial defrost results, and the residual water and slush will re-freeze into ice during the next run cycle. Ice removal will require a manual defrost.

Adequate off-cycle time is a function of system capacity. If the system is too small for the room, ice build-up will usually result. Use of an air defrost timer is sometimes successful on undersized systems to avoid coil icing. A temporary rise in room temperature will occur during the defrost cycle.

Optional defrost timers are suitable for Time Initiated, and either Time or Temperature terminated air defrost. Time termination is done by setting the fail-safe dial of the timer to the desired defrost duration. This keeps the compressor off during that duration. Temperature termination requires the mounting of a close-on-rise termination thermostat whose remote sensing bulb can be affixed to the coil at the point of heaviest frosting. The best setting for the termination temperature is usually the design room temperature.

ELECTRIC DEFROST - The recommended electric defrost circuitry is typical wiring designed for the Paragon 8145-20 and Precision…