KeepRite Parallel Manual

Compressor systems

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Bulletin K90-KPCS-IM-2

1090001

Part #

PRODUCT SUPPORT

web: k-rp.com/support

see inside back cover for details

WARNING:

components, including all controls, should perform the installation and start-up of the system.

CONTENTS

General Safety............................................................................................................................

Inspection..................................................................................................................................

Handling, Placement and Installation...........................................................................................

Vibration Isolation.......................................................................................................................

Ventilation..................................................................................................................................

Electrical Information..................................................................................................................

Refrigerant Piping.......................................................................................................................

System Accessories....................................................................................................................

Leak Testing...............................................................................................................................

Evacuation and Dehydration.........................................................................................................

Line Insulation.............................................................................................................................

Refrigerant Charging....................................................................................................................

Compressor Oils..........................................................................................................................

System Start-Up Checklist............................................................................................................

Pressure Controls........................................................................................................................

Low Temperature Room Pull-Down...............................................................................................

Checking Superheat.....................................................................................................................

System Operational Checklist.......................................................................................................

System Troubleshooting..............................................................................................................

Customer Instructions.................................................................................................................

Maintenance Program.................................................................................................................

Service Parts Availability.............................................................................................................

Equipment Start-Up Information...................................................................................................

Product Support Resources.........................................................................................................

"As Built" Service Parts List.........................................................................................................

scan:

Only a qualified refrigeration mechanic who is familiar with refrigeration systems and

Parallel Compressor Systems

Installation and Maintenance

Manual

Air, Water and Remote Models

Hermetic, Semi-Hermetic and

Scroll Compressors

Page

3 - 4

6 - 7

11 - 12

13 - 14

17 - 19

BACK

18/04/22

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Summary of Contents for KeepRite Parallel

Page 1: Table Of Contents
Parallel Compressor Systems Installation and Maintenance Manual Bulletin K90-KPCS-IM-2 1090001 Part # Air, Water and Remote Models scan: PRODUCT SUPPORT Hermetic, Semi-Hermetic and web: k-rp.com/support see inside back cover for details Scroll Compressors WARNING: Only a qualified refrigeration mechanic who is familiar with refrigeration systems and components, including all controls, should perform the installation and start-up of the system.
Page 2: General Safety
GENERAL SAFETY IMPORTANT SAFETY NOTE Only a qualified refrigeration mechanic who is familiar with refrigeration systems and components, including all controls, should perform the installation and start-up of the system. To avoid potential injury, use care when working around coil surfaces (if applicable) or sharp edges of metal cabinets.
Page 3: Handling, Placement And Installation
(b) Distance to suitable electrical supply. SPECIAL NOTE FOR LARGE PARALLEL RACK UNITS: Parallel (c) Distance to the evaporator. rack units are large and heavy pieces of mechanical equipment (d) Adequate air circulation and ventilation.
Page 4: Vibration Isolation
On units equipped with rigid mounted compressors, check the compressor mounting bolts to insure they have not vibrated loose SPECIAL NOTE FOR LARGE PARALLEL RACK UNITS: Vibration during shipping. isolation pads should be put under the rack. Refer to the sketch below for typical isolator locations.
Page 5: Ventilation
To allow for peak summer temperatures a maximum rise of 10°F is recommended. This ventilation is only for the parallel compressor system. Ad- ditional ventilation must be taken in to account after considering In case of compressors with remote condensers, approx. 10% of other heat loads of the building.
Page 6: Refrigerant Piping
REFRIGERANT PIPING WARNING All local codes must be observed in the installation of refrigerant piping. IMPORTANT PIPING NOTE Appropriate line sizing practices must be used throughout the installation of the refrigeration system. REFRIGERATION GRADE COPPER TUBING MUST BE USED FOR PIPING SYSTEMS. Piping practice and line sizing charts as recommended by At the temperatures encountered in the condenser, receiver and A.S.H.R.A.E.
Page 7 REFRIGERANT PIPING (cont’d) IMPORTANT PIPING NOTE If steps of capacity control are supplied on a compressor, provisions must be made for oil return by sizing suction risers to maintain adequate gas velocities at reduced refrigerant flow. IMPORTANT: All suction lines outside of the refrigerated space Liquid Line: Horizontal liquid lines should be sized on a basis of must be insulated.
Page 8: System Accessories
IMPORTANT ENVIRONMENTAL NOTE / WARNING A proper refrigerant leak detector must be employed and monitored at all times in the machine room where the parallel compressor system is installed. An effective monitoring and quick response is necessary to avoid any prolonged leakage of refrigerant.
Page 9: Evacuation And Dehydration
EVACUATION AND DEHYDRATION CAUTION Do not use the refrigeration compressor to evacuate the system. Never start the compressor or perform a megger insulation test while the system is in a vacuum. When the system is completely free of refrigerant leaks, an Copper jumper lines should be used to interconnect both high evacuation of the entire system should be completed by using a and low-pressure sides of the system.
Page 10: Line Insulation
LINE INSULATION After the final system leak test is complete, it is important that COMPLETELY INSULATED. Liquid lines exposed to high ambient all refrigerant lines exposed to high ambient conditions must be temperatures should be insulated with 1/2 inch wall insulation insulated to reduce the heat pick-up and prevent the formation or better.
Page 11: Compressor Oils
COMPRESSOR OILS Check to see that the oil level is 1/8 to 1/3 up on the compressor DO NOT re-use drained oil that has been exposed to the sight glass on compressors so equipped before starting the atmosphere. compressor and after 15 to 20 minutes of operation. DO NOT re-fill, at any one time more than a total of 110 % of the CAUTION: Oil levels should not be allowed to go above the centre compressor’s factory specified charge.
Page 12 COMPRESSOR OILS (cont’d) Bitzer Semi-Hermetic Reciprocating Compressors: 2KC-05.2(Y) to 6F-50.2(Y) HFC's (H)CFC R134a Interim Blends R-401A, R-401B, R-402A, R404A R507 Lubricant Type R-408A, R-409A, R407C R407A R407A (MP-39, MP-66, R448A R448A R449A R449A HP-80, FX-10, FX56) ICI (Virgina KMP) Emkarate RL32S Polyol Ester Mobil EAL Arctic 32 Castrol Icematic SW32...
Page 13: System Start-Up Checklist
SYSTEM START-UP CHECK LIST IMPORTANT START-UP NOTE Only a qualified refrigeration mechanic who is familiar with compressor performance and the function and adjustment of all controls and components should start up the compressor. Finishing up work on the installations should be planned so that a qualified mechanic Before any refrigeration system is started, the following items should be checked: Before any refrigeration system is started, the following items should be checked: Check that the wiring diagrams, instructions, bulletins etc.
Page 14: Pressure Controls
SYSTEM START-UP CHECK LIST (cont’d) Low Pressure Control Settings R407A R407A R407C R134a R404A R507 Minimum R448A R448A R449A R449A Temperature °F * Cut-out Cut-out Cut-out Cut-in Cut-in (PSIG) Cut-in (PSIG) Cut-in (PSIG) Cut-out (PSIG) (PSIG) (PSIG) (PSIG) (PSIG) * The coldest Temperature of either the fixture or outdoor ambient. High Pressure Control Settings Maximum Cut-out (PSIG) Refrigerant...
Page 15: Checking Superheat
CHECKING SUPERHEAT IMPORTANT SYSTEM BALANCING NOTE To obtain maximum system capacity and insure trouble free operation it is necessary to check both the compressor and evaporator superheat. Compressor Superheat Compressor suction superheat must be checked. To check the superheat at the compressor the following steps should be followed: Measure the suction pressure at the suction service valve of the compressor.
Page 16: System Operational Checklist
SYSTEM OPERATIONAL CHECK LIST When the system has been running trouble free for an extended time (two weeks or more) and design conditions are satisfied, the following check list should be followed: Check that compressor discharge and suction pressures are operating within the allowable design limits for the compressor.
Page 17: System Troubleshooting
SYSTEM TROUBLESHOOTING The following System Troubleshooting Guide lists the most common types of malfunctions encountered with refrigeration systems. These simple troubleshooting techniques can save time and money minimizing unnecessary downtime and end-user dissatisfaction. Contact the factory or your local sales representative for further information or assistance. System Troubleshooting Guide Condensing Unit Problem Possible Causes...
Page 18 SYSTEM TROUBLESHOOTING (cont’d) System Troubleshooting Guide Continued Condensing Unit Problem Possible Causes Discharge pressure too high. 1. Non-condensables in the system. 2. System overcharged with refrigerant. 3. Discharge service valve partially closed. 4. Condenser fan not running. 5. Dirty condenser coil.(air-cooled condensers) 6. Dirty tubes. .(water-cooled condensers) 7. Defective or improperly set water regulating valve.
Page 19 SYSTEM TROUBLESHOOTING (cont’d) System Troubleshooting Guide Continued Condensing Unit Problem Possible Causes Room temperature too high. 1. Defective room thermostat or improper differential / setting. 2. Malfunctioning liquid line solenoid valve. 3. Insufficient air across evaporator coil (iced up coil, product blocking evaporator, fan blade / motor problem). 4. Improper evaporator superheat (low refrigerant charge, plugged TXV strainer, poor TXV bulb contact, incorrect TXV setting).
Page 20: Customer Instructions
CUSTOMER INSTRUCTIONS Completely fill in System Start-Up Worksheets located at the back Give the owner / end user instructions on normal operation of this Installation and Maintenance Manual. This document of the system. Explain electrical characteristics, location of should be left with the equipment for future reference. disconnect switches as well as other safety precautions.
Page 21 NOTES K90-KPCS-IM-2 - 21 - 18/04/22...
Page 22: Equipment Start-Up Information
START-UP INFORMATION Important: This start-up information should be completely filled in on each installation and remain with the unit as a permanent record for future reference. PLEASE PRINT LEGIBLY Name & address of installation ________________________________________________________________________________ ______________________________________________________________________________________________________________ _______________________________________________________________________________________________________________ Name, address, phone & fax # of Installing contractor __________________________________________________________ _______________________________________________________________________________________________________________ _______________________________________________________________________________________________________________ Type of System (Cooler, Freezer, etc…) ___________ Design Box Temperature_________°F...
Page 23: Product Support Resources
PRODUCT SUPPORT RESOURCES web: pcs.k-rp.com email: racks@k-rp.com call: 1-844-893-3222 x525 email: troubleshooting@k-rp.com call: 1-844-893-3222 x529 web: k-rp.com/parts email: parts@k-rp.com call: 1-844-893-3222 x525 web: k-rp.com/warranty email: warranty@k-rp.com call: 1-844-893-3222 x501 email: orders@k-rp.com call: 1-844-893-3222 x501 email: shipping@k-rp.com call: 1-844-893-3222 x503 K90-KPCS-IM-2 - 23 - 18/04/22...
Page 24: As Built" Service Parts List
“AS BUILT” SERVICE PARTS LIST Service Parts List Label To Be Attached HERE KeepRite Refrigeration Brantford, ON • Longview, TX 1-800-463-9517 info@k-rp.com www.k-rp.com Due to the manufacturer’s policy of continuous product improvement, we reserve the right to make changes without notice. 18/04/22...