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H-IM-72B
Replaces H-IM-72A
Installation, Operation and
Parallel Compressor Systems
2175 W
P
EST
October 1999
Maintenance Guide
H
I
. R
EATCRAFT
NC
P
B
., S
M
ARK
LACE
LVD
TONE
OUNTAIN
.
.
WWW
HEATCRAFTRPD
COM
Compressor
Compressor
Compressor
Compressor
Compressor
Installation
Installation
Installation
Installation
Installation
P
EFRIGERATION
RODUCTS
, GA 30087 • 770-465-5600 • F
•
-
:
.
@
E
MAIL
HRPD
FEEDBACK
Parallel
Parallel
Parallel
Parallel
Parallel
Systems
Systems
Systems
Systems
Systems
Part No. 25000102
D
IVISION
770-465-6016
AX
.
HEATCRAFT
COM
1
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Table of Contents
Related Manuals for Heatcraft Refrigeration Products H-IM-72A
Summary of Contents for Heatcraft Refrigeration Products H-IM-72A
- Page 1 H-IM-72B Replaces H-IM-72A Installation, Operation and Maintenance Guide Parallel Compressor Systems EATCRAFT 2175 W LACE HEATCRAFTRPD October 1999 EFRIGERATION RODUCTS ., S , GA 30087 • 770-465-5600 • F TONE OUNTAIN • MAIL HRPD FEEDBACK Parallel Parallel Parallel Parallel Parallel...
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Page 2: Table Of Contents
Table of Contents Introduction Inspection Unit Designation Model Definition ... 3 System Warranty Rigging Location of Equipment - INDOOR Clearances Floor & Foundation Requirements Vibration Mounts Figure 1. Vibration Pad & Spring Isolator Figure 2. Vibration Pad Locations ... 4 Location of Equipment - OUTDOOR Ground Mounting Roof Mounting... -
Page 3: Inspection
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. -
Page 4: System Warranty
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 manufacturers warranty. (a) System piping must be in accordance with good refrigeration practices. -
Page 5: Location Of Equipment - Outdoor
LOCATION OF EQUIPMENT - OUTDOOR • The mounting platform or base should be level 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. •... -
Page 6: Unit Access
UNIT ACCESS Always provide sufficient clearance for 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. -
Page 7: Ventilation Requirements
Ventilation Requirements INDOOR UNITS If compressors or condensing units are located in a machine room, adequate ventilation air must be provided to avoid an excessive temperature rise in the room. To allow for peak summer temperatures a 10 F temperature rise is recommended, although a 15 F rise might be acceptable. -
Page 8: Refrigerant Line Insulation
• In systems equipped with capacity control compressors, or where multiple compressors are used with one or more compressors cycled off for capacity control, double suction risers should be installed. See Figure 6 below. The two lines should be sized so that the total cross-section area is equivalent to the cross section area of a single riser that would have both satisfactory gas velocity and... -
Page 9: Expansion Loops
Expansion Loops Suction, liquid and remote condenser lines are subject to expansion and contraction and proper piping techniques must be employed (especially on hot gas lines) to prevent line breakage. This is critical on long straight runs of generally 70’ or more where expansion loops must be provided and hangers should allow for longitudinal movement of the piping. - Page 10 Table 2.Pressure Loss of Liquid Refrigerants (In Liquid Line Risers - Expressed in Pressure Drop, PSIG, and Subcooling Loss, F) 10’ 15’ Refrigerant PSIG F PSIG F PSIG R502 R134A R507, R404A Based on 110 F liquid temperature at bottom of riser. Table 3.
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Page 11: Table 4. Weight Of Refrigerants In Copper Lines During Operation
Table 4. Weight of Refrigerants in Copper Lines During Operation (Pounds per 100 Lineal feet of type "L" tubing.) Line Size O.D. in Inches Refrigerant 12, 134a R507, 502, 404A 12, 134a R507, 502, 404A 12, 134a R507, 502, 404A 12, 134a R507, 502, 404A 12, 134a... - Page 12 Table 5A. Recommended Line Sizes for R-404A and R507 * SYSTEM +20˚F CAPACITY Equivalent Lengths BTU/H 100' 150' 1,000 3,000 4,000 6,000 9,000 12,000 15,000 18,000 1 1/8 24,000 1 1/8 1 1/8 30,000 1 1/8 1 1/8 1 1/8 36,000 1 1/8 1 1/8 1 1/8 1 3/8 42,000...
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Page 13: Table 5B. Recommended Line Sizes For R-404A And R507 (Continued)
Table 5B. Recommended Line Sizes for R-404A and R507 (continued) * SUCTION LINE SIZE SUCTION TEMPERATURE -20˚F -30˚F Lengths Equivalent Lengths 100' 150' 200' 100' 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 1 1/8 1 1/8 1 1/8... - Page 14 Table 6A. Recommended Line Sizes for R-22 * SYSTEM +40˚F CAPACITY Equivalent Lengths BTU/H 100' 150' 1,000 3,000 4,000 6,000 9,000 12,000 15,000 18,000 24,000 1 1/8 30,000 1 1/8 1 1/8 36,000 1 1/8 1 1/8 1 1/8 1 1/8 42,000 1 1/8 1 1/8 1 1/8 1 1/8 48,000...
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Page 15: Table 6B. Recommended Line Sizes For R-22 (Continued)
Table 6B. Recommended Line Sizes for R-22 (continued) * SUCTION LINE SIZE SUCTION TEMPERATURE 0˚F -10˚F Lengths Equivalent Lengths 100' 150' 200' 100' 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 1 1/8... -
Page 16: Table 7. Recommended Remote Condenser Line Sizes
Table 7. Recommended Remote Condenser Line Sizes R-12 & R-134a Total Discharge Evaporator Equiv. Line Capacity Length (O.D.) 3,000 6,000 9,000 12,000 18,000 24,000 36,000 1 1/8 1 1/8 48,000 1 1/8 1 1/8 60,000 1 3/8 1 1/8 72,000 1 3/8 1 3/8 90,000... -
Page 17: Leak Checking, Evacuation, And Start-Up
Leak Checking, Evacuation, and Start-up Warning: 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. To check the systems for leaks, leave all valves closed on suction, liquid and hot gas manifolds. -
Page 18: Refrigerant Distribution
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. -
Page 19: Electronic Control System
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) controller. -
Page 20: Compressors
Compressors The majority of the Heatcraft Parallel systems incorporate the Copeland compressor. Other brand compressors are available upon customer request. The compressors are solid mounted to a base frame or mounted on the refrigerant receiver. All reciprocating compressors incorporate oil floats. Crankcase heaters will be installed and wired. -
Page 21: Approved Copeland Lubricants
Table 12. Oil Charges Model Standard Family Initial (oz) 4DA3-100E 4DL3-150E 4DA3-200E 4DT3-220E 4DH3-250E 4DJ3-300E 6DT3-300* 6DJ3-400* Approved Copeland Lubricants Mineral Oil - Suniso 3GS or Equivalent Alkyl Benzene - Copeland Ultra 200 / Shrieve Zerol 200 TD / Soltex AB 200A / Thermal Zone 200 Carlyle Compressors Approved Carlyle Lubricants For CFC and HCFC refrigerants use:... - Page 22 Table 14. Oil Safety Switch Carlyle Danfoss Part No. Part No. 634-2008 60B2101 P529-2130 634-2050 60B2151 P529-2100 Carlyle Johnson Part No. Part No. O6DA660115 P345 Table 15. Part Load Performance Multipliers Compressor Model Capacity All 4 Cylinder Models All 6 Cylinder Models Table 16.
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Page 23: Sight Glass & Moisture Indicator
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. - Page 24 Table 17. Henry Relief Valve Capacity Ratings Pounds of Air per Minute for all Refrigerants Except Ammonia R717 TYPE CATALOG NUMBER ANGLE 526E 527E 5231 5231-A STRAIGHT 5231 THROUGH 5232 5240-1/2 5242-3/4 5244-1 5246-1-1/4 Table 18. Discharge Piping Table RELIEF DEVICE CAPACITY SOFT COPPER TUBE O.D.
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Page 25: Series P100 Pressure Control
Series P100 Pressure Control The P100 series, manufactured by Johnson Control, Inc., are encapsulated, non adjustable, single-pole single throw, 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 available. -
Page 26: Module Replacement
Module Replacement Disconnect power at the fuse box. Remove wiring box from the retainer. Remove the IRR 4000-93 Ring with an IRR P-101 or equivalent retaining ring pliers. Remove the Retainer. Pull out the module by the leads. Install new Module. Verify the voltage rating. -
Page 27: Temprite Models
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 valve 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. -
Page 28: Troubleshooting Oil System
Table 22. A C & R Model Regulators A C & R CONNECTION OPERATION OIL LEVEL, MODEL SIZE PRESSURE DIFF, psig S-9010 3 BOLT S-9010A 4 BOLT S-9015 3/4” NPTF F. S-9090 3 BOLT S-9090A 4 BOLT S-9110 3 BOLT S-9120 3 BOLT S-9130... -
Page 29: Suction Filter
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. -
Page 30: Superior Valve Company
Superior Valve Company Replaceable Suction Filter • On many parallel systems, the Superior Valve Co. suction filter is installed. Table 25. Type F Filter Replaceable Cartridges Shell Catalog IBCA 2CFA F25A 51071 3CFA F35A 51072 4CFA F45A 51073 5CFA F55A 51074 Table 26. -
Page 31: Liquid Drain Control Method
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 warm ambient temperature conditions valves A and C will be open and Valve B will be closed. When the ambient temperature at the condenser drops, the condenser pressure will tend to become lower. -
Page 32: Alco Controls
Adjusting these valves can be complicated because the load must be varied 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. Therefore, sufficient load must be available in some form to raise the suction pressure above the desired valve setting. -
Page 33: General Maintenance Schedule
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 •... -
Page 34: Service Diagnosis Chart
SERVICE DIAGNOSIS CHART Symptom Compressor Motor Line open. does not run Fuse blown Tripped overload Control contacts dirty or jammed in open position Piston seized Frozen compressor or motor bearings Unit short Control differential set too close cycles Discharge valve leaking Motor compressor ??? Refrigerant shortage Refrigerant over charge... - Page 35 Symptom Cause Insufficient refrigerant in system discharge Faulty condenser temp. regulation pressure Compressor suction or discharge valve inefficiencies. Low suction pressure Head pressure control valve set wrong or no head pressure control valve High suction Excessive load pressure Expansion valve overfeeding Low suction Lack of refrigerant pressure...
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Page 36: Service Record
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 service and maintenance, additional copies should be prepared as necessary. System Reference Data The following information should be filled out and signed by the Refrigeration Installation Contractor.