Heatcraft Refrigeration Products H-IM-72A manual

1 H-IM-72B October 1999 Part No. 25000102 H EATCRAFT I NC . R EFRIGERATION P RODUCTS D IVISION 2175 W EST P ARK P LACE B LVD ., S TONE M OUNTAIN , GA 30087 • 770-465-5600 • F AX 770-465-6016 WWW . HEATCRAFTRPD . COM • E - MAIL : HRPD . FEEDBACK @ HEATCRAFT . COM Parallel Parallel Parallel Parallel Parallel Compressor Compressor Compressor Com[...]

2 © Heatcraft 1999 Table of Contents Introduction Inspection Unit Designation Model Definition ................................................................................ 3 System W arranty Rigging Location of Equipment - INDOOR Clearances Floor & Foundation Requirements Vibration Mounts Figure 1. Vibration P ad & Spring Isolator Figu[...]

3 HEATCRAFT INC. Parallel Compressor Units INTRODUCTION Parallel Compressor systems are central refrigeration units employing 2 to 8 parallel piped compressors, a control panel, and receiver mounted on one common base frame. The system may be designed for either Indoor or Outdoor use. The Outdoor design ma y include the condenser mounted and piped.[...]

4 Figure 2. Vibration Pad Locations SYSTEM WARRANTY This equipment is designed to operate properly and produce the rated capacity when installed in accordance with good refrigeration practice. The following conditions should be adhered to when installing this unit to maintain the manuf acturers warranty . (a) System piping must be in accordance wit[...]

5 LOCATION OF EQUIPMENT - OUTDOOR • The mounting platform or base should be lev el and located so as to permit free access of supply air. • Units must not be located in the vicinity of steam, hot air or fume exhausts. • The unit should be mounted awa y from noise sensitive spaces such as offices. • The unit must hav e adequate suppor t to a[...]

6 UNIT ACCESS Alwa ys provide sufficient clearance f or unit maintenance and service. Minimum clearances for most situations are described below (except 60 Inches of free space is required in front of the control panel). Please note that these are minimums and more clearance may be required by local codes. Vertical Clearance Overhead obstructions a[...]

7 Ventilation Requirements INDOOR UNITS If compressors or condensing units are located in a machine room, adequate ventilation air must be provided to avoid an e xcessive temperature rise in the room. T o allow f or peak summer temperatures a 10 ° F temperature rise is recommended, although a 15 ° F rise might be acceptable. With compressors with[...]

8 • 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 long radius ell’ s f or lower pressure drop . • Provide expansion loops in long straight refrigerant lines that are subject to expansion and contraction. See [...]

9 In order to compensate for the expansion of the tubing, it is necessary to estimate the amount of expansion and then provide offsets or loops in the refrigerant piping. Normally the area to be most concerned with is the straight line distance from the fixture to the parallel compressor unit. A simple form of expansion loop can be made of soft tem[...]

10 T able 3. Equivalent Feet of Pipe (Due to V alve and Fitting F riction) Copper T ube , O .D., T ype "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 V alve (Open) 14 16 22 28 36 42 57 69 83 99 11 8 13 8 16 8 Angle V alve (Open) 7 9 12 15 18 21 28 34 42 49 57 7 0 83 90 ° T ur n[...]

11 T able 4. W eight of Refrig erants in Copper Lines During Operation (Pounds per 100 Lineal feet of type "L" tubing.) Line Size Suction Line at Suction T emperature O.D. Liquid Hot Gas in Inches Refrigerant Line Line -40 ° F -20 ° F0 ° F +20 ° F +40 ° F 12, 134a 4.0 .15 .01 .01 .02 .04 .06 3/8 22 3.9 .22 .02 .03 .04 .06 .08 R507, 5[...]

12 T able 5A. Recommended Line Sizes for R-404A and R507 * SUCTION LINE SIZE SUCTION TEMPERATURE SYSTEM +20 ˚ F +10 ˚ F- 1 0 ˚ F- 2 0 ˚ F CAPACITY Equivalent Lengths Equivalent Lengths Equivalent Lengths Equivalent BTU/H 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50[...]

13 T able 5B. Recommended Line Sizes for R-404A and R507 (continued) * SUCTION LINE SIZE LIQUID LINE SIZE SUCTION TEMPERATURE Receiver to -20 ˚ F -30 ˚ F -40 ˚ F Expansion Valve SYSTEM Lengths Equivalent Lengths Equivalent Lengths Equivalent Lengths CAPACITY 100' 150' 200' 25' 50' 75' 100' 150' 200' 2[...]

14 T able 6A. Recommended Line Sizes for R-22 * SUCTION LINE SIZE SUCTION TEMPERATURE SYSTEM +40 ˚ F +20 ˚ F +10 ˚ F0 ˚ F CAPACITY Equivalent Lengths Equivalent Lengths Equivalent Lengths Equivalent BTU/H 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75' [...]

15 T able 6B. Recommended Line Sizes for R-22 (continued) * SUCTION LINE SIZE LIQUID LINE SIZE SUCTION TEMPERATURE Receiver to 0 ˚ F -10 ˚ F -20 ˚ F Expansion Valve SYSTEM Lengths Equivalent Lengths Equivalent Lengths Equivalent Lengths CAPACITY 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50&ap[...]

16 3,000 6,000 9,000 12,000 18,000 24,000 36,000 48,000 60,000 T able 7. Recommended Remote Condenser Line Sizes R-12 & R-134a R-22 R-502 R507 & R-404A Liquid Line Liquid Line Liquid Line Liquid Line Net Total Discharge Cond. to Discharge Cond. to Discharge Cond. to Discharge Cond. to Evaporator Equiv. Line Receiver Line Receiver Line Recei[...]

17 Leak Checking, Evacuation, and Start-up W arning: It is illegal to knowingly vent or discharge any CFC’ s and HCFC’ s to the atmosphere. ALL CFC’ s and HCFC’ s must be reclaimed or recycled. Leak Check 1. T o check the systems f or leaks, leav e all valv es closed on suction, liquid and hot gas manif olds. The unit is shipped with a hold[...]

18 Refrigerant Distribution The distribution system is selected 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, particularly systems with long line runs. The solenoid will prev [...]

19 Electronic control system The electronic controller has become the standard on parallel compressor systems. The increased capabilities of the controllers magnify the efficiency of the parallel compressor system making it a very attractive accessory item. The electronic control system preferred by Heatcraft is the Computer Process Control ( RMCC)[...]

20 T able 11. Oil Saf ety Switch Pressure Alarm Copeland MFGRS. Model No. Diff. Psi (bar) Circuit Part No. Cut-In Cut-Out Sentronic 7 – 9 12 - 14 Y e s 085-0062-00 Penn P45NCA-12 No Ranco P30-5826 Y es Robertshaw PD21-2502 9 ( ± 2) 14 No 085-0088-00 Robertshaw PD21-1006 Y es Penn P45NCB-3 Y es 085-0101-00 Robertshaw LG21-2501 Y es All controls a[...]

21 T able 12. Oil Charges Model Standard Deep Sump Family Initial (oz) Recharge (oz) Initial (oz) Recharge (oz) 2D 80 72 1 10 95 3D 1 1 5 105 190 170 4DA3-100E 140 130 - - 4DL3-150E 135 120 250 235 4DA3-200E 135 120 250 235 4DT3-220E 130 120 245 235 4DH3-250E 130 120 245 235 4DJ3-300E 140 125 255 240 6D 140 130 255 245 6DT3-300* 255 245 255 245 6DJ[...]

22 T able 14. Oil Saf ety Switch Pressure Carlyle Danfoss Time Diff. Psi (bar) Part No. Part No. Delay Cut-In Cut-Out Reset 634-2008 OR 60B2101 P529-2130 45 sec. 8 – 11 4 - 8 Manual 634-2050 (.55 - .76) (.28 - .55) OR 60B2151 P529-2100 Pressure Carlyle Johnson Time Diff. Psi (bar) Part No. Part No. Delay Cut-In Cut-Out Reset O6D A660115 P345 45 s[...]

23 Sight Glass & Moisture Indicator The sight glass/moisture indicator helps determine that a unit has sufficient refrigerant charge and/or when the liquid line filter drier cores need to be replaced. Bubbles in the glass may indicate a shortage of refrigerant or a restriction in the liquid line (i.e. plugged liquid line filter drier). Moisture[...]

24 T able 17. Henry Relief V alve Capacity Ratings P ounds of Air per Minute for all Refrigerants Except Ammonia R717 TYPE CA T ALOG SIZE CONNECTION ST AND ARD PRESSURE SETTINGS PSIG NUMBER INLET OUTLET 350 400 425 450 ANGLE 526E 3/8 M.P .T . 3/8 FLARE 10.2 11.6 12.3 13.0 527E 1/2 M.P .T . 5/8 FLARE 28.5 32.4 34.4 36.3 5231 3/8 M.P .T . 3/8 FLARE 1[...]

25 Series P100 Pressure Control The P100 series, manufactured by Johnson Control, Inc., are encapsulated, non adjustable, single-pole single thro w , direct mount pressure controls typically used for low or high pressure cutouts. On the Heatcraft manufactured parallel systems, the control is used for High Pressure cutout. There are two types av ail[...]

26 Module Replacement 1. Disconnect power at the fuse box. 2. Remove wiring bo x from the retainer . 3. Remove the IRR 4000-93 Ring with an IRR P-101 or equivalent retaining ring pliers. 4. Remove the Retainer . 5. Pull out the module by the leads. 6. Install new Module. 7. V erify the voltage rating. 8. Reassemble the Retainer , Ring, and wir ing.[...]

27 Before the oil separator 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 float the needle valv e float. This amount of oil will stay in the oil separator when in operation and will seal the needle and prevent damage to the float mechanism. Oil Precharge is very important[...]

28 Table 22. A C & R Model Regulators A C & R CONNECTION OPERATION OIL LEVEL, MODEL SIZE PRESSURE SIGHT NO. DIFF, psig GLASS S-9010 3 BOLT 5 - 30 1/2 S-9010A 4 BOLT 5 - 30 1/2 S-9015 3/4” NPTF F. 5 - 30 1/2 S-9090 3 BOLT 5 - 90 Adjustable S-9090A 4 BOLT 5 - 90 Adjustable S-9110 3 BOLT 5 - 30 1/2 S-9120 3 BOLT 5 - 30 1/4 + S-9130 3 BOLT 5 [...]

29 Suction Filter Replaceable core suction filters are supplied as standard on all units. The flanged shell holds replaceable pleated filter elements suitable for installation in the suction line of refrigeration systems. In this way any contaminants left in the system at start-up can be removed before they circulate back to the compressor . The su[...]

30 Superior Valve Company Replaceable Suction Filter • On many parallel systems , the Super ior V alv e Co . suction filter is installed. Table 25. Type F Filter Replaceable Cartridges Shell Catalog IBCA Cartridge Filter No. No. No. OD (in) Area (in 2 ) 2CFA F25A 51071 1 - 23/32 66 3CFA F35A 51072 2 - 5/8 115 4CFA F45A 51073 3 - 17/32 189 5CFA F5[...]

31 Liquid Drain Control Method This method is ideal for large capacity systems since a smaller regulator is required for liquid line than for discharge line. During war m ambient temperature conditions v alves A and C will be open and V alve B will be closed. When the ambient temperature at the condenser drops, the condenser pressure will tend to b[...]

32 Adjusting these valves can be complicated because the load must be v aried during the setting procedure and it is difficult to determine exactly when the bypass valve opens unless a pressure gauge can be located at the valve outlet. Theref ore, sufficient load must be a vailable in some f or m to raise the suction pressure above the desired valv[...]

33 General Maintenance Schedule (Service/Maintenance should be performed only by a qualified / certified refrigeration service technician.) Weekly • Check refrigerant charge using the liquid line sight glass. • Check compressor oil level. • Check compressor crankcase heater operation. • Check main power and control voltage • Check appeara[...]

34 SERVICE DIAGNOSIS CHART Symptom Cause Remedy Compressor 1. Motor Line open. 1. Close starter or disconnect switch does not run 2. Fuse blown 2. Replace fuse 3. T r ipped overload 3. See electrical section 4. Control contacts dirty or jammed in 4. Repair or replace open position 5. Piston seized 5. Remove motor-compressor head, look for broken va[...]

35 Symptom Cause Remedy Low 1. Insufficient refr igerant in system 1. Check for leaks. Repair and add charge discharge 2. Faulty condenser temp. regulation 2. Check condenser control operation pressure 3. Compressor suction or discharge valve 3. Clean or replace leaky valve plates inefficiencies. 4. Low suction pressure 4. See corrective steps for [...]

36 SERVICE RECORD A permanent data sheet should be prepared on each installation, with a copy for the owner and the original for the installing contractor’ s files. If another firm is to handle ser vice and maintenance, additional copies should be prepared as necessar y . System Reference Data The f ollowing inf ormation should be filled out and [...]