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Air-Cooled Condenser
Installation & Operation
Bulletin No. H-IM-90
August 2008
Part Number 25007301
Replaces.H-IM-90,.March.2006
Table of Contents
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
System.Warranty .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Unit.Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Sound.Vibration .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .2
Rigging.Instructions .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .3
Space.and.Location.Requirements .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .4
Typical.Arrangements .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .5
Installation,.Refrigerant.Piping .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .5
Line.Sizing .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .6
Discharge.Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Electrical.Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Typical.Wiring.Diagram .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .7
Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Discharge.Gas.Pulsation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Winter.Operation.Head.Pressure.Control. . . . . . . . . . . . . . . . . .8
Fan.Cycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Fan.Cycling.Head.Pressure.Controls .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .9
Flooding.Head.Pressure.Controls. . . . . . . . . . . . . . . . . . . . . . . . .9
Refrigerant.Charge .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .9
Minimum.Ambient.for.Fan.Cycling .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 10
Mechanical.Fan.Cycling.Thermostat.Settings. . . . . . . . . . . . 10
Air-Cooled
Electronic.Fan.Cycling.Thermostat.Settings . . . . . . . . . . . . . 11
Pressure.Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Flooded.Charge.Temperature.Difference.Factor. . . . . . . . . 13
Condensers
Additional.Refrigerant.Charges .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 13
Model.Cross.Reference .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 13
Maintenance .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 13
Cleaning.Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
In-Warranty.Return.Material.Procedure . . . . . . . . . . . . . . . . . 14
InterLink.Parts.List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
E.Series.Motors.with.Integrated.Variable.Speed . . . . . . . . . 15
Speed.Adjustment.Characteristics. . . . . . . . . . . . . . . . . . . . . . 15
External.Control.Signal .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 15
Installation and
Proportional.Pressure.Control. . . . . . . . . . . . . . . . . . . . . . . . . . 15
Head.Pressure.Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Minimum.Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Throttling.Range .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 16
Operation Guide
Integration.Constant .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 16
Reverse.Acting.or.Direct.Acting.Mode . . . . . . . . . . . . . . . . . . 16
Master/Slave.Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Protective.Features .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 17
Applicable.for.Bohn,.Larkin,
Phase.Failure .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 17
.Climate.Control,.and.Chandler.brands
EC.Motor.Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Typical.1.x.4.EC.Motor.Wiring.Diagram .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 18
Typical.EC.Condenser.Wiring.with.Ext ..Signal. . . . . . . . . . . . 19
Typical.EC.Condenser.Wiring.with.Proportional . . . . . . . . . 19
Pressure.Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation.Check.List .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 20
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Table of Contents
Related Manuals for Heatcraft Refrigeration Products Air-Cooled Condensers none
Summary of Contents for Heatcraft Refrigeration Products Air-Cooled Condensers none
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Page 1: Table Of Contents
Air-Cooled Condenser Installation & Operation Bulletin No. H-IM-90 August 2008 Part Number 25007301 Replaces.H-IM-90,.March.2006 Table of Contents Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 System.Warranty .. -
Page 2: Inspection
Inspection Responsibility.should.be.assigned.to.a.dependable.individual.at. the.job.site.to.receive.material ..Each.shipment.should.be.carefully. checked.against.the.bill.of.lading ..The.shipping.receipt.should. not.be.signed.until.all.items.listed.on.the.bill.of.lading.have.been. accounted.for .. Check.carefully.for.concealed.damage ..Any.shortage.or.damages. should.be.reported.to.the.delivering.carrier .. Damaged.material.becomes.the.delivering.carrier's.responsibility,. and.should.not.be.returned.to.the.manufacturer.unless.prior. approval.is.given.to.do.so ..When.uncrating,.care.should.be.taken. to.prevent.damage ..Heavy.equipment.should.be.left.on.units. shipping.base.until.it.has.been.moved.to.the.final.location .. System Warranty This.equipment.is.designed.to.operate.properly.and.produce. rated.capacity.when.installed.in.accordance.with.accepted. industry.standards ..Failure.to.meet.the.following.conditions.may. result.in.voiding.of.the.system.warranty: 1 .. System.piping.must.be.installed.following.industry.. standards.for.good.piping.practices .. 2 .. Inert.gas.must.be.charged.into.piping.during..welding .. 3 .. System.must.be.thoroughly.leak.checked.and.. . evacuated.before.initial.charging ..High.vacuum. -
Page 3: Rigging.instructions
Drawing 1. Rigging Instructions... -
Page 4: Space.and.location.requirements
Space and Location Requirements The.most.important.consideration.which.must.be.taken. into.account.when.deciding.upon.the.location.of.air-cooled. equipment.is.the.provision.for.a.supply.of.ambient.air.to.the. condenser,.and.removal.of.heated.air.from.the.condenser.area .. Where.this.essential.requirement.is.not.adhered.to,.it.will.result.in. higher.head.pressures,.which.cause.poor.operation.and.possible. eventual.failure.of.equipment ..Units.must.not.be.located.in.the. vicinity.of.steam,.hot.air.or.fume.exhausts . Walls or Obstructions The.unit.should.be.located.so.that.air.may.circulate.freely.and.not. be.recirculated ..For.proper.air.flow.and.access.all.sides.of.the.unit. should.be.a.minimum.of.“W”.away.from.any.wall.or.obstruction .. It.is.preferred.that.this.distance.be.increased.whenever. possible ..Care.should.be.taken.to.see.that.ample.room.is.left.for. maintenance.work.through.access.doors.and.panels ..Overhead. obstructions.are.not.permitted ...When.the.unit.is.in.an.area.where. it.is.enclosed.by.three.walls.the.unit.must.be.installed.as.indicated. for.units.in.a.pit . Multiple Units For.units.placed.side.by.side,.the.minimum.distance.between. units.is.the.width.of.the.largest.unit ..If.units.are.placed.end.to. end,.the.minimum.distance.between.units.is.4.feet . Units in Pits The.top.of.the.unit.should.be.level.with.the.top.of.the.pit,.and. -
Page 5: Typical.arrangements
Typical Arrangements Figure.1.illustrates.a.typical.piping.arrangement.involving.a. remote.condenser.located.at.a.higher.elevation,.as.commonly. encountered.when.the.condenser.is.on.a.roof.and.the.compressor. and.receiver.are.on.grade.level.or.in.a.basement.equipment. room .. In.this.case,.the.design.of.the.discharge.line.is.very.critical ...If. properly.sized.for.full.load.condition,.the.gas.velocity.might.be. too.low.at.reduced.loads.to.carry.oil.up.through.the.discharge. line.and.condenser.coil ..Reducing.the.discharge.line.size.would. increase.the.gas.velocity.sufficiently.at.reduced.load.conditions;. however,.when.operating.at.full.load,.the.line.would.be.greatly. undersized,.and.thereby.create.an.excessive.refrigerant.pressure. drop ..This.condition.can.be.overcome.in.one.of.two.following. ways:. . 1 ..The.discharge.line.may.be.properly.sized.for.the.desired..pressure.drop.at.full.load.conditions.and.an.oil.separator. . . installed.at.the.bottom.of.the.trap.in.the.discharge.line. . . from.the.compressor .. . 2 ..A.double.riser.discharge.line.may.be.used.as.shown.in. . . Figure.2 ..Line.“A”.should.be.sized.to.carry.the.oil.at.minimum.. . -
Page 6: Line.sizing
Discharge Lines The.proper.design.of.discharge.lines.involves.two.objectives:. 1 .. To.minimize.refrigerant.pressure.drop,.since.high.. . pressure.losses.cause.increased.compressor.. horsepower.per.ton.of.refrigerant . Table 1. Tons of Refrigeration Line Size Type L Copper R-22 Sat. Suction Temp (°F) 0 .75 0 .8 1 .4 1 .5 3 .7 4 .0 1-1/8. 7 .5 8 .0 1-3/8 13 .1... -
Page 7: Typical.wiring.diagram
Diagram 1. Typical Condenser Wiring Diagram with Fan Cycle Controls... -
Page 8: Start-Up
Start-Up Check.for.proper.fan.rotation ...Air.is.drawn.through.the.coil.on.all. units ...Be.sure.the.fans.turn.freely .. Rotation.of.the.motors.and.blades.should.be.in.a.“CW”.direction. looking.at.the.unit.from.the.blade.side ...On.three.phase.units,.it. may.be.necessary.to.reverse.two.of.the.three.power.leads.to.the. unit . NOTE: The manifold assembly is not designed to support field piping. Any damages to the condenser due to excessive weight, pressure or vibration will not be covered by our standard warranty. Discharge Gas Pulsation Gas.pulsations.in.a.refrigeration.system.are.most.commonly. -
Page 9: Fan.cycling.head.pressure.controls
Fan Cycling Head Pressure Controls Condenser.fans.are.cycled.to.maintain.adequate.head.pressure .. Ambient.and.pressure.fan.cycling.are.available.as.optional. equipment .. Ambient.fan.cycling.cycles.fans.in.response.to.the.ambient.air. temperature ..This.control.is.ideal.for.multi-circuited.condensers. or.for.systems.operating.in.mild.ambient.conditions ..See.table. 3.for.minimum.ambient.temperatures.for.fan.cycling ..Set.points. for.thermostats.will.vary.depending.on.the.number.of.fans.and. condenser.design.T .D ..See.table.4.for.recommended.set.points .. Pressure.fan.cycling.cycles.fans.in.response.to.condenser. pressure ..This.style.of.control.is.more.appropriate.where.the.load. on.the.condenser.will.vary.due.to.multiple.compressor.operation. or.stages.of.unloading.or.systems.incorporating.heat.reclaim.or. hot.gas.defrost . Variable Speed Condenser.head.pressure.control.is.provided.by.varying.the. air.flow.through.the.condenser.by.changing.the.RPM.of.the. condenser.fan ...This.control.package.is.offered.in.combination. with.ambient.fan.cycling ..The.fan.motor.next.to.the.header.end.of. the.condenser.is.the.variable.speed.fan .. The.remainder.of.the.fans.are.constant.speed.and.are.cycled. separately.using.ambient.sensing.thermostats ..On.condensers. -
Page 10: Minimum.ambient.for.fan.cycling
Table 3. Minimum Ambient for Fan Cycling Number of Fans Single Double 6./.7. 12./.14. *.Based.on.maintaining.90°F.minimum.condensing.temperature . Table 4. Mechanical Fan Cycling Thermostat Settings ..Number of Fans Single Double Design Rows T.D. 6./.7. 12./.14. Design T.D.* Thermostat Setting... -
Page 11: Electronic.fan.cycling.thermostat.settings
Table 5. Electronic Fan Cycling Thermostat Settings * Number of Fans A350 Single Double Design Rows T.D. 6./.7. 12./.14..*.Johnson.Controls.Style.S350.operation ..5°.differential.set.on.all.modules ...All.modules.set.in.the.“heating”.mode . Table 6. Pressure Chart Number of Fans Single Double Design Rows T.D. 6./.7. 12./.14. Based.on.20º.T .D .; For.(R404A/R507).set.cutout.35.PSIG.below.cut-in;.for.(R134A).set.cutout.25.PSIG.below.cut-in . -
Page 12: Refrigerant.charge.for.fan.cycling.plus.flooded.condenser
Table 7. Refrigerant Charge for Fan Cycling plus Flooded Condenser (lbs. R-22) 25° TD Summer Model* Charge 40°F 20°F 0°F Table 8. Refrigerant Charge. Lbs. R-22 for Flooded Condenser Refrigerant R-22 Charge for summer Model* Operation, Lbs. 20° TD -20°F 40°F 20°F 0°F... -
Page 13: Flooded.charge.temperature.difference.factor
Table 9. Flooded Charge Temperature Difference Factor Ambient, °F – 0 .59 0 .76 0 .84 0 .88 Table 10. Model Cross Reference Model Reference *NH-S01-A007 *NH-S01-A009 *NH-S02-A011 *NH-S02-A015 *NH-S02-A017 *NH-S03-A022 *NH-S03-A026 *NH-S04-A030 *NH-S04-A034 *NH-S05-A037 *NH-S05-A044 *NH-S06-A053 *NH-S07-A061 *NH-D04-A021 *NH-D04-A029 *NH-D04-A034 *NH-D06-A044 *NH-D06-A051... -
Page 14: In-Warranty.return.material.procedure
In-Warranty Return Material Procedure Material.may.not.be.returned.except.by.permission. of.authorized.factory.service.personnel.of.Heatcraft. Refrigeration.Products.in.Stone.Mountain,.Georgia ..A. “Return.Goods”.tag.will.be.sent.to.be.included.with.the. returned.material ..Enter.the.required.information.on.the. tag.in.order.to.expedite.handling.at.our.factories.and. prompt.issuance.of.credits ...All.parts.shall.be.returned. to.the.factory.designated.on.the.“Return.Goods”.tag,. transportation.charges.prepaid .. The.return.of.a.part.does.not.constitute.an.order.for. replacement ..Therefore,.a.purchase.order.must.be.entered. through.your.nearest.Heatcraft.Refrigeration.Products. representative ...The.order.should.include.part.number,. model.number.and.serial.number.of.the.unit.involved . Following.our.careful.inspection.of.the.returned.part.and.if. it.is.determined.that.the.failure.is.due.to.faulty.material.or. workmanship,.credit.will.be.issued.on.customer's.purchase. order . Parts by InterLink™ When.writing.to.the.factory.for.service.or.replacement. parts,.refer.to.the.model.number.and.serial.number.of.the. unit.as.stamped.on.the.serial.plate.attached.to.the.unit .. If.replacement.parts.are.required,.mention.the.date.of. installation.of.the.unit.and.date.of.failure,.along.with.an. explanation.of.the.malfunctions.and.a.description.of.the. replacement.parts.required . -
Page 15: E.series.motors.with.integrated.variable.speed
E Series Motors with Integrated Variable Speed E.Series.units.use.an.EC.motor/fan.blade.combination.to.provide.variable.speed.condenser.control ...All.components.required. to.run.the.motor.at.variable.speeds.are.built.into.the.motor ..value.being.saved,.the.motor.will.restart.. . Speed Adjustment Characteristics The.EC.motor.varies.it’s.speed.linearly.based.on.a.0-10V.input.signal ...At.10.VDC,.the.motor.runs.at.full.speed ...At.0.VDC,.the. motor.turns.off ...A.chart.of.the.speed.control.curve.is.shown.below . The.input.control.signal.can.be.supplied.from.any.controller.that.outputs.a.0-10.VDC.signal ...For.units.with.a.control.signal. supplied.from.a.rack.control.or.other.external.controller,.the.unit.is.provided.with.a.terminal.board.for.control.signal.wiring ... Units.with.factory.installed.proportional.pressure.controls.require.no.installation.wiring . External Control Signal Contact.control.manufacturer.for.setup.of.external.controller.to.provide.0-10.VDC.control.signal ...Wire.the.control.signal.to. terminal.board.in.unit.control.box ...See.Diagram.#3.for.typical.external.signal.control.wiring . Proportional Pressure Control Units.with.factory.installed.proportional.pressure.controls.use.a.PI.controller.to.vary.the.motor.speed.in.order.to.maintain.a. -
Page 16: Head.pressure.setpoint
Head Pressure Setpoint The.head.pressure.setpoint.potentiometer.is.adjustable. from.90-250.psig . . .A.typical.setpoints.are.from.170-200.psig . . . Note:..Very.low.setpoints.may.cause.the.fan.motors.to.run. full.speed.continually.if.the.condenser.is.not.properly.sized . . . The.fans.will.turn.off.if.the.system.pressure.falls.below.the. desired.setpoint . Minimum Output The.minimum.output.potentiometer.controls.the.minimum. signal.sent.to.the.motor . . .It.is.adjustable.from.0-60% . . .If.this.is. adjusted.to.60%,.the.motors.will.not.start.running.until.6V.is. applied.to.the.motor . . .The.motor.will.start.running.at.60%.of. full.speed . . .To.maximize.sound.reduction.and.energy.savings. and.to.provide.the.most.stable.control,.it.is.recommended. this.setting.be.left.at.0% . Throttling range The.throttling.range.potentiometer.controls.how.far.the. -
Page 17: Master/Slave.configuration
Master/Slave Configuration The.EC.motor.control.signals.are.wired.in.a.Master/ Slave.configuration ...This.configuration.allows.for.the. maximum.sound.and.energy.reduction.as.well.as.the. most.stable.head.pressure.control ...The.control.signal.is. delivered.to.the.master.motor.(located.at.the.header.end. of.the.unit) ...The.master.motor.relays.the.control.signal.to. the.adjacent.slave.motor ...This.relay.is.done.until.the.last. motor.is.reached ...As.each.slave.relays.the.control.signal,. it.adjusts.the.signal.so.the.next.slave.will.run.slightly. slower.than.the.upstream.motor ...The.end.result.of.this.is. that.when.a.motor.receives.a.small.enough.signal,.it.will. turn.off ...This.provides.built-in.fan.cycling . Protective Features The.EC.motors.have.many.built-in.protective.features . The.EC.motors.have.functions.within.the.motor.to. protect.against: •.over-temperature.of.electronics •.over-temperature.of.motor •.incorrect.rotor.position.detection With.any.of.these.failures,.the.motor.stops.electronically. and.the.alarm.relay.is.switched ...With.one.of.these. failures,.the..motor.WILL.NOT.automatically.restart ...To. reset,.the.power.supply.has.to.be.switched.off.for.a. minimum.20.seconds.once.the.motor.is.at.standstill . Locked-rotor protection As.soon.as.the.rotor.is.blocked,.the.motor.gets.switched. -
Page 18: Typical.1.X.4.Ec.motor.wiring.diagram
TYPICAL 1X4 EC MOTOR WIRING Diagram 2. Typical 1 x 4 EC Motor Wiring with 0-10V DC Control Signal WITH 0-10V DC CONTROL SIGNAL CONTROL WIRING 0 - 10V DC CONTROL SIGNAL POWER WIRING 3Ø POWER SUPPLY FAN 1 (HEADER FAN) 3Ø... -
Page 19: Typical.ec.condenser.wiring.with.ext
Diagram 3. Typical EC Condenser Wiring Diagram with External Signal FAN MOTOR IDENTIFICATION FAN SPEED CONTROL CIRCUIT 0 to 10V DC TERMINAL BOARD 2 8 - GND 7 - 0-10V PWM 2 - GND 1 - OUT 8 - GND 7 - 0-10V PWM 2 - GND 1 - OUT... -
Page 20: Installation.check.list
Start Up Date Model # Serial # Electrical Voltage Amperage Installer: Please retain this information with the condenser. Since.product.improvement.is.a.continuing.effort,.we.reserve.the.right.to.make.changes.in. The name behind the brands you trust. CLIMATE CONTROL H-IM-90-0808. Installation Check List Condenser Name & Address Telephone: specifications.without.notice . ™ Commercial Refrigeration Parts...
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