Related Manuals for Heatcraft Refrigeration Products PARALLEL COMPRESSOR SYSTEMS 25000102
Summary of Contents for Heatcraft Refrigeration Products PARALLEL COMPRESSOR SYSTEMS 25000102
- Page 1 Installation and Operation Manual Bulletin No. H-IM-PCS October 2004 Part Number 25000102 (Replaces H-IM-72B, October 2004) Parallel Compressor Systems...
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Page 2: Table Of Contents
Table 30. Control settings for R-404A/R-507 Table 31. Control settings for R-22 Low Pressure Switch Setting for RMCC General Maintenance Schedule... 33 SERVICE DIAGNOSIS CHART ...34-35 Service Record ... 36 System Reference Data © 2007 Heatcraft Refrigeration Products LLC Part # 25000102... -
Page 3: Introduction
Parallel Compressor Systems 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 may include the condenser mounted and piped. -
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 (b) Inert gas must be charged into the piping during brazing... -
Page 5: Location Of Equipment - Outdoor
Parallel Compressor Systems absorbing spring mounts (optional equipment) must be placed under the base frame of each unit. See Figure 1 for view of Spring Isolator. The spring mounts are placed under the unit and the unit carefully lowered on to the mounts. Note that no other mounting hardware is required and any unevenness in the floor or uneven weight distribution may be compensated for by turning the spring mount leveling nuts with an open-... -
Page 6: Unit Access
Installation and Operations Manual 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
Parallel Compressor Systems 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: Figure 6. Double Suction Risers
• 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 acceptable pressure drop at maximum load conditions. -
Page 9: Expansion Loops
Parallel Compressor Systems 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
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 R-12 R-22 R-502 R-134A R-404A/R-507 Based on 110°F liquid temperature at bottom of riser Table 3. -
Page 11: Table 4. Weight Of Refrigerants In Copper Lines During Operation
Parallel Compressor Systems Table 4. Weight of Refrigerants in Copper Lines During Operation (Pounds per 100 Lineal Feet of Type “L” Tubing) Line Size Refrigerant OD (in.) 12, 134A R-507, 502, 404A 12, 134A R-507, 502, 404A 12, 134A R-507, 502, 404A 12, 134A R-507, 502, 404A 12, 134A... - Page 12 Table 5A. Recommended Line Sizes for R-404A/R-507* System Capacity 20˚F BTU/H Equivalent Lengths 25’ 50’ 75’ 100’ 150’ 200’ 25’ 50’ 75’ 100’ 150’ 200’ 25’ 50’ 75’ 100’ 150’ 200’ 25’ 50’ 75’ 1,000 3,000 4,000 6,000 9,000 12,000 15,000 18,000 1-1/8 1-1/8...
- Page 13 Parallel Compressor Systems Table 5B. Recommended Line Sizes for R-404A/R-507 (continued)* Suction Line Size Suction Temperature -20˚F -30˚F Lengths Equivalent Lengths 100’ 150’ 200’ 25’ 50’ 75’ 100’ 150’ 200’ 25’ 50’ 75’ 100’ 150’ 200’ 25’ 50’ 75’ 100’ 150’ 200’ 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8...
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Page 14: Table 6A. Recommended Line Sizes For R-22
Table 6A. Recommended Line Sizes for R-22* System Capacity 40˚F BTU/H Equivalent Lengths 25’ 50’ 75’ 100’ 150’ 200’ 25’ 50’ 75’ 100’ 150’ 200’ 25’ 50’ 75’ 100’ 150’ 200’ 25’ 50’ 75’ 1,000 3,000 4,000 6,000 9,000 12,000 15,000 18,000 24,000... -
Page 15: Table 6B. Recommended Line Sizes For R-22 (Continued)
Parallel Compressor Systems Table 6B. Recommended Line Sizes for R-22 (continued)* Suction Line Size Suction Temperature 0˚F -10˚F Lengths Equivalent Lengths 100’ 150’ 200’ 25’ 50’ 75’ 100’ 150’ 200’ 25’ 50’ 75’ 100’ 150’ 200’ 25’ 50’ 75’ 100’ 150’ 200’ 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8... -
Page 16: Table 7. Recommended Remote Condenser Line Sizes
Table 7. Recommended Remote Condenser Line Sizes R-12 & R-134A Total Liquid Line Discharge Evap. Equiv. Cond. to Line Capacity Length Receiver (OD) (OD) 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
Parallel Compressor Systems 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 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
Parallel Compressor Systems 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: Table 11. Oil Safety Switch
Parallel Compressor Systems Table 11. Oil Safety Switch Copeland MFGRS. Part No. 085-0062-00 Penn Ranco Robertshaw 085-0088-00 Robertshaw Penn 085-0101-00 Robertshaw All controls are Manual Reset type with a 120 second nominal time delay at the rated voltage Table 12. Oil Charges Model Standard Family... -
Page 22: Table 14. Oil Safety Switch
Table 14. Oil Safety Switch Carlyle Danfoss Time Part No. Part No. Delay 634-2008 60B2101 P529-2130 45 sec. 634-2050 60B2151 P529-2100 Carlyle Johnson Time Part No. Part No. Delay O6DA660115 P345 45 sec. Table 15. Part Load Performance Multipliers Multiplication Factor For 1 Bank Unloaded Compressor Model Capacity... -
Page 23: Sight Glass & Moisture Indicator
Parallel Compressor Systems 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
Table 17. Henry Relief Valve Capacity Rating Catalog Type Number 526E Angle 527E 5231 5231-A 5231 5232 Straight Through 5240-1/2 5242-3/4 5244-1 5246-1-1/4 1-1/4 MPT Table 18. Discharge Piping Table Maximum Length of Discharge Pipe in Feet Relief Device Soft Copper Tube (OD) Capacity 3/8”... -
Page 25: Series P100 Pressure Control
Parallel Compressor Systems 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. -
Page 26: Module Replacement
Module Replacement 1. Disconnect power at the fuse box 2. Remove wiring box 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. -
Page 27: Temprite Models
Parallel Compressor Systems to the compressor. 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. AC&R Model Regulators AC&R Operation Connection Model Pressure Size Diff., psig S-9010 3 BOLT 5 - 30 S-9010A 4 BOLT 5 - 30 S-9015 3/4” NPTF F. 5 - 30 S-9090 3 BOLT 5 - 90 S-9090A 4 BOLT 5 - 90 S-9110 3 BOLT... -
Page 29: Suction Filter
Parallel Compressor Systems 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 Cartridge OD (in.) 2CFA F25A 51071 1-23/32 3CFA F35A 51072 2-5/8 4CFA F45A... -
Page 31: Liquid Drain Control Method
Parallel Compressor Systems 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
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
Parallel Compressor Systems 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 •... -
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 Parallel Compressor Systems Symptom 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...
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Page 36: Service Record
Since product improvement is a continuing effort, we reserve the right to make changes in specifications without notice. The name behind the brands you trust. CLIMATE CONTROL Heatcraft Refrigeration Products LLC H-IM-PCS-1107 | version 000 P: 770.465.5600 • F: 770.465.5990 • www.heatcraftrpd.com _______________________...