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Heatcraft Refrigeration Products 25000102 manual

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Table of contents for the manual

  • Page 1

    P ar allel C ompr essor S y st ems Bulletin No . H-IM-PCS Oc tober 2004 P ar t Number 25000102 (Replaces H-IM-72B, October 2004) Installation and Opera tion Manual[...]

  • Page 2

    2 Part # 25000102 T able of C ontents Introduction .............................................................................................................. 3 Inspection Unit Designation Model Denition Syst em W arranty ....................................................................................................... 4 Rigging Location[...]

  • Page 3

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 3 P a ra l le l Comp ressor Syst ems Introduction P arallel Compressor systems are central refrigeration units employing 2 to 8 parallel piped compressors, a contr ol panel, and rece iver moun ted on one common base frame. The system may be desig ned f or eit her Indo [...]

  • Page 4

    4 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l F igure 2. V ibration P ad Locations Sy stem W arranty This equipment is designed to operate properly and produce the rated capacit y when installed in accordance with good refrigeration practice . The follo wing conditions should be adhered to when installing this unit to maintain the ma[...]

  • Page 5

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 5 Compr essor Spring Vibr ation Isola tors On units with this option, the compressors are secur ed rigidly to make sure there is no transit damage. Before operating the unit, it is necessary to follow these steps: 1. Remove the upper nuts and washers 2. Discard the shi[...]

  • Page 6

    6 Part # 25000102 Unit Ac cess Always provide sucient clearance f or unit maintenance and ser vice . Minimum clearances for most situations are described below (except 60 Inches of free space is required in fr ont of the control panel). Please note tha t these are minimums and more clearance may be r equired by local codes . V er tical Clearanc [...]

  • Page 7

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 7 V entilation Requirements Indoor Units If compressors or condensing units are located in a machine room, adequate ventilation air must be provided to avoid an excessiv e temperature rise in the room. T o allow for peak sum me r t emp er at ur es a 1 0°F te mp er atu[...]

  • Page 8

    8 Part # 25000102 In systems equipped with capacit y contr ol compressors, or where multiple c ompressors are used with one or more comp res sors cycled o for capac ity con tro l, double suction risers should be installed. See F igure 6 below . The two lines should be sized so that the total cross-section area is equivalent to the cross section [...]

  • Page 9

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 9 In order to compensate for the expansion of the tubing, it is necessary to estimate the amount of expansion and then provide osets or loops in the refrigerant piping. Normally the area to be most concerned with is the straight line distance from the xture to th[...]

  • Page 10

    10 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l Liquid Line Rise in Feet Refrigerant 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 R-12 5.4 2.8 8.1 4.2 10.7 5.4 13.4 6.9 16.1 8.3 21.5 11.3 26.9 14.3 40.3 22.4 53.7 31.0 R-22 4.8 1.6 7.3 2.3 9.7 3.[...]

  • Page 11

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 11 P a ra l le l Comp ressor Syst ems Line Size OD (in.) Refrigerant Liquid Line Hot Gas Line Suction Line at Suction T emperature -40°F -20°F 0°F 20°F 40°F 3/8 12, 134A 22 R-507, 502, 404A 4.0 3.9 3.4 .15 .22 .31 .01 .02 .03 .01 .03 .04 .02 .04 .06 .04 .06 .09 .0[...]

  • Page 12

    12 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l S y ste m C ap aci ty B T U/ H Su ct i on Li ne S iz e Su ct i on T em p er at ur e 20 ˚ F Eq uiv ale n t L eng ths 10 ˚ F Eq uiv ale n t L eng ths -1 0 ˚F Eq uiv ale n t L eng ths -2 0 ˚F Eq uiv ale n t 25 ’ 5 0’ 7 5’ 100 ’ 1 50 ’ 200 ’ 25 ’ 5 0’ 7 5’ 100 ’ 1 50 [...]

  • Page 13

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 13 P a ra l le l Comp ressor Syst ems Su ct i on Li ne S iz e Li q ui d L i ne Si z e S y ste m C ap aci ty B T U/ H S u ct io n T em pe r atu re Re c eiv er t o Ex p an sio n V al v e Eq uiv ale n t L eng ths -2 0 ˚F L en g th s -3 0 ˚F Eq uiv ale n t L eng ths -4 0[...]

  • Page 14

    14 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l S y ste m C ap aci ty B T U/ H Su ct i on Li ne S iz e Su ct i on T em p er at ur e 40 ˚ F Eq uiv ale n t L eng ths 20 ˚ F Eq uiv ale n t L eng ths 10 ˚ F Eq uiv ale n t L eng ths 0˚ F Eq uiv ale n t 25 ’ 5 0’ 7 5’ 100 ’ 1 50 ’ 200 ’ 25 ’ 5 0’ 7 5’ 100 ’ 1 50 ’ [...]

  • Page 15

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 15 P a ra l le l Comp ressor Syst ems Su ct i on Li ne S iz e Li q ui d L i ne Si z e S y ste m C ap aci ty B T U/ H Su ct i on T em p er at ur e Re c eiv er t o Ex p an sio n V al v e Eq uiv ale n t L eng ths 0˚ F L en g th s -1 0 ˚F Eq uiv ale n t L eng ths - 2 0˚[...]

  • Page 16

    16 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l Net Evap . Capacity T otal Equiv . Length R-12 & R-134A R-22 R-502 R-507 & R-404A Discharge Line (OD ) Liquid Line Cond . to Receiv er (OD ) Discharge Line (OD ) Liquid Line Cond . to Receiv er (OD ) Discharge Line (OD ) Liquid Line Cond . to Receiv er (OD ) Discharge Line (OD ) [...]

  • Page 17

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 17 P a ra l le l Comp ressor Syst ems W arning: I t is ille gal to kno wing ly v ent or dis cha rge any CFC’ s and HCFC’ s to the atmosph ere . ALL CFC ’ s and HCFC’ s must be reclaimed or recycled. Leak Check 1. T o check the systems for leaks, leave all valve[...]

  • Page 18

    18 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l Refrigerant Distribution The distr ibution system is selec ted based upon the type of defrost for that particular system. For each set of liquid/suction lines a distribution system must be selected. Liquid solenoids are recommended to be installed at the evaporator on all systems, par ti[...]

  • Page 19

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 19 P a ra l le l Comp ressor Syst ems Elec tr onic Con trol S yst em The elec tronic controller has become the standard on parallel compressor systems. The increased capabilities of the controllers magnify the ecienc y of the parallel compressor system making it a v[...]

  • Page 20

    20 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l V oltage Code 60 Hertz R ating 50 Hertz R ating Rating Min. Max. Rating Min. Max. B 230-1 207 253 - - - C 208/230-3 187 253 200/220-3 180 240 D 460-3 414 506 380/420-3 342 462 E 575-3 518 633 500-3 450 550 K 208/230/460-3 187 506 200/380/400-3 180 440 M - - - 380/420-3 342 462 N 230/460-[...]

  • Page 21

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 21 P a ra l le l Comp ressor Syst ems Copeland Part No . MFGRS. Model No . Pressur e Di . P si (bar) Alarm Circuit Cut-In C ut-Out Sentronic 7 – 9 12 - 14 Y es 085-0062-00 Penn P45NCA-12 9 (± 2) 14 No Ranco P30-5826 Y es Rober tshaw PD21-2502 No 085-0088-00 Rober[...]

  • Page 22

    22 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l Carlyle Part No . Danfoss Part No . Time Delay Pressure Di . P si (bar) Reset Cut-In C ut-Out 634-2008 OR P529-2130 60B2101 45 sec. 8 – 11 (.55 - .76) 4 - 8 (.28 - .55) Manual 634-2050 OR P529-2100 60B2151 Carlyle Part No . Johnson Part No . Time Delay Pressure Di . P si (bar) Re[...]

  • Page 23

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 23 P a ra l le l Comp ressor Syst ems Sight Glass & Moisture Indicator The sight glass/moisture indicator helps determine that a unit has sucient refrigerant charge and/or when the liquid line lter drier cores need to be r eplaced. Bubbles in the glass may in[...]

  • Page 24

    24 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l For Relief Devices set at 400 psig • Obtain the capacity at 400 psig setting • Locate this capacity or the nearest larger capacity in the left-hand column of the discharge piping table abo ve and read across t o obtain the maximum lengths for each tube and pipe size For r elief devic[...]

  • Page 25

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 25 P a ra l le l Comp ressor Syst ems Series P100 Pressure C ontrol The P100 series, manufac tured by Johnson Control, I nc., are encapsulated, non adjustable , single -pole single thro w , direct mount pre ssure co ntrol s typically used for lo w or high pressur e cut[...]

  • Page 26

    26 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l Module Replacement 1. Disconnect power at the fuse bo x 2. Remove wiring bo x from the retainer 3. Re mo v e the IRR 40 00 -9 3 Ring wit h an IRR P- 10 1 or e qu iv al en t retaining ring pliers 4. Remove the Retainer 5. Pull out the module b y the leads 6. Install new Module 7. V erify [...]

  • Page 27

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 27 P a ra l le l Comp ressor Syst ems to the compressor . Before the oil separat or is installed, an initial charge of oil must be added to it. This initial charge of oil is the amount that is needed to just oat the needle valve oat. This amount of oil will stay [...]

  • Page 28

    28 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l A C&R Model No . Connection Size Operation Pressure Di ., psig Oil Lev el, Sight Glass S-9010 3 BOL T 5 - 30 1/2 S-9010A 4 BOL T 5 - 30 1/2 S-9015 3/4” NPTF F . 5 - 30 1/2 S-9090 3 BOL T 5 - 90 A djustable S-9090A 4 BOL T 5 - 90 Adjustable S-9110 3 BOL T 5 - 30 1/2 S-9120 3 BOL [...]

  • Page 29

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 29 P a ra l le l Comp ressor Syst ems Suction Filter Replaceable core suc tion filters are supplied as standard on all units. The flanged shell holds replaceable pleated lter elements suitable for installation in the suction line of refrigeration systems . In this w[...]

  • Page 30

    30 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l Superior V alve C ompany Replaceable Suction Filter On many parallel systems , the Superior Valve Co. suction lter is installed. • Alco C ontrols Alco Suction Filt er Com para ble to the Supe rior su ction lt ers and inter cha ngeab le cores . T able 28. T ype AFD (for cleanup) R[...]

  • Page 31

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 31 P a ra l le l Comp ressor Syst ems Liquid Drain C ontrol Method This method is ideal for large capacity systems since a smaller regulator is r equired for liquid line than f or discharge line . During warm ambient temperature conditions valves A and C will be open a[...]

  • Page 32

    32 Part # 25000102 Insta lla tion a nd Op er a tions Ma nua l must be varied during the setting procedure and it is dicult to determine exactly when the bypass valve opens unless a pressure gauge can be locat ed at the valve outlet. Theref ore, sucient load must be available in some form to rais e the sucti on pr essur e abo ve the desi red v[...]

  • Page 33

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 33 P a ra l le l Comp ressor Syst ems General Maintenanc e Schedule (Ser vice/Main tenance should be per formed only by a qualied / certied refrigeration ser vice technician.) W eek ly Check refrigerant charge using the liquid line sigh t glass Check compressor o[...]

  • Page 34

    34 Part # 25000102 SERVICE DIA GNOSIS CHART Symptom C ause Remedy Compr essor Does Not Run 1. 2. 3. 4. 5. 6. Motor Line open F use blown T ripped overload Control c ontacts dir ty or jammed in open position Piston seiz ed Fr ozen compr essor or motor bearings 1. 2. 3. 4. 5. 6. Close starter or disconnect switch Replace fuse See electrical sec tion [...]

  • Page 35

    Par allel Compressor S ystems Installation & Operations Manual, October 2004 35 Symptom C ause Remedy Low Discharge Pressure 1. 2. 3. 4. 5. Insucient refrigerant in system F aulty condenser temp . regulation Compressor suction or discharge valv e ineciencies Low suction pressur e Head pressure con trol valve set wr ong or no head pressure[...]

  • Page 36

    SERVICE REC ORD A permane nt data sheet shoul d be prepar ed on each installa tion , with a copy for the own er and the orig inal fo r the instal ling co ntra ctor’ s les. If another rm is to handle service and maintenance, additional copies should be pr epared as necessary. Sy stem Ref erenc e Data The following inf ormation should be l[...]