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Installationand
Operations Manual
H-IM-CU August 2008 PartN o.25008101
Replaces None. Information formerly included in H-IM-64L.
Condensing
Units
Table ofC ontents
General Safety Information...............................................................................2
Inspection ...............................................................................................................2
Warranty Statement .........................................................................
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General Safety Information 3. Make sure that all field wiring conforms to the requirements 1. Installation and maintenance to be performed only by qualified of the equipment and all applicable national and local codes. personnel who are familiar with this type of equipment. 4. Avoid contact with sharp edges and coil surfaces. 2. Some units are pressurized with dry air or inert gas. They are a potential injury hazard. All units must be evacuated before charging the system with refrige
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AIR FLOW AIR FLOW Space and Location Requirements for Air CooledC ondensingUnits andRemot eC ondensers The most important consideration which must be taken into account when Another consideration which must be taken is that the unit should be deciding upon the location of air-cooled equipment is the provision for a mounted away from noise sensitive spaces and must have adequate support supply of ambient air to the condenser, and removal of heated air from the to avoid vibration and n
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Requirements for Remote and Water Cooled Condensing Units General Installation 2. A double riser discharge line may be used as shown in The indoor compressor units are designed to be used with a remote Diagram 2. Line “A” should be sized to carry the oil at minimum condenser. The water cooled units are similar, except that they have an load conditions and the line “B” should be sized so that at the integral water cooled condenser. Inlet and outlet water connections are to
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CondensingUnit Riggingand M ounting Figure. Spring M ount 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 abov
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HeadP ressureC ontrol Several types of head pressure control systems are available on C. Ambient Fan Cycle Control condensing units: This is an automatic winter control method which will maintain a condensing A. Dual Valve System. (See section on operation and adjustment.) pressure within reasonable limits by cycling fan motors in response to B. Single Valve system. No adjustments are necessary. outside air temperature. The thermostat(s) should be field adjusted to shut (See secti
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Refrigeration Oils* Oil Types With the changes that have taken place in our industry due to the CFC Table 2 below summarizes which oils/lubricants are approved for use in issue, we have reevaluated our lubricants to ensure compatibility with the Copeland compressors. new HFC refrigerants and HCFC interim blends offered by several chemical Mineral Oils producers. As a secondary criteria, it is also desirable that any new lubricant be compatible with the traditional refrigerants such as HCFC-2
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d) Suitable P-type oil traps should be located at the base of each PhaseL ossM onitor suction riser to enhance oil return to the compressor. The combination phase sequence and loss monitor relay protects the system e) For desired method of superheat measurement, a pressure tap against phase loss (single phasing), phase reversal (improper sequence) and should be installed in each evaporator suction line in low voltage (brownout). When phase sequence is correct and full line volt
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Three Pipe System Liquid Lines The three pipe system (sometimes called re-evap.) uses three pipes: one for Liquid lines should be sized for a minimum pressure drop to prevent liquid line, one for suction line, and one for hot gas line. In addition, a re- “flashing”. Flashing in the liquid lines would create additional pressure drop evaporator accumulator is used at the suction outlet of the evaporator. The and poor expansion valve operation. If a system requires long liquid lines hot gas i
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Determine linesiz e1 (main line from condensingunit) : Unit Cooler Piping 1. 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). Pipe size example : 2. Refer to 24,000 @100 feet at -20°F SST R404A on the chart. Given: -10°FF reezer with one system having (2) evaporators You will find the suction line to be 1-3/8" and 1/2" liquid line. • One condensing unit rated at 24,000 BTUH’s @ -20°F SST R404A
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Table . Pressure Loss of Liquid Refrigerantsin Liquid Line Risers (Expressedin PressureD rop,PSIG, and Subcooling Loss, ˚F) Liquid Line Risein Feet Refrigerant 10' 15' 20' 25' 0' 0' 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 temperat
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Table 7. Recommended Line Sizes for R-22 * Suc tionLine Siz e Liquid Line Size Suction Temperature Receiver to Expansion Valve Capacity +0˚F +20˚F +10˚F 0˚F -10˚F -20˚F Equivalent BTUH Equivalent Lengths Equivalent Lengths Equivalent Lengths Equivalent Lengths Equivalent Lengths Equivalent Lengths 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
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Table 8. Recommended LineSiz es for R-0 A and R507* Suc tion LineSiz e Liquid LineSiz e Suction Temperature Receiver to Expansion Valve Capacity +20˚F +10˚F -10˚F -20˚F -0˚F -0˚F Equivalent BTUH Equivalent Lengths Equivalent Lengths Equivalent Lengths Equivalent Lengths Equivalent Lengths Equivalent Lengths 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/
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Evacuation and Leak Detection Due to the smaller molecule size of HFC’s, they will tend to leak more readily Repeat this operation a second time. than CFC’s. Consequently, it is of the utmost importance that proper system Open the compressor service valves and evacuate the entire system to 500 evacuation and leak detection procedures be employed. microns absolute pressure. Raise the pressure to 2 psig with the refrigerant Copeland recommends a minimum evacuation to 500 microns. In additio
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Check Out and Start Up After the installation has been completed, the following points should be covered before the system is placed in operation: a) Check all electrical and refrigerant connections. Be sure they are all tight. b) 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. c) Remove upper mounting nuts on the compressor feet. Remove the shipping spacer
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Operational Check Out SystemB alancing - CompressorSup erheat After the system has been charged and has operated for at least two hours at IMPORTANT: normal operating conditions without any indication of malfunction, it should be allowed to operate overnight on automatic controls. Then a thorough In order to obtain the maximum capacity from a system, and to ensure recheck of the entire system operation should be made as follows: trouble-free operation, it is necessary to balance each
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GeneralS equenceof Operation Electric Defrost Troubleshooting The electric defrost units are relatively simple and trouble-free in operation: Refrigeration Cycle Timer 1. Power is supplied to the timer at terminals “1” and “N”. If the system does not go through its proper sequence , check timer 2. The fan delay and the defrost termination thermostat is closed in the fan operation through a defrost cycle. Check for loose wires or terminals. Before delay position and open in the defros
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Table 10. System TroubleshootingC hart PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS Compressor will not 1. Main switch open. 1. Close switch. run 2. Fuse blown. 2. Check electrical circuits and motor winding for shorts or grounds. Investigate for possible overloading. Replace fuse after fault is corrected. 3. Thermal overloads tripped. 3. Overloads are automatically reset. Check unit closely when unit comes back on line. 4. Repair or replace. 4. Defective contactor or coil. 5. Dete
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PreventiveM aintenance • Check moisture indicator/sightglass for flash gas. If found check UnitC oolers entire system for refrigerant leaks and add refrigerant as needed after At every six month interval, or sooner if local conditions cause clogging repairing any leaks. or fouling of air passages through the finned surface, the following items • Check compressor sightglass (if equipped) for proper oil level. should be checked. • Check condition of condenser. Look for accumulation of dirt
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Diagram . Typical Wiring Diagram for Single Evaporator with andwithout Defrost Timer Diagram . Typical Wiring Diagram for Single Evaporator with Defrost Timer Only 20
