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HomeMy WebLinkAboutBLDG PERMIT #11269Date: RECEIVED AUG 14 2014 ®�®�® Tracking # Permit # 112 6 9 (321)868-1222 City of Cape Canaveral Building Department - 7510 N. Atlantic Ave. - Cape Canaveral, FL 32920 You may download this application: www.ci ofcapecanaveral.org. You may fax to: (321)868-1247. All applications must include the backside of this form. Important: Please complete the checklist on the back of this form and provide other documentation as indicated on the checklist. A copy of contract may be required. Application packages will not be accepted unless complete. APPLICANT WILL BE CALLED WHEN PERMIT IS READY (Contractor/Owner-Builder is required to sign for the building permit, unless indicated otherwise by affidavit. I.D. may be required) Address of Job Site: -� ft p � - e) (V Zoning classification: Flood Zone: Legal description of property: TWN: RNG: SEC: SUBD: BLK: LOT: PB: PG: Property Owner Name: K Phone: t" — —1 C1 1 Address:��� —1y V' S 31 Fee Simple Titleholder's Name (if other than owner): Address: Bonding Company: Address: Mortgage Lender: Address: q Type of Permit Brief description of work: Building Electrical Plumbing�6(4- 42 f- G Mechanical le yZ � � t Other Type of Square Const. occu- FPL lines City Sewer # of # of # of # of + # of Building Feet Type panty currently available Concrete( stories dwel- , bed- Valuation of work water please (indicate under (1A, Classifies available to to serve Asphalt � rooms (Copy Of Contmet Required) closets as roof VB, -tion serve this this Parkingunits Name of Company: State License No.: applicable) Phone (cell/pager.): etc) (B,R1,R3 ProPertJY" property? Spaces etc.) Yes/No Yes/No Commercial $ �® FR $ Townhouse $ Apartment $ ondominiu $ Other $ Architect(Engineer Name: Address: Name of Company: State License No.: Phone (office): phone (cell/pager.): Fax: Primary Contractor Name: Address: Name of Company: State License No.: Electrical Contractor Name: Address: Phone (office): Phone (cell/pager.): Name of Company: Fax: State License No.: Phone (office): Phone (cell/pager.): Fax: Plumbing Contractor Name: Address: Name of Company: State License No.: Phone (office): Phone (cell/pager.): Fax: Mechanical Contractor N e: Address: Name of Company: 3 State License No.: Phone (office): I,� � — (,35 31 LCoPhone (cell/pager.):O ax:3,2I _(0 3Y -2n � Specialty/Other Contractor Name: Address: Name of Company: State License No.: Phone (office): Phone (cell/pager.): Fax: F•'- Building Permit Application Checklist Notes -Completed Permit Application Current code edition: FL Bldg. Code 2010 (as revised) Current survey showing all Eoposed construction and landscaping Check with Bldg. Dept for setbacks Notarized signature — Owner/Builder Affidavit If owner is acting as contractor Sewer Impact Fee receipt May be deferred until C.O. Unless job is remodeling County Impact Fee receipt May be deferred until C.O. Capital Expansion Impact Fee receipt Maybe deferred until C.O. Sidewalk Impact Fee recei t If sidewalk exists on lot Recorded Warran Deed / Proof of Ownershi Copy of Recorded Notice of Commencement over $2,500) Over $7,500 for Mechanical change out Current Cert. Of Liability Ins./Worker's Comp. Policy / Exemption Record will be kept on file after initial submittal Community Appearance Board Approval For all work visible from Public Right-of-way Planning and Zonin Board Site Plan Approval For all new construction of four units or more Concurrency Forms For all new construction not part of approved site plan Primary Contractor's State License Record will be kept on file after initial submittal Subcontractor's Authorizations: State License Record will be kept on file after initial submittal Notify Building Department of contractor changes Plumbing Contractor Plumbing Contractor lectrical Contractor Electrical Contractor Mechanical Contractor Mechanical Contractor Roofing Contractor Roofing Contractor Swimming Pool Contractor Swimming Pool Contractor Gas Contractor Gas Contractor Specialty/Other Contractor Specialty/Other Contractor Construction Drawings: Per F.B.C. 104 Three sets of sealed construction drawings Per F.B.C. 104 Truss layout and reaction summary Cut sheets and shop drawings will be needed at time of insp. Electrical Load Calculations Plans must indicate person responsible for calculations Electrical Riser All new service must be located underground Plumbing Riser Plans must indicate person responsible for design A/C layout Plans must indicate person responsible for design Two sets of Energy Calculations Plans must indicate person responsible for calculations Lot Drainage Surye Four sets of Fire Suppression/Sprinkler/Alarm specifications Requires Fire Dept approval prior to issuance of permit Pool Barrier Requirement Form si ed) Pool permits will not be issued without barrier Application is hereby made to obtain a permit to do the work and installations as indicated. I certify that no work or installation has commenced prior to the issuance of a permit and that all work will be performed to meet the standards of all laws regulating construction in this jurisdiction. The Building Code in effect at the time of this application is the Florida Building Code 2010 Edition. I understand that all permits require inspections as indicated and that it is the responsibility of the permit holder to notify the building department when ready for inspection(s). This permit application is valid for six months from date of submission. By signing, applicant affirms that all above is true and correct and that he/she is an authorized agent of the Contractor/Owner and has the authority to apply for this permit. *ALL OTHER APPLICABLE STATE OR FEDERAL. PERMITS MUST BE OBTAINED PRIOB-10 COMMEYCJZMENT* Applicant's Name:"�Gm S Eheil �r, roll Applicant's Signature: Date: d - )(4- `i Site Address: . t For Notary use only: State of Florida, Cqunty of Brevard I 1 J Sworn and subscribed before me this +� day of 20 /q, by Printed name of Applicant who produced identification: is personal ,.. 0 1 Seal: GA31ci2.D�Ix-romis 13M* HOPE M. PERRY Notary Public - State of Florida My Comm. Expires Aug 26, 2015 Commission # EE 90423 -E ­,nm Rev Ma'. 10.=019 or Ae Q - n Q — M. P,, �� �,!:: � _ Signature - Notary Public At Large This form may be duplicated Nola - Fan Submittal d% M111,~i Arm EE —i=o coAMExsrAu. v€rrraeer N €GUMV W Order # 2089625 - A2 -G15 Fan #1 A2 -G15 ( 348 lbs. ) http://nola.captiveaire.com/Order/Fans/Subniittal.aspx?jid=176... Untempered Supply Unit with 15" Blower in Size #2 Housing Construction Features Supply Motor: Housing constructed of heavy duty G90 galvanized steel • Model 001180S3E56-48PK, 1.000 HP, 3 Phase 208 V, 60Hz, Forward curved centrifugal blower wheel • Vibration 3.3 FLA, ODP (Open Drip Proof) isolation • Adjustable drive assemblies • Adjustable motor mount • Ball bearing motors • Heavy duty, pre -lubricated Supply Motor Pulleys: bearings rated for 200,000 hours of operation • Static resistant belts • Service doors on both sides • Horizontal & Part Tyne gty Browning # Tums Out down discharge • Weatherproof safety disconnect switch • Belt 1 AX56 Large Intake area ensures low pressure drop across unit • High Efficiency Motors • Lifting Points Blower Pulley 1 AK114 x 1 Motor Pulley 1 1VL40 x 5/8 2.0 Blower: Supply Performance: 15" forward curved, centrifugal blower. Pillow Block ball Volume: 3300 cfm RPM: 491 TS: 1928 ft/min bearings. Galvanized finish. 1" x 27-1/8" Shaft. 2000-7500 SP: 0.395 w.g. CFM. 1800 max. RPM. Used In heated and non -heated supply (0.350" Ext. + 0.046" Int.) fans. BHP: 0.619 Intake: Altitude: 95' Entering Dry Bulb Temp: 70°F Sloped Filtered Intake for Size #2 Modular Untempered Supply Unit. 26.813" Wide X 53.625" Long X 31.313" High. Supply Installation Information: Includes 2" MV EZ Kleen Metal Mesh Filters. Motor/Control 4.2 Amps MCA, 15 Amps MOP, 208 V, Filters: Circuit: 14 AWG Wire Min. 3x MV EZ Kleen Metal Mesh Filter. 20"x 25"x 2" Used for Supply Unit 3 phs 208 V 60Hz heater and supply fan Intakes. (3416) Voltage: [2'e P la cer►,,e40--1'— V '"" 76 i,_e C6e,,5 I of 3 7/14/14 3:08 PM Nola - Fan Submittal LD"TING 18 http://nola.captiveaire.com/Order/Fans/Submittal.aspx?jid=176... 37 3/8' 0 0 Ulla 36 3/4' 00 3 3/4' 4D 1/8' AIRFrLW 7 SERVICE DISCMGM SNITCH BLaWERA OTOR ACCESS DOOR 24' SERVICE CLEARANCE REI. 2 of 3 7/14/14 3:08 PM Nola - Fan Submittal http://nola.captiveaire.com/Order/Fans/Submittal.aspx?jid=176... 3300 CFM, 0.335 SP iia 491 RPM and 0.619 BHP at 95 feet and 70 deg F Please note that these curves were adjusted for job specific temperature and altitude. 2.000 1.750 1.500 1.250 SP 1.D00 0.750 0.500 0.250 0.000 2000 2500 3000 3500 4000 4500 5000 5500 6000 CFM A2-615 supply sound data @ 491 RPM: LWA:65.9 Sones:7 DBA: 54.4 Octave 1 Octave 2 Octave 3 Octave 4 Octave 5 Octave 6 Octave 7 Octave 8 72.2 67.9 65.9 64.2 60.1 56 50.8 44.8 3 of 3 7/14/14 3:08 PM r t , Nola - Fan Submittal AA S a 140 i � &A-21== COUAIVIML VENTLATMEWFUW Order # 2089625 - A2 -G15 Fan #1 A2 -G15 ( 348 lbs. ) Untempered Supply Unit with 15" Blower in Size #2 Housing Supply Motor: Model 00118OS3E56-48PK, 1.000 HP, 3 Phase 208 V, 60Hz, 3.3 FLA, ODP (Open Drip Proof) Supply Motor Pulleys: Part Type Qty Browning # Turns Out Belt 1 AX56 Blower Pulley 1 AK114 x 1 Motor Pulley 1 1VL40 x 5/8 2.0 Supply Performance: Volume: 3300 cfm RPM: 491 TS: 1928 ft/min SP: 0.395" w.g. (0.350" Ext. + 0.046" Int.) BHP: 0.619 Altitude: 95' Entering Dry Bulb Temp: 70°F Supply Installation Information: Motor/Control 4.2 Amps MCA, 15 Amps MOP, 208 V, Circuit: 14 AWG Wire Min. Supply Unit 3 phs 208 V 60Hz Voltage: http://nola.captiveaire.com/Order/Fans/Submittal.aspx?jid=176... our 0%is" Construction Features Housing constructed of heavy duty G90 galvanized steel • Forward curved centrifugal blower wheel • Vibration Isolation • Adjustable drive assemblies • Adjustable motor mount • Ball bearing motors • Heavy duty, pre -lubricated bearings rated for 200,000 hours of operation • Static resistant belts • Service doors on both sides • Horizontal & down discharge • Weatherproof safety disconnect switch • Large Intake area ensures low pressure drop across unit • High Efficiency Motors • Lifting Points Blower: 15" forward curved, centrifugal blower. Pillow Block ball bearings. Galvanized finish. 1" x 27-1/8" Shaft. 2000-7500 CFM. 1800 max. RPM. Used in heated and non -heated supply fans. Intake: Sloped Filtered Intake for Size #2 Modular Untempered Supply Unit. 26.813" Wide X 53.625" Long X 31.313" High. Includes 2" MV EZ Kleen Metal Mesh Filters. Filters: 3x MV EZ Kleen Metal Mesh Filter. 20"x 25"x 2" Used for heater and supply fan intakes. (3416) 1 of 3 7/14/14 3:08 PM Nola - Fan Submittal LIFTING 18 http://nola.captiveaire.com/Order/Fans/Subniittal.aspx?jid=176... 37 3/8' �0 0 LUG 36 3/4' 1 OD 3 -31/4—' 40 1/8' AIRFLOW SERVICE DISCONNECT SWITCH BL.OWERAMTM ACCESS DOOR 24' SERVICE CLEARANCE RED. 2 of 3 7/14/14 3:08 PM Nola - Fan Submittal http://nola.captiveaire.com/Order/Fans/Subniittal.aspx?jid=176... 3300 CFM, 0.395 SP @ 491 RPM and 0.619 BMP at 95 feet and 70 deg F Please note that these curves were adjusted for jab specific temperature and altitude. 2.000 1.750 1.500 1.250 SP 1.000 0.750 0.500 0.250 0 0.004 L `-- -< A'=I 2000 2500 3000 3500 4000 4500 5000 $500 6+000 CFM A2 -G15 supply sound data @ 491 RPM: LWA:65.9 Sones:7 DBA: 54.4 Octave 1 Octave 2 Octave 3 Octave 4 Octave 5 Octave 6 Octave 7 Octave 8 72.2 67.9 65.9 64.2 60.1 56 50.8 44.8 3 of 3 7/14/14 3:08 PM Susan Juliano From: Todd Morley Sent: Friday, October 31, 201411:27 AM To: John Cunningham Cc: Susan Juliano Subject: RE: Fresh air intake system replacemen Kelsey's Thanks John. Todd Morley, Director Community & Economic Development Dept. City of Cape Canaveral 110 Polk Ave. P.O. Box 326 Cape Canaveral, FL 32920 (321) 868-1222 x14 (321) 868-1247 (fax) t.morlevAcitvofcanecanaveral.ora www.ciiyofcgpecanaveral.org "If it is to be, it is up to men u From: John Cunningham [mailto:Jcunningham@ccvfd.or41 Sent: Friday, October 31, 2014 10:39 AM To: Todd Morley Cc: Susan Juliano Subject: RE: Fresh air intake system replacement at Kelsey's Todd, This was reviewed and sent back on August 22, 2014, with no comments. This was attach to the walk-in cooler and has already been inspected. From: Todd Morley [mailto:T.Morley ci ofcapecanaveral.oral Sent: Friday, October 31, 2014 9:14 AM To: John Cunningham Cc: Susan Juliano Subject: Fresh air intake system replacement at Kelsey's John, We are ready to issue the permit for the fresh air intake system replacement at Kelsey's at 8699 Astronaut Blvd. It was forwarded to your department on August 20th. Did you have any comments? Todd Todd Morley, Director Community & Economic Development Dept. City of Cape Canaveral 110 Polk Ave. P.O. Box 326 Cape Canaveral, FL 32920 (321) 868-1222 x14 (321) 868-1247 (fax) t.morlev(&cityofcapecanaveral.org www. c ityofcat)ec anaveral. org "If it is to be, it is up to me" Florida has a very broad public records law. As a result, any written communication created or received by the City of Cape Canaveral officials and employees will be made available to the public and/or media upon request, unless otherwise exempt. Under Florida Law, email addresses are public records. If you do not want your email address released in response to a public -records request, do not send electronic email to this entity. Instead, contact our office by phone or in writing Florida has a very broad public records law. As a result, any written communication created or received by the City of Cape Canaveral officials and employees will be made available to the public and/or media upon request, unless otherwise exempt. Under Florida Law, email addresses are public records. If you do not want your email address released in response to a public -records request, do not send electronic email to this entity. Instead, contact our office by phone or in writing Florida has a very broad public records law. As a result, any written communication created or received by the City of Cape Canaveral officials and employees will be made available to the public and/or media upon request, unless otherwise exempt. Under Florida Law, email addresses are public records. If you do not want your email address released in response to a public -records request, do not send electronic email to this entity. Instead, contact our office by phone or in writing Susan Juliano From: Susan Juliano Sent: Wednesday, October 29, 2014 9:05 AM To: John Cunningham Ocunningham@ccvfd.org) Subject: Permit #11269 Morning, Do you have the above permit comments? (Kelsey's — Walk in Cooler & Exhaust Hood) I'm showing Joy sent this to you on 8/20/14. Thanks! --------------------- Sad" Seew" 7510 N. Atlantic Ave./P.O. Box 326 Cape Canaveral, FL 32920 (321) 868-1222 x15 (321) 868-1247 (fax) s.iu liano@citvofcaoecanaveral.ore www.cityofcapecanaveral.org CI OF ANAVERAL Florida has a very broad public records law. As a result, any written communication created or received by the City of Cape Canaveral officials and employees will be made available to the public and/or media upon request, unless otherwise exempt. Under Florida Law, email addresses are public records. If you do not want your email address released in response to a public -records request, do not send electronic email to this entity. Instead, contact our office by phone or in writing. Florida MASTERTEMP PROPOSAL 3475 N. HIGHWAY 1112, & STE#1 `l 1 COCOA, FL. 32926 Rev ®'!�,.;0Aj Phone (321) 639-3166 Fax (321)638-2473 To: Kelsey's RE: A/C Est. — Revised scope of work We hereby submit specifications and estimates for: ➢ FMT scope of work: • Disconnect and remove existing AM from attic. • Install new AM and secondary pan into location. • Tie in Freon lines, low and high voltage electric. • Add one extra return with filter grill. • Finish complete. DATE: October 2, 2014 ❖ New Tempstar M# FXM4X6000A will match and connect to existing Trane 5 ton system. ➢ Florida MasterTemp warrants its labor and material for 1 year with the exception of filters, fuses, and general maintenance. WE PROPOSE hereby to furnish material --complete in accordance with these specifications, for the sum of- Proposal f Proposal may be withdrawn if not accepted Within 30 days. Authorized signature ACCEPTANCE OF PROPOSAL: Signature Date ®FFICF COPY FAN COILS FXM4X • 1-1/2 thru 5 tons • Available for Environmentally Sound R-41 OA systems • TXV metering device factory installed • ECM motor • Copper tube / aluminum fin coil on standard models •Available with industry exclusive tin coated copper main tubing for additional corrosion protection • Sweat connections • Primary and secondary drain fittings with brass inserts • 3 amp automotive type fuse in wire harness • Multiple electrical entry locations • Time delay relay (TDR) programmed in motor • Field installed heater packages from 5 kW - 30 kW available separately • HUD approved for manufactured housing • 208/230-1-60 supply voltage • Units tested and certified by manufacturer to achieve a 2% or less leakage rate at 1.0 inch water column • 1 inch thick insulation with R value of 4.2 • Multiposition installation - upflow or horizontal left standard, horizontal right with minor modification (field convertible to downflow with available accessory kit) • No Heat (Plug) Kit factory installed • Filter (washable) factory supplied Use of the AHRI CertMed TM Mark indicates a menu}acturer's panldpdon In the•gram. For vent don of w0cation for truNdual products, go to www.anddhoM.org. WARRANTY* • 5 year No Hassle replacement limited warranty • 5 year parts limited warranty - With timely registration, an additional 5 year parts limited warranty * Applies to original purchaser/homeowner, some limitations may apply. See Warranty certificate for complete details: Model Number Tions Nom. CFM (L/s) Dimensions H x W x D in. (mm) Filter Size in. (mm) Ship Wt lbs. (kg) FXM4X1800A 11/2 600 (283) 49-5/8 x 17-5/8 x 22-1/16 16-3/8x 21-1/2 122 (55) FXM4X1800AT (1261 x 448 x 560) (416 x 546) FXM4X2400A 2 800 (378) 49-5/8 x 17-5/8 x 22-1/16 16-3/8 x 21-1/2 122 (55) FXM4X2400AT (1261 x 448 x 560) (416 x 546) 21/2 1000 (472) 3 (1357 53-7/16357 /2 19(505 146 (66) FXM4X3000AT x1537 x 560)22-1/16. x 546) FXM4X3600A 3 1200 (566) 49-5/8 x 21-1/8 x 22-1/16 19-7/8 x 21-1/2 157 (71) FXM4X3600AT (1261 x 537 x 560) (505 x 546) FXM4X4200A 3'/z 1400 (661) 49-5/8 x 21-1/8 x 22-1/16 19-7/8 x 21-1/2 t 57 (71) FXM4X4200AT (1261 x 537 x 560) (505 x 546) FXM4X4800A 4 1600 (755) 53-1/16 x 24-11/16 x 22-1/16 23=5/16 x 21-1/2 185 (84) FXM4X4800AT (1357 x 627 x 576) (592 x 546) 11�` !p 2,0 59-3/16 x 24-11/16 x 22-1 /16 23-5/16 x 21-1/2 201 (91) FXM4X6000AT (1503 x 627 x 576) (592 x 546) speouioevone M eftot to change wttnam nova 496 21 5401 03 August 2012 BUILDING PERMIT FEES Address: � 9 7 �S�wl 11269 CONSTRUCTION TYPE SO. FT. COST *MODIFIER VALUE 1&2 FAM. CONDITIONED: .91 $ 1&2 FAM. UNCONDITIONED: OTHER: .91 $ OTHER: .91 $ OTHER: .91 S TOTAL CONSTRUCTION VALUE BASED ON ICC VALUATION CHART S -11 VTOTAL CONSTRUCTION VALUE BASED ON CONTRACTOR ESTIMATE: S 120 y BUILDING PERMIT FEE: $ Ts— GROSS s— GROSS SQUARE FOOTAGE: BUILDING PLAN REVIEW FEE: (U2 THE BUILDING PERMIT FEE) $ 3 5 (J ELECTRICAL: $ PLUMBING: $ MECHANICAL: $ FIRE DEPT. PLAN REVIEW FEE: $ BUILDING PERMIT SURCHARGE: (GREATER OF $4.00 OR 3% OF TOTAL FEE) $ ZJ _1L__ CONCURRENCY MANAGEMENT FEE: TOTAL FEE DUE: CalculatedBy. -2d,Date: Modifier is a regional cost modifier set by the International Code Council �4 - Permit fees by total valuation: Valuation Fee $500.00 or less: $45.00 $501.00 to and including $1,000.00 $60.00 $1,001.00 to and including $2,000.00 $75.00 $2,001.00 to and including $20,000.00 $75.00 for the first $2,000.00 and $5.00 for each additional $1,000 or fraction thereof to and including $20,000.00 $20,001.00 to $100,000.00 $165.00 for the first $20,000.00 and $5.00 for each additional $1,000 or fraction thereof to and including $100,000.00 $100,001.00 to $500,000.00 $565.00 for the first $100,000.00 and $4.00 for each additional $1,000 or fraction thereof to and including $500,000 $500,001.00 and up $2165.00 for the first $500,000.00 and $3.00 for each additional $1,000 or fraction thereof The total valuation for assessment of permit fees for new structures shall be based on the latest valuation data published by the International Code Council (I.C.C.) For construction work not addressed in the latest valuation data published by the I.C.C_, such valuation shall be based upon the actual construction contract price, with satisfactory evidence of same being submitted to the building official, or a construction cost estimate made by the building official, except as otherwise provided in this section. (B) Plan checking fee. In addition to any fee or fees charged in subsection (a) above: When the valuation of the proposed construction exceeds $1,000.00 and plans and/or specifications are required to be submitted, a plan checking fee shall be paid at the time the permit is issued. The plan checking fee shall be equal to one-half the building permit fee. Such plan checking fee shall be in addition to the building permit fee. When the valuation of the proposed construction exceeds $500,001.00, a nonrefundable plan review deposit shall be paid at the time of permit application submittal. Such deposit may not exceed the anticipated plan review fee. When a dispute exists in the review of the plans and specifications for construction, the applicant may request a hearing before the construction board of adjustment. (C) In addition to any fee or fees charged in subsections (A) and (B), a fee set forth below shall be paid at the time the permit is issued. Note: Reroofing, remodeling, alterations, additions and repairs permit fees shall be aid in accordance with subsections A and B only. Plumbing, new, residential, per bathroom $60.00 Plumbing, new, hotel/motel, per unit $60,00 Plumbing, new, commercial, per bathroom $60.00 Sewer tap inspection fee $60.00 Electrical, new, single-family $100.00 Electrical, new, multifamily, per unit $75,00 Electrical, new, hotel/motet, per unit $60.00 Electrical, new, commercial, per unit $60.00 Mechanical, new, residential, per unit $75,00 Mechanical, new, hotel/motel, per unit $50.00 Mechanical, new, commercial, per system $50.00 Well, deep or shallow $50.00 Moving of building $150.00 Demolition of building $100.00 City of Cape Canaveral Inter -Office Transmittal To: John Cunningham, Assistant Fire Chef From: Joy Lombardi, Building Department Re: 8699 Astronaut Blvd. — Walk -In Cooler & Exhaust Hood — Kelsey's We Transmit: ® Herewith THE FOLLOWING: ® Plans ❑ Prints ❑ Other These are transmitted for: ❑ Permit Issue ® Approval ® Review & Comment ❑ In accordance with your request ® Specifications ❑ Copy of Letter ❑ Record ❑ Use ❑ Shop Drawings ❑ Information ❑ Information ❑ Distribution -CR&S Date Description 3 8/20/14 Plans Remarks: Copies to: File By: ,4� oy Lombardi Air Conditioning • Heating • Commercial Refrigeration ,24 /-lour Emorgency ervice Scope of work for Kelsey's — 8699 Astronaut Blvd. Scope of work hood exhaust: • Disconnect and remove existing hood. • Install new hood and secure into place. • Reconnect electrical from disconnect. Scope of work cooler: • Cooler already assembled. • Mount and secure two evaporators inside cooler. • Set condenser on approved stand on roof and secure. • Pipe new Freon lines to and from condenser to evaporators thru penetration on roof — penetration to have roof jack. • Electrician to run all electrical and connect. 3475 N. US 1 Suite 1 - Cocoa, FL 32926 - Ph: 321-639-3166 - Fax: 321-638-2473 State Certified CAC1816171 - s Air Conditioning ® Heating • commercial Refrigeration 04 Hour EMer enc is Scope of work for Kelsey's — 8699 Astronaut Blvd. Scope of work hood exhaust: • Disconnect and remove existing hood. • Install new hood and secure into place • Reconnect electrical from disconnect. Scope of work cooler: • Cooler already assembled. • Mount and secure two evaporators inside cooler. • Set condenser on approved stand on roof and secure. • Pipe new Freon lines to and from condenser to evaporators thru penetration on roof — penetration to have roof jack. • Electrician to run all electrical and connect. 3475 N. US 1 Suite 1 - Cocoa, FL 32926 - Ph: 321-639-3166 - Fax: 321-638-2473 State Certified CAC1816171 NOTE: ALL ELECTRICAL CONNECTIONS PROVIDED BY OTHERS SLEEVE IN BUILDING FOR REFRIGERATION LINES PROVIDES AND SEALED BY OTHERS CONDENSATE WATER REQUIRES PROPER DRAINAGE I� pl 3 H.P. CONDENSING UNIT OUTDOOR REMOTE 22' [263.9695] r-------------- i r -------------- i j EVAPMTOR COIL j 1 EVAPMATOR COIL j I 1 L—��----�—� I I L--mom-----'�--� 'AIR LAIR 26" X 78" INSWING DOOR ® APPROVED WITH CLOSURE 9'-0" HIGH FLOORLESS CONSTRUCTION EXTERIOR FINISH: BLACK FRONT AND SIDES INTERIOR FINISH: WHITE -6'-4" [76.0000]-� 19'-5 7/16" [233.4633]- 26" 233.4633]- 2" X 4" VERTICAL UPRIGHTS 12" OC 3/4" PLYWOOD REINFORCING 7t CLASS DISPLAY DOORS MATH DOOR AND FRAME CONDENSATE HEATERS AND EPDXY COATED MARE SHELVES CUSTOMER SIGNATURE REQUIRED x CUSTOMER APROVES THAT ORDER WILL BE BUILT TO SPECIFICATIONS PROVIDED HERE ADJUSTABLE ALUMINUM ROOF STAND - REV A 1 Unit System Mr WDE CONFORM TO 2010 FRC 1584 7 24" LEG 5/16'X 1-13116" —j ST NUT & BOLT 1"x 1"x0.125" 4'x4"x3116" INSTALLATION INSTRUCTIONS: 1-114` x 1-114" x 0.093' 1. USE 31W x 1-114" STAINLESS OR COATED BOLT. NUT & 1" WASHER AT 4 LOCATIONS THROUGH UNITS BOTTOM PAN AND TOP RAIL OF UNIT STAND. 114" x 314` ST/S' THUMBSCREIR -1-112" x 1-1i2" x 0.090" NOTES: 1 6061 •T&6005 -T5 ALU44INUM ALLOY CONSTRUCTION FOR EXTERIOR EXPOSURE APPLICATIONS 2 ALL WELDED JOINTS AND SEAMS UNLESS OTHERWISE STATED 3. WELD FILLER SIIALL BE ALUMINUM ALLOY 4043 WITH TENSILE STRENGTH OF 15 KSI. 4 AIC UNIT & FRAME WITHSTANDS WIND SPEEDS UP TO 160 MPH PER 2010 FBC AND ASCE 7-10. 5 RESPONSIBILITY OF INSTALLING CONTRACTOR TO PROVIDE ADEQUATE ANCHORAGE AND CORROSION RESISTANT ISOLATION PADS AT THE BOTTOM OF ALL BASE PLATES WHEN BEARING ON CONCRETE AND STEEL STRUCTURES 6 EXPANSION BOLTS AND LAG SCREWS SHALL HAVE A MINIMUM SPACING OF 25" AND A MINIMUM EDGE DISTANCE OF 1" FOR LAGS AND 3" FOR EXPANSION BOLTS 7 VIBRATION ISOLATOR PADS SHALL BE PROVIDED BY THE AIC CONTRACTOR SO AS NOT TO CAUSE VIBRATION TO EXISTING SUB -STRUCTURE 5 CALCULATIONS ARE BASED ON AIC UNIT SURFACE THIS IS DETERMINED BY MULTIPLYING THF UNIT MOTH BY THE UNIT HEIGHT. WITH THE RESULT BEING THE SURFACE SQUARE FOOTAGE MAXIMUM SIZES ALLOWED FOR THE CONDENSER STAND ARE DENOTED IN THE TABLE DEPICTED ON THE NEXT 2. USE 4 'METAL SHOP ANCHOR COMPLIES WITH ASCE 7-10 @ 160 MPH DESIGN WIND PRESSURE AIC STAND ON CONCRETE ROOF, STEEL MAX WIND PRESSURE JOIST STRUCTURE, OR WOOD DECK 82.3 PSF A1C STAND REACTIONS TABLE ALLOWABLE ROOF ELEV @ ALLOWABLE BENDING j MATERIAL 160 MPH WT/UNIT UPLIFT LATERAL COMP MOMENT CONC. DECK( 160' 350 LBS 2540 33116 605& 262 FT -LB STEEL JOIST MOOD DECK 75' 350 LBS 2940 331st 6M 295 FT -LB RISK CATEGORY 111 AND EXPOSURE C ACCORDING TO CHAPTER 16 OF 2010 FBC %,LlrQ iPI / IM 1 Y a.vnwcra7 Vr VA'Al I AND TOP RAIL OF UNIT STAND. RAIL SECTION CLAMP SECTION BASE PLATE - 3. WRAP UNIT AND TOP RAIL WITH 22 GA. HURRICANE COIL STRAP, 0.094` " 0.2" O 1 GALVANIZED AT 2 LOCATIONS AND 4" BOLT STRAP TO TOP RAIL OF - r1.375" Tt�_ STAND USING 114" GALVANIZED OR 0.125" t5" O O STAINLESS STEEL BOLTS, NUTS, & WASHERS. 4" TYPICAL CONNECTIONS TO SLAB ON GRADE TO STD- WEIGHT CONCRETE TO WOOD BEAMITRUSS SLAB FASTENERS CONCRETE DECK 1ONA1 OPTCONCRETE (2) 318' LAG SCREWS WI 3-Itr EMBED INTO (4) 114- HILTI -KW BEALMRUSS (TVP EACH BASE PLATE) BASE PLATE GRADE �SE BOLT II Wt 2- EmsEO OPIATE OR (4)114- DIA RAWL MUSHROOM HEAD PRE -DRILL FOR LAGS BASF PLATE SPIKES W11-114' EMBED L N -`i MLN ANCHOR SPACING HEAM7TRU55 FASTENERS' (4) +J4 -DIA HEX -HEAD TAP -CONS WITH I-142'EMBED SHALL BE 2 5' MIN EDGE DISTANCE SHALT. BE 3 0' CONCRETE BEAM FATENERS (4) REWS W/ 2-112- MIN EMBED INTEAM (TYP EACH BASE PLATE MIN ANCHOR SPACING: 25' MIN EDr,F OfStANCF. + 0' TYPICAL CONNECTION TO STEEL JOIST JOIST STIFFENER REOUIREMENTS CUT AWAY METAL DECK SPAN PLATE TO BEAR DIRECTLY 913 5PAN-- ON JOIST TOP CHORD s F TFNERS OPTIOCrIAt (4) HILTI MODEL 0EDS22P10 x 314' HEX HEAD SELF POWER DRIVEN FASTENERS TAPPING T TYP AT EA BASE PLATE TAPPING TEK SCREWS ADD 1tWE8 MEMBER EN STAND LEG IS --WHEN CENTER 113 SPAN " The Metal Sh®p 2541 W. DIInllcllon Rd. Ph: (352) 522-0006 Dunnellon, FL 34434 Fax: (352) 522-0007 www.mctalshop.org Engineer: Keith R. Brad P.E. `' .---- © � �. �, tisk � � � FL P.E. IF 4322$ e � � Bern BayPark Dr. Seminole.. FL FL 33777 ~ � ; 7 r <¢ (727) 319-3947 1krbradburyLgmall.com r. �9 ; STATE OF y Drawn a T/2 Dale: 07/31/2012 Scale: N.T.S_ Page: 1 of 2 �% OR 10_ P:�N /i.. NAI_ ADJUSTABLE ALUMINUM ROOF STAND - REV A 1 -UNIT SYSTEM LEGS 6' FROM.... INSIDE LEGS 24' APART A 1 IkI11r QVQYCAA 2 -UNIT SYSTEM LEGS • INSIDE LEGS 48' APART G I Ik11Y QVQYCAA 3 -UNIT SYSTEM LEGS INSIDE LEGS 4r APART C 1 Ik11Y QVQYCAA LEGS 12' FROM END INSIDE LEGS 40' APART LEGS 92- FROM END INSIDE LEGS 39' APART The Metal Shop Engineer: Keith R. Bradbury. P.E. FL P.E. # 43228 2541 W. Dunnellon Rd. Ph: (352) 522-0006 B e, FL Park Dr Sern Dunnellon. FL 34434 Fan: (352) 522-0007 Seminole. 33777 (727)319-399 47 w -Am metalshop.org 7krbradbury@gmaii.com LEGS 12' FROM END INSIDE LEGS 39 4' APART NOTE: UNIT/SIZE TABLE MAINTAIN EQUAL LEG SPACING PER UNIT STAND SIZE 3 FT 6 FT 9 FT 12 FT 15 FT 18 FT ROOF TYPE ALL ALL ALL ALL ALL ALL MULTIPLE UNITS 1 2 3 4 5 6 MAX # UMTS 9 SF 9 SF 9 SF 9 SF 9 SF 9 SF MAX SIZE EACH WOOD DECK 9 SF 18 SF 27 SF 136 SF 45 SF i 54 SF The Metal Shop Engineer: Keith R. Bradbury. P.E. FL P.E. # 43228 2541 W. Dunnellon Rd. Ph: (352) 522-0006 B e, FL Park Dr Sern Dunnellon. FL 34434 Fan: (352) 522-0007 Seminole. 33777 (727)319-399 47 w -Am metalshop.org 7krbradbury@gmaii.com LEGS 12' FROM END INSIDE LEGS 39 4' APART NOTE: MAINTAIN EQUAL LEG SPACING PER UNIT SYSTEM CONFIGURATION \,001111111///// •" .� Drawn By: TJF e :N14 340 Date: 07/31/2012 _ -- Scale: N.T.S. O.�'. '--++ Page: 2 of 2 OiVAL 0/11111110 Replaces None. Information formerly included in H -IM -64L 6 H -IM -CU -0808 I Version 000 Condensing Units Table of Contents GeneralSafety Information...............................................................................2 Inspection...............................................................................................................2 WarrantyStatement............................................................................................2 Space and Location Requirements...............................................................3 Remote and Water Cooled Condensing Units Requirements..............4 City &Tower Water Connections.....................................................................4 Condensing Unit Rigging and Mounting....................................................5 HeadPressure Control........................................................................................6 RefrigerantOils......................................................................................................7 PhaseLoss Monitor..............................................................................................8 Recommended Refrigerant Piping Practices.............................................8 Refrigeration Pipe Supports............................................................................8 SuctionLines..........................................................................................................8 LiquidLines............................................................................................................9 HotGas Defrost Systems...................................................................................9 UnitCooler Piping.............................................................................................10 Line Sizing Tables........................................................................................10-13 Evacuation and Leak Detection...................................................................14 Refrigerant Charging Instructions...............................................................14 FieldWiring..........................................................................................................14 CheckOut and Start Up..................................................................................15 OperationalCheck Out....................................................................................16 System Balancing - Compressor Superheat.............................................16 General Sequence of Operation..................................................................17 Electric Defrost Troubleshooting.................................................................17 System Troubleshooting Guide....................................................................18 Preventive Maintenance Guidelines...........................................................19 TypicalWiring Diagrams...........................................................................20-23 Interl-ink' Replacement Parts......................................................................24 General Safety Information 1. Installation and maintenance to be performed only by qualified personnel who are familiar with this type of equipment. 2. Some units are pressurized with dry air or inert gas. All units must be evacuated before charging the system with refrigerant. 3. Make sure that all field wiring conforms to the requirements of the equipment and all applicable national and local codes. 4. Avoid contact with sharp edges and coil surfaces. They are a potential injury hazard. 5. Make sure all power sources are disconnected before any service work is done on units. WARNING: Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly. Failure to follow this warning may result in personal injury or death. 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. 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 its shipping base until it has been moved to the final location. Check the serial tag information with invoice. Report any discrepancies to your Heatcraft Refrigeration Products Sales Representative. Warranty Statement Seller warrants to its direct purchasers that products, including Service Parts, manufactured by SELLER shall be of a merchantable quality, free of defects in material or workmanship, under normal use and service for a period of one (1) year from date of original installation, or eighteen (1 S) months from date of shipment by SELLER, whichever first occurs. Any product covered by this order found to Seller's satisfaction to be defective upon examination at Seller's factory will at SELLER's option, be repaired or replaced and returned to Buyer via lowest common carrier, or SELLER may at its option grant Buyer a credit for the purchase price of the defective article. Upon return of a defective product to SELLER's plant, freight prepaid, by Buyer, correction of such defect by repair or replacement, and return freight via lowest common carrier, shall constitute full performance by SELLER of its obligations hereunder. SELLER shall have no liability for expenses incurred for repairs made by Buyer except by prior, written authorization. Every claim on account of breach of warranty shall be made to SELLER in writing within the warranty period specified above — otherwise such claim shall be deemed waived. Seller shall have no warranty obligation whatsoever if Its products have been subjected to alteration, misuse, negligence, free chemicals in system, corrosive atmosphere, accident, or if operation is contrary to SELLER's or manufacturer's recommendations, or if the serial number has been altered, defaced, or removed. MOTOR COMPRESSORS: Motor compressors furnished by SELLER are subject to the standard warranty terms set forth above, except that motor compressor replacements or exchanges shall be made through the nearest authorized wholesaler of the motor compressor manufacturer (not at SELLER's factory) and no freight shall be allowed for transportation of the motor compressor to and from the wholesaler. The replacement motor compressor shall be identical to the model of the motor compressor being replaced. Additional charges which may be incurred throughout the substitution of other than identical replacements are not covered by this warranty. An optional, non assignable, four (4) year extended compressor warranty may be purchased within the boundaries of the United Sates of America, its territories and possessions, and Canada. With this extended compressor warranty, replacements are administered by an authorized compressor distributor only. Replacements within the first year of the warranty area available through the distributor; the second through fifth years, the purchaser must submit a proof -of - purchase of a compressor and supply it to Heatcraft Refrigeration Products Warranty Claims for reimbursement. Seller makes no express warranties except as noted above. All implied warranties are limited to the duration of the Express Warranty. Liability for incidental and consequential damages is excluded. The forgoing is in lieu of all other warranties, express or implied, notwithstanding the provisions of the uniform commercial code, the Magnuson -Moss Warranty - Federal Trade Commission Improvement Act, or any other statutory or common law, federal or state. SELLER makes no warranty, express or implied, of fitness for any particular purpose, or of any nature whatsoever, with respect to products manufactures or sold by seller hereunder, except as specifically set forth above and on the face hereof. It is expressly understood and agreed that SELLER shall not be liable to buyer, or any customer of buyer, for direct or indirect, special, incidental, consequential or penal damages, or for any expenses incurred by reason of the use or misuse by buyer or third parties of said products. To the extent said products may be considered "consumer products, As defined in Sec. 101 of the Magnuson -Moss Warranty - Federal Trade Commission Improvement Act, SELLER makes no warranty of any kind, express or implied, to "consumers, except as specifically set forth above and on the face hereof. 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. c) The power supply to the unit must meet the following conditions: A. Three phase voltages must be +/-10% of nameplate ratings. Single phase must be within +10% or -5% of nameplate ratings. B. Phase imbalance cannot exceed 2%. d) All control and safety switch circuits must be properly connected according to the wiring diagram. e) The factory installed wiring and piping must not be changed without written factory approval. f) All equipment is installed in accordance with Heatcraft Refrigeration Products specified minimum clearances. O 2008 Heatcraft Refrigeration Products LLC Space and Location Requirements for Air Cooled Condensing Units and Remote Condensers 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 condensing unit or remote condenser area. Where this essential requirement is not adhered to, it will result in higher head pressures, which cause poor operation and potential failure of equipment. Units must not be located in the vicinity of steam, hot air or fume exhausts. Corrosive atmospheres require custom designed condensers. Another consideration which must be taken is that the unit should be mounted away from noise sensitive spaces and must have adequate support to avoid vibration and noise transmission into the building. Units should be mounted over corridors, utility areas, rest rooms and other auxiliary areas where high levels of sound are not an important factor. Sound and structural consultants should be retained for recommendations. Figure 1. Space and Location Requirements for Condensing Units 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. Walls or Obstructions for Horizontal Air Flow Clearance from walls or obstructions AIRFLOW yA I W L —AIRFLOW -- —J r — Units in Pits The top of the unit should be level with the top of the pit, and side distance increased to "2W". If the top of the unit is not level with the top of pit, discharge cones or stacks must be used to raise discharge air to the top of the pit. This is a minimum requirement. Clearance for units in pits STAIN AIR FLOW (SUPPLIED BY OTHERS) MAX. / \ IF 2W !r i L 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. Multiple Units with Horizontal Air Flow Clearance for multiple units placed side by side AIRFLOW ABR FLOW 1F if W W MM W ow - _ J nw.�C C aaF(ow Decorative Fences Fences must have 50% free area, with 1 foot undercut, a "W" minimum clearance, and must not exceed the top of unit. If these requirements are not met, unit must be installed as indicated for "Units in pits". NOT RECOMMENDED Clearance for fence enclosures AIIRL,R FLOW W W N. i� 1 FT.MIN. AIRFLOW -- J - -- I [ L 1 N I � * "W"=Total width of the condensing unit 3 Requirements for Remote and Water Cooled Condensing Units General Installation The indoor compressor units are designed to be used with a remote condenser. The water cooled units are similar, except that they have an integral water cooled condenser. Inlet and outlet water connections are to be made in the field. On units having a compressor water jacket, incoming water shall be routed through the jacket prior to entering the condenser. For cleaning purposes, condenser end plates can be removed to give access to the water tubes. Cleaning is accomplished by a simple spiral tool powered by an ordinary electric drill. During installation, allow space for cleaning the condenser. Commercial equipment of this type is intended for installation by qualified refrigeration mechanics. Typical Arrangements Diagram 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 creating an excessive refrigerant pressure drop. This condition can be overcome in one of two of the following ways: 1. The discharge line maybe 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. (°E 11 PHiE ERREE�1 tllTCH DISCHARGE LIRE SUBCDOL3 J LIQUID PI�?CH RELIEF LINE VALVE TRAP CDIHIRESS�i RECEIVER Diagram 1 City & Tower Water Connections In the refrigeration industry "City" and "Tower" are designations of temperature and flow conditions, not applications. The term "City" refers to operating conditions where incoming water is 75"F, and condensing temperature is 105`F. "Tower" refers to a higher temperature relationship which is normally 85T, incoming water and 105°F condensing temperature. Water circuits in some condenser models provide a center, or Tower, outlet connection to allow divided inlet water flow. This extra water port reduces water velocity, water pressure drop, and condenser wear in applications such as cooling towers where higher inlet temperatures and water flows occur. Water Connections for City For City water (open system) high pressure applications, the Tower connections is plugged. Water Connections for Tower ForTower usage and low pressure applications, both normal water connections will be used as inlets and the tower connection as an outlet. 2. A double riser discharge line maybe used as shown in Diagram 2. Line"A"should be sized to carry the oil at minimum load conditions and the line "B" should be sized so that at the full load conditions both lines would have sufficient flow velocity to carry the oil to the condenser. Water Regulating Valve Using this control on the water cooled condensing units, the head pressure can be maintained by adjusting the flow of water through the condenser section. This type control is most often located on the water entering side of the condenser and is regulated by the refrigerant condensing pressure. Subcooler Diagrams 1 and 2 below show typical subcooler piping. Diagram 1 is the preferred connection with receiver as it provides maximum subcooling. Diagram 2 may be used if the receiver is located far from the condenser. Notes: 1. All oil traps are to be as short in radius as possible. Common practice is to fabricate the trap using three 90 degree ells. 2. Pressure relief valves are recommended at the condenser for protection of the coil. 3. A pressure valve at the high point in the discharge line is recommended to aid in removing non-condensables. 4. The placement of a subcooler should be that it does not interfere with normal airflow of the condenser. Increased static of the unit could cause a decrease in system capacity and fan motor damage. Diagram 2 rigure z. water connections OUT PLUG OUT 3f IN PLUG kow PITCH CONDENSER DISCHARGE LINE B DISCHARGE LINE A HOOKLP RELIEF LIQUID LINE VALVE TRM CO. RECEIVER Diagram 2 rigure z. water connections OUT PLUG OUT 3f IN PLUG kow Condensing Unit Rigging and Mounting 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 above ground level provides some protection from ground water and wind blown matter. Before tightening mounting bolts, recheck level of unit. The unit should in all cases be located with a clear space in all directions that is at a minimum, equal to the height of the unit above the mounting surface. A condensing unit mounted in a corner formed by two walls, may result in discharge air recirculation with resulting loss of capacity. Roof Mounting Due to the weight of the units, a structural analysis by a qualified engineer may be required before mounting. Roof mounted units should be installed level on steel channels or an I-beam frame capable of supporting the weight of the unit. Vibration absorbing pads or springs should be installed between the condensing unit legs or frame and the roof mounting assembly. Access Provide adequate space at the compressor end of the unit for servicing. Provide adequate space on the connection side to permit service of components. Spring Mounted Compressor Compressors are secured rigidly to make sure there is no transit damage. Before operating the unit, it is necessary to follow these steps: a) Remove the upper nuts and washers. b) Discard the shipping spacers. c) Install the neoprene spacers. (Spacers located in the electrical panel or tied to compressor.) d) Replace the upper mounting nuts and washers. e) Allow 1/16 inch space between the mounting nut/washer and rubber spacer. Mounting spring must not be fully compressed when mounting nut is properly installed. See Figures 3 and 5. Rigid Mounted Compressor Some products use rigid mounted compressors. Check the compressor mounting bolts to insure they have not vibrated loose during shipment. See Figure 4. Figure 3. Spring Mount Compressor Mounting Foot Shipping Spacer Figure 4. Solid Mount for Mobile or Deep Sump Application Washer Figure S. Spring Mount pressor ting ting Foot Mounting Nut Mounting Stud (upper) Rubber Spacer Compressor f Mounting Rubber Spaf Spring (Lower)cer Mounting Base Locking Device Mounting Nut (Lower) Mount is shown in properly adjusted position. Head Pressure Control Several types of head pressure control systems are available on condensing units: A. Dual Valve System. (See section on operation and adjustment.) B. Single Valve system. No adjustments are necessary. (See section on operation.) C. Ambient Fan Cycle Control. (See section on operation and adjustment.) A. Dual Valve System The system employs an ORI (open on rise of inlet pressure) valve and an ORD ( open on rise of differential pressure) valve. The high pressure discharge gas is introduced above the liquid in the receiver tank. The receiver discharge is regulated by the ORI valve. The discharge pressure of the ORI valve must be adjusted to regulate the unit for proper operating conditions. Adjust the ORI valve shown on the following diagram to maintain a discharge pressure of 160 to 180 PSIG. Figure 6. Dual Valve Piping Arrangement Compressor B. Single Valve System The standard valve used on high pressure refrigerant systems controls the head pressure at approximately 180 PSIG. There is no adjustment for this valve. On low pressure refrigerant systems the valve controls pressure at approximately 100 PSIG. For energy efficiency, the 100 PSIG valve is sometimes used on high pressure refrigerant systems. At condensing pressures above the valve setting, flow enters Port C and leaves Port R. When the condensing pressure falls below the valve setting, the valve modulates to permit discharge gas to enter Port D. Metering discharge gas into the refrigerant flow leaving the condenser produces a higher pressure at the condenser outlet, reduces the flow, and causes the level of liquid refrigerant to rise in the condenser. This "flooding" of the condenser with liquid refrigerant reduces the available condensing surface, holding the condensing pressure at the valve setting. Figure 7. Single Valve Flooding Valve Piping Arrangement Cc C. Ambient Fan Cycle Control This is an automatic winter control method which will maintain a condensing pressure within reasonable limits by cycling fan motors in response to outside air temperature. The thermostat(s) should be field adjusted to shut off the fan when the condensing temperature is reduced to approximately 90T. Table 1 lists approximate settings for several system T.D.s. These settings are approximate as they do not take into account variations in load. Table 1. Ambient Fan Cycle Thermostat settings Desicin Thermostat Settings Models 30 60 2 -fan units: 25 65 20 70 4 -fan units: 15 75 30 60 40 3 -fan units: 25 65 55 20 70 60 6 -fan units: 15 75 65 30 60 50 30 8 -fan units: 25 65 55 40 20 70 65 50 15 75 70 60 NOTE: Cycle pairs of fans on double wide units. Operation and Adjustment Condensing units with dual valves require sufficient charge to partially flood the condenser during low ambient conditions. Valve adjustment should be made with gauges connected to the discharge port of the compressor. Adjustments should be made during mild or low ambient conditions. Turning the valve stem "clockwise"on the ORI valve will increase the discharge pressure, while turning the valve stem "counterclockwise"will decrease the discharge pressure. If adjustments are made during warm ambient conditions, it may not be possible to adjust the regulator valve as low as desired. Readjustment may be necessary once cooler conditions prevail. CAUTION: Fans closest to the headers should not be cycled on standard temperature or pressure controls. Dramatic temperature and pressure changes at the headers as a result of fan action can result in possible tube failure. Fan motors are designed for continuous duty operation. Fan cycling controls should be adjusted to maintain a minimum of (5) minutes on and (5) minutes off. Short cycling of fans may result in a premature failure of motor and/or fan blade. Compressors operating below +107 SST must have air flowing over the compressor at all times when the compressor is running. CAUTION: Under no circumstance should all condenser motors be allowed to cycle off on one control. At least one motor shall be wired to operate at all times. Under most circumstances, the condenser motor nearest the inlet header should remain on whenever the compressor is operating. Refrigeration Oils* With the changes that have taken place in our industry due to the CFC issue, we have reevaluated our lubricants to ensure compatibility with the new HFC refrigerants and HCFC interim blends offered by several chemical producers. As a secondary criteria, it is also desirable that any new lubricant be compatible with the traditional refrigerants such as HCFC -22 or R502. This "backward compatibility" has been achieved with the introduction of the Polyol ester lubricants. Polyol Ester Lubricants Hygroscopicity Ester lubricants (POE) have the characteristic of quickly absorbing moisture from the ambient surroundings. This is shown graphically in Figure 8 where it can be seen that such lubricants absorb moisture faster and in greater quantity than conventional mineral oils. Since moisture levels greater than 100 ppm will results in system corrosion and ultimate failure, it is imperative that compressors, components, containers and the entire system be kept sealed as much as possible. Lubricants will be packaged in specially designed, sealed containers. After opening, all the lubricant in a container should be used at once since it will readily absorb moisture if left exposed to the ambient. Any unused lubricant should be properly disposed of. Similarly, work on systems and compressors must be carried out with the open time as short as possible. Leaving the system or compressor open during breaks or overnight MUST BE AVOIDEDI Figure 8. Hygroscopicity 0 s0 100 150 200 260 300 Time. Hours Color As received, the POE lubricant will be clear or straw colored. After use, it may acquire a darker color. This does not indicate a problem as the darker color merely reflects the activity of the lubricant's protective additive. Oil Level During Copeland's testing of Polyol ester oil, it was found that this lubricant exhibits a greater tendency to introduce oil into the cylinder during flooded start conditions. If allowed to continue, this condition will cause mechanical failure of the compressor. A crankcase heater is required with condensing units and it must be turned on several hours before start -up - Oil level must not exceed 1/4 sight glass. Table 2. Refrigeration Oils Oil Types Table 2 below summarizes which oils/lubricants are approved for use in Copeland compressors. Mineral Oils The BR and Scroll compressors use Sontex 200, a "white oil". This oil is not suitable for low temperature applications nor is it available through the normal refrigeration wholesalers. For field "top-off"the use of 3GS or equivalent, or Zerol 20OTD is permissible, as long as at least 50% of the total oil charge remains Sontex 200. Suniso 3GS, Texaco WF32 and Calumet R015 (yellow oils) are available through normal refrigeration wholesalers. These oils are compatible if mixed and can be used on both high and low temperature systems. Polyol Ester Lubricants The Mobil EAL ARCTIC 22 CC is the preferred Polyol ester due to unique additives included in this lubricant. ICI Emkarate RL 32S is an acceptable Polyol ester lubricant approved for use when Mobil is not available. These POE's must be used if HFC refrigerants are used in the system. They are also acceptable for use with any of the traditional refrigerants or interim blends and are compatible with mineral oils. They can therefore be mixed with mineral oils when used in systems with CFC or HCFC refrigerants when Copeland compressors are used. These lubricants are compatible with one another and can be mixed. Alkyl Benzenes Zerol 20OTD is an alkyl benzene (AB) lubricant. Copeland recommends this lubricant for use as a mixture with mineral oil (MO) when using the interim blends such as R-401 A, R-401 B and R -402A (MP39, MP66 and HP80). A minimum of 50% AB is required in these mixtures to assure proper oil return. Shell MS 2212 is a 70/30 mixture of AB/MO. If this lubricant is used in a retrofit situation virtually all of the existing MO must be drained prior to refilling with the MS 2212 to assure a minimum 50% AB content. POE's Mobil EAL ARCTIC 22 CC A A P ICI (Virginia KMP) EMKARATE RL 32CF A A P Mineral Oils Suniso 3GS P PM NOTACCEPTABLE Texaco WF32 P PM Calumet RO15 (Witco) P PM Sontex 200 -LT (White Oil) (BR & Scroll Only) Witco LP -200 P A/B Zerol 20OTD AM PM NOT ACCEPTABLE Soltex Tvoe AB -200 PM P = Preferred Lubricant Choice A= Acceptable Alternative M =Mixture of Mineral Oil and Alkyl Benzene (AB) with minimum 50% AB. *(Reprinted by permission from Copeland Corporation) Phase Loss Monitor The combination phase sequence and loss monitor relay protects the system against phase loss (single phasing), phase reversal (improper sequence) and low voltage (brownout). When phase sequence is correct and full line voltage is present on all three phases, the relay is energized as the normal condition indicator light glows. Note: If compressor fails to operate and the normal condition indicator light on the phase monitor does not glow, then the supplied electrical current is not in phase with the monitor. This problem is easily corrected by the following steps: 1. Turn power off at disconnect switch. 2. Swap any two of the three power input wires. 3. Turn power on. Indicator light should glow and compressor should start. 4. Observe motors for correct rotation. Recommended Refrigerant Piping Practices The system as supplied by Heatcraft Refrigeration Products, was thoroughly cleaned and dehydrated at the factory. Foreign matter may enter the system by way of the evaporator to condensing unit piping. Therefore, care must be used during installation of the piping to prevent entrance of foreign matter. Install all refrigeration system components in accordance with applicable local and national codes and in conformance with good practice required for the proper operation of the system. The refrigerant pipe size should be selected from the Line Sizing Tables. The interconnecting pipe size is not necessarily the same size as the stub -out on the condensing unit or the evaporator. The following procedures should be followed: a) Do not leave dehydrated compressors or filter -driers on condensing units open to the atmosphere any longer than is absolutely necessary. b) Use only refrigeration grade copper tubing, properly sealed against contamination. c) Suction lines should slope 1/4" per 10 feet towards the compressor. Figure 9. Example of Pipe Support Suction Lines Horizontal suction lines should slope away from the evaporator toward the compressor at the rate of 1/4 inch per 10 feet for good oil return. When multiple evaporators are connected in series using a common suction line, the branch suction lines must enter the top of the common suction line. For dual or multiple evaporator systems, the branch lines to each evaporator should be sized for the evaporator capacity.The main common line should be sized for the total system capacity. Suction lines that are outside of refrigerated space must be insulated. See the Line Insulation section on page 14 for more information. Figure 11. Suction P -Traps OIL � J "INCORRECT" RE Slope 1/4" per 10 ft. %ZkUCE toward compressor "CORRECT" d) Suitable P -type oil traps should be located at the base of each suction riser to enhance oil return to the compressor. e) For desired method of superheat measurement, a pressure tap should be installed in each evaporator suction line in the proximity of the expansion valve bulb. f) When brazing refrigerant lines, an inert gas should be passed through the line at low pressure to prevent scaling and oxidation inside the tubing. Dry nitrogen is preferred. g) Use only a suitable silver solder alloy on suction and liquid lines. h) Limit the soldering paste or flux to the minimum required to prevent contamination of the solder joint internally. Flux only the male portion of the connection, never the female. After brazing, remove excess flux. I) See Table 6 for discharge and liquid drain line sizes for remote condenser connections. j) If isolation valves are installed at the evaporator, full port ball valves should be used. Refrigerant Pipe Support 1. Normally, any straight run of tubing must be supported in at least two locations near each end of the run. Long runs require additional supports. The refrigerant lines should be supported and fastened properly. As a guide, 3/8 to 7/8 should be supported every 5 feet; 1-1/8 and 1-3/8 every 7 feet; and 1-5/8 and 2-1/8 every 9 to 10 feet. 2. When changing directions in a run of tubing, no corner should be left unsupported. Supports should be placed a maximum of 2 feet in each direction from the corner. 3. Piping attached to a vibrating object (such as a compressor or compressor base) must be supported in such a manner that will not restrict the movement of the vibrating object. Rigid mounting will fatigue the copper tubing. 4. Do not use short radius ells. Short radius elbows have points of excessive stress concentration and are subject to breakage at these points. 5. Thoroughly inspect all piping after the equipment is in operation and add supports wherever line vibration is significantly greater than most of the other piping. Extra supports are relatively inexpensive as compared to refrigerant loss. Figure 10. Condensing Unit / Compressor to Wall Support Factory Clamp Clamp Wall Compressor "Incorrect" Suction Line Risers Clamp„1104 Here 10 x Pope FaMery Diameters Clamp "Correct' Prefabricated wrought copper traps are available, or a trap can be made by using two street ells and one regular ell. The suction trap must be the same size as the suction line. For long vertical risers, additional traps may be necessary. Generally, one trap is recommended for each length of pipe (approximately 20 feet) to insure proper oil movement. See Figure 11 for methods of constructing proper suction line P -traps. Figure 12. Double Suction Riser Construction /nlrl/ T Sized for r1m.Y� Sized for q Load Minimum Ij SUCTION LINE Load TO COMPRESSOR SizedSi ed EVAP. I REE J I �fbroad l EVAP. I REE 1J-� I I` f Load l ELI] .\�JfrU-BEND OR METHOD A �`..// 2 ELLS METHOD B NOTE: A suction line trap must be installed at the point where piping changes the direction of refrigerant flow from any horizontal run to an u ward vertical run. Liquid Lines Liquid lines should be sized for a minimum pressure drop to prevent "flashing" Flashing in the liquid lines would create additional pressure drop and poor expansion valve operation. If a system requires long liquid lines from the receiver to the evaporator or if the liquid has to rise vertically upward any distance, the losses should be calculated to determine whether or not a heat exchanger is required. The use of a suction to liquid heat exchanger may be used to subcool the liquid to prevent flashing. This method of subcooling will normally provide no more than 20'F subcooling on high pressure systems. The amount of subcooling will depend on the design and size of the heat exchanger and on the operating suction and discharge pressures. An additional benefit from the use of the suction to liquid type heat exchanger is that it can help raise the superheat in the suction line to prevent liquid return to the compressor via the suction line. Generally, heat exchangers are not recommended on R-22 low temperature systems. However, they have proved necessary on short, well insulated suction line runs to provide superheat at the compressor. Hot Gas Defrost Systems Hot Gas Defrost systems can be described as reverse cycle, re-evap., or alternating evaporator. Please see manual H-IM-HGD for Mohave- systems. Refrigerant Piping Install all refrigerant components in accordance with applicable local and national codes and in accordance with good practice for proper system operation. The thermostatic expansion valve must be the externally equalized type. It can be mounted inside the unit end compartment. Mount the expansion valve bulb on a horizontal run of suction line as close as possible to the suction header. Use the clamps provided with the valve to fasten the bulb securely so there is a tight line -to -line contact between the bulb and the suction line. Suction and hot gas connections are made on the outside of the unit. Suction lines should be sloped towards the compressor at the rate of one (1) inch per ten (10) feet for good oil return. Vertical risers of more than four (4) feet should be trapped at the bottom with a P -trap. If a P -trap is used, the expansion valve bulb should be installed between the unit and the trap. Reverse Cycle System The hot gas unit coolers can be used in reverse cycle hot gas defrost systems using multiple evaporators connected to one condensing unit. Generally, not more than one-third of the system defrosts at one time. During the reverse cycle defrost, the reversing valve, located in the compressor discharge line, diverts hot gas through the suction line to the evaporator. See the piping view in the Reverse Cycle Defrost Piping diagram. The suction line check valve directs the hot gas through the drain pan loop which prevents condensate in the pan from freezing. The hot gas exits the loop at the pan loop outlet header and enters the evaporator through the check valve assembly. As the hot gas defrosts the coil, heat is removed from the hot gas and eventually it condenses into a liquid and exits the coil at the distributor side port. The liquid then flows through the check valve of the thermostatic expansion valve bypass assembly, around the thermostatic expansion valve, and into the system liquid line. The liquid refrigerant then feeds other evaporators on the cooling cycle, evaporates, and returns to the compressor through their suction lines. REVERSE CYCLE DEFROST PIPING EVAP. COIL TXV (SjI + CHECK �y T VALVE CHECK VALVE , PAN LOOP , i� LIQUID ----------- UNE CHECK VALVE �� SUCTON �- LINE Three Pipe System The three pipe system (sometimes called re-evap.) uses three pipes: one for liquid line, one for suction line, and one for hot gas line. In addition, a re - evaporator accumulator is used at the suction outlet of the evaporator. The hot gas is taken from the discharge line between the compressor and the condenser, through a hot gas solenoid valve, then to the evaporator drain pan circuit, distributor tee, through the coil. See the Three -Pipe Defrost Piping Diagram for typical piping at the evaporator coil. Alternating Evaporator System In the alternating evaporator hot gas defrost system, a third line is taken off the compressor discharge line as the re-evap system. It is piped with solenoids at each evaporator, so that hot gas defrost is accomplished on one or more evaporators while the remaining evaporators continue to function in a normal manner. The liquid from defrosting evaporators is reintroduced to the main liquid line and it is necessary that 75% or greater capacity be retained in the normal refrigeration cycle to offset the capacity that is being removed by the units on the hot gas defrost. IMPORTANT - It is imperative that with the alternating evaporator hot gas defrost system, no more that 25% of the operating refrigeration load be in defrost at any time. Hot gas line sizes for R-22, R404A and R507 SystemCapacity Equivalent Discharge Length (Ft.) 00 150 4,000 1/2 1/2 1/2 1/2 1/2 5,000 1/2 1/2 1/2 1/2 1/2 6,000 1/2 1/2 1/2 5/8 5/8 7,000 1/2 1/2 5/8 5/8 5/8 8,000 1/2 5/8 5/8 5/8 5/8 9,000 1/2 5/8 5/8 5/8 5/8 10,000 1/2 5/8 5/8 5/8 5/8 12,000 5/8 5/8 5/8 7/8 7/8 14,000 5/8 5/8 7/8 7/8 7/8 16,000 5/8 5/8 7/8 7/8 7/8 18,000 5/8 7/8 7/8 7/8 7/8 20,000 5/8 7/8 7/8 7/8 7/8 25,000 7/8 7/8 7/8 7/8 1-1/8 30,000 7/8 7/8 7/8 1-1/8 1-1/8 35,000 7/8 7/8 1-1/8 1-1/8 1-1/8 40,000 7/8 1-1/8 1-1/8 1-1/8 1-1/8 45,000 7/8 1-1/8 1-1/8 1-1/8 1-1/8 50,000 7/8 1-1/8 1-1/8 1-1/8 1-1/8 60,000 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 70,000 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 80,000 1-1/8 1-1/8 1-3/8 1-3/8 1-5/8 90,000 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 100,000 1 1-1/8 1 1-3/8 1 1-3/8 1 1-5/8 1-5/8 Note: Use next larger hot gas line size for -20°F. and lower suction temperatures. THREE -PIPE DEFROST PIPING EVAP. COIL M 1CHECK VALVE PAN LOOP --------------------- HOT AS UNE i --------LIQUID UNE HEAT-% ______________ SUCTION UNE Unit Cooler Piping Pipe size example: Given: -10°F Freezer with one system having (2) evaporators • One condensing unit rated at 24,000 BTUH's @ -201F SST R404A refrigerant. • Two evaporators each rated at 12,000 BTUH's @ 10°F TD. • 100 feet of actual line run between condensing unit to first evaporator and 20 feet of actual line run between the first evaporator and the second evaporator (see figure below). How to figure line sizes: 1. Determine equivalent line run= actual run + valves and fitting allowances. 2. Use Line Sizing Tables to size lines. 3. Note any special considerations. Line size 1 Line size 2 Evap.2 - Evap.1 Single condensing unit above two evaporators Two evaporators with a vertical rise less than 4 feet Fittings in this Ustem: • (6) 90" elbows in main line plus a 90" turn through a tee. • (5) acidtional 90" elbows to first evaporator. • (4) additional 90" elbows to second evaporator. Determine line size 1 (main line from condensing unit): 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). 2. Refer to 24,000 @100 feet at -20"F SST R404A on the chart. You will find the suction line to be 1-3/8" and 1/2" liquid line. 3. Refer to Table 5. For every 1-3/8" 90" elbow you must add 4 equivalent feet of pipe and 2.5 equivalent feet of pipe for each 1-3/8" tee. Therefore, total equivalent line run = Actual line run 100 feet + (6) 1-3/8" elbows @ 4' 24 feet + (1) 1-3/8" tee @ 2.5' 2.5 fee Total equivalent line run 126.5 feet 4. Refer to Table 8. For 126.5 total equivalent feet, the suction line size should be 1-3/8" and the liquid line stays at 1/2" line. Note: The gray shaded areas on Table 8. For 24,000 BTUH's, the maximum suction riser is 1-1 /8" to insure proper oil return and pressure drop from the bottom p -trap to the top p -trap. Determine line size 2 (evaporators): 1. Line sizing to each evaporator is based on 12,000 BTUH's and equivalent run from condensing unit. First evaporator has an 105 ft. run and the second evaporator has a 120 ft. run. 2. Table 8 indicates 1-1 /8" suction for the first evaporator and indicates 1-1 /8" suction for the second evaporator. 3. Refer to Table 5. Each 1-1/8" 90" elbow adds 3 equivalent feet of pipe. Each 90° turn through a 1-1/8" tee adds 6 equivalent feet. 4. Actual line run (evap 1) 105 feet + (5) 1-1/8" elbows @ 3' 15 feet + (1) 90" turn through tee @ 6' 6 feet Total equivalent line run 126 feet Actual line run (evap 2) 120 feet + (4) 1-1/8" elbows @ 3' 12 feet Total equivalent line run 132 feet 5. Table 8 indicates 1-1/8" suction line and 3/8" liquid line from main line to both evaporators. Line Sizing The following Tables 7 and 8 indicate liquid lines and suction lines for all When determining the refrigerant line length, be sure to add an allowance condensing units for R22, R404A, and R507. for fittings. See Table 5. Total equivalent length of refrigerant lines is the sum of the actual linear footage and the allowance for fittings. Table 3. Weight O.D.Line Size 3/8 of Refrigerants in Copper Lines During Operation (Pounds per 100 lineal feet of type •'L" tubing) Temperature•- � 22 3.9 0.22 0.02 0.03 0.04 0.06 r 0.08 R507, 404A 3.4 0.31 0.03 0.04 0.06 0.09 0.13 1/2 22 7.4 0.41 0.03 0.05 0.07 0.11 0.15 R507, 404A 6.4 0.58 0.04 0.07 0.13 0.16 0.24 5/8 22 11.8 0.65 0.05 0.08 0.12 0.17 0.25 R507, 404A 10.3 0.93 0.07 0.11 0.17 0.25 0.35 7/8 22 24.4 1.35 0.10 0.16 0.24 0.36 0.51 R507, 404A 21.2 1.92 0.15 0.23 0.37 0.51 0.72 1-1/8 22 41.6 2.30 0.17 0.28 0.42 0.61 0.87 R507, 404A 36.1 3.27 0.26 0.39 0.63 0.86 1.24 13/8 22 63.5 3.50 0.27 0.42 0.64 0.93 1.33 R507, 404A 55.0 4.98 0.40 0.58 0.95 1.32 1.87 1-5/8 22 90.0 4.96 0.37 0.59 0.90 1.33 1.88 R507, 404A 78.0 7.07 0.56 0.82 1.35 1.86 2.64 21/8 22 156 8.61 0.65 1.03 1.57 2.30 3.26 R507, 404A 134 12.25 0.98 1.43 2.35 3.23 4.58 2-5/8 22 241 13.70 1.01 1.59 2.42 3.54 5.03 R507, 404A 209 18.92 1.51 2.21 3.62 5.00 7.07 3-1/8 22 344 18.95 1.44 2.28 3.45 5.05 7.18 R507, 404A 298 27.05 2.16 3.15 5.17 7.14 9.95 3-5/8 22 465 25.60 1.94 3.08 4.67 6.83 9.74 R507 404A 403 36.50 2.92 1 4.25 6.97 19.65 13.67 41/8 22 605 33.40 2.53 4.01 6.08 8.90 12.70 8507, 404A 526 47.57 3.80 5.55 9.09 12.58 17.80 Table 4. Pressure Loss of Liquid Refrigerants in Liquid Line Risers (Expressed in Pressure Drop, PSIG, and Subcooling Loss, °F) Based on 110°F liquid temperature at bottom of riser. Table S. Equivalent Feet of Pipe Due to Valve and Fitting Friction Copper Tube,O.D.,Type"U 1/2 5/8 7/8 1-1/8 1-3/8 1-5/8 2-1/8 2-5/8 3-1/8 3-5/8 4-1/8 5-1/8 6-1/8 Globe Valve (Open) 14 16 22 28 36 42 57 69 83 99 118 138 168 Angle Valve (Open) 7 9 12 15 18 21 28 34 42 49 57 70 83 90* Turn Through Tee 3 4 5 6 8 9 12 14 17 20 22 28 34 Tee (Straight Through) or Sweep Below .75 1 1.5 2 2.5 3 3.5 4 5 6 7 9 11 90° Elbow or Reducing Tee (Straight Through) 1 1 1 2 1 2 3 1 4 1 4 1 5 1 7 1 8 1 10 1 12 1 14= 7/8 Table 6. Recommended Remote Condenser Line Sizes Net Evaporator Total Equiv.' Length Discharge 50 R-22 O.D.Capacity Line 3/8 Receiver •• 3/8 • 3/8 R507 & 0. Liquid Line Cond. to •. •. 3/8 3,000 100 3/8 3/8 3/8 3/8 6,000 50 3/8 3/8 1/2 3/8 100 1/2 3/8 1/2 3/8 9,000 50 1/2 3/8 1/2 3/8 100 1/2 3/8 1/2 3/8 50 1/2 3/8 1/2 3/8 12,000 100 5/8 3/8 5/8 1/2 18,000 50 5/8 3/8 5/8 1/2 100 5/8 3/8 7/8 1/2 50 5/8 3/8 5/8 1/2 24,000 100 7/8 1/2 7/8 5/8 50 7/8 1/2 7/8 5/8 36,000 100 7/8 5/8 7/8 7/8 50 7/8 5/8 7/8 5/8 48,000 100 7/8 7/8 1-1/8 7/8 60,000 50 7/8 5/8 7/8 7/8 100 1-1/8 7/8 1-1/8 7/8 50 7/8 7/8 1-1/8 7/8 72,000 100 1-1/8 7/8 1-1/8 1-1/8 50 1-1/8 7/8 1-1/8 7/8 90,000 100 1-1/8 7/8 1-1/8 1-1/8 120,000 50 1-1/8 7/8 1-1/8 1-1/8 100 1-3/8 1-1/8 1-3/8 1-3/8 50 1-3/8 1-1/8 1-3/8 1-3/8 180,000 100 1-5/8 1-3/8 1-5/8 1-5/8 50 1-3/8 1-3/8 1-5/8 1-3/8 240,000 100 1-5/8 1-3/8 2-1/8 1-5/8 50 1-5/8 1-3/8 1-5/8 1-5/8 300,000 100 2-1/8 1-5/8 2-1/8 2-1/8 50 1-5/8 1-5/8 2-1/8 1-5/8 360,000 100 2-1/8 2-1/8 2-1/8 2-1/8 50 2-1/8 1-5/8 2-1/8 2-1/8 480,000 100 2-118 2-1/8 2-1/8 2-5/8 50 2-1/8 2-1/8 2-1/8 2-1/8 600,000 100 2-5/8 2-5/8 2-5/8 2-5/8 50 2-1/8 2-1/8 2-1/8 2-5/8 720,000 100 2-5/8 2-5/8 2-5/8 3-1/8 50 2-1/8 2-1/8 2-5/8 2-5/8 840,000 100 2-5/8 2-5/8 2-5/8 3-1/8 960,000 50 2-5/8 2-5/8 2-5/8 2-5/8 100 2-5/8 3-1/8 3-1/8 3-5/8 50 2-5/8 2-5/8 2-5/8 3-1/8 1,080,000 100 3-1/8 3-1/8 3-1/8 3-5/8 50 2-5/8 2-5/8 2-5/8 3-1/8 1,200,000 100 3-1/8 3-1/8 3-5/8 4-1/8 50 2-5/8 3-1/8 3-1/8 3-5/8 1,440,000 100 3-1/8 3-5/8 3-5/8 4-1/8 50 3-1/8 3-1/8 3-1/8 3-5/8 1,680,000 100 3-5/8 3-5/8 3-5/8 4-1/8 11 Table 7. Recommended Line Sizes for R-22 '* NOTES: 1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size. Properly placed suction traps must also be used for adequate oil return. All sizes shown are for O.D. Type L copper tubing. 2. Suction line sizes selected at pressure drop equivalent to 2°F. Reduce estimate of system capacity accordingly. 3. Recommended liquid line size may increase with reverse cycle hot gas systems. 4. If system load drops below 40% of design, consideration to installing double suction risers should be made. 4, Receiver Equivalent Lengths to - Suction Temperature ExpansionValve 1,000 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 1/2 3/8 3/8 3/8 1/2 3/8 3/8 1/2 1/2 3/8 3/8 3/8 3/8 3,000 3/8 3/8 1/2 1/2 3/8 1/2 1/2 5/8 3/8 1/2 1/2 5/8 1/2 1/2 5/8 5/8 1!2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 3/8 3/8 3/8 3/8 4,000 3/8 3/8 1/2 1/2 3/8 1/2 1/2 5/8 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 1/2 5/8 5/8 7/8 3/8 3/8 3/8 3/8 6,000 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 1/2 5/8 5/8 7/8 5/8 5/8 5/8 7/8 1/2 5/8 7/8 7/8 5/8 5/8 7/8 7/8 3/8 3/8 3/8 3/8 9,000 1/2 5/8 5/8 7/8 1/2 5/8 5/8 7/8 5/8 5/8 7/8 7/8 5/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 5/8 7/8 7/8 1/8 3/8 3/8 3/8 3/8 12,000 5/8 5/8 7/8 7/8 5/8 5/8 7/8 7/8 5/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 3/8 3/8 3/8 3/8 1/8 1/8 1/8 15,000 5/8 5/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 7/8 1 7/8 7/8 7/8 1 7/8 7/8 '- 1- 7/8 7/8 1- 1- 3/8 3/8 3/8 3/8 1/8 1/8 1/8 1/8 1/8 1/8 18,000 5/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 7/8 1 7/8 7/8 1- 1- 7/8 7/8 1- 1- 7/8 1- 1- 1- 3/8 3/8 3/8 1/2 1/8 1/8 1/8 1/8 1/8 1/8 1/8 1/8 24,000 5/8 7/8 7/8 11- 7/8 7/8 7/8 1 7/8 7/8 1- 1- 7/8 1- 1- 1- 7/8 1- 1 1- 7/8 1- 1- 1- 3/8 3/8 1/2 1/2 1/8 1/8 1/8 1/8 1/8 1/8 1/8 1/8 1/8 3/8 1/8 3/8 3/8 30,000 7/8 7/8 1- 1- 7/8 7/8 1- 1- 7/8 1- 1- 1- 7/8 1- 1- 1- 7/8 1- 1- 1- 1- 1- 1- 1- 3/8 3/8 1/2 1/2 1/8 1/8 1/8 1/8 1/8 1/8 1/8 1/8 1/8 3/8 1/8 3/8 3/8 1/8 1/8 3/8 3/8 36,000 7/8 1- 1- 1- 7/8 1- 1- 1- 7/8 1- 1- 1- 1- 1 1- 1 1- 1- 1- 1- 1- 1- 1- 1- 3/8 1/2 1/2 1/2 1/8 1/8 1/8 1/8 1/8 1/8 1/8 1/8 3/8 1/8 1/8 3/8 3/8 1/8 1/8 3/8 3/8 1/8 3/8 3/8 5/8 42,000 7/8 1- 1- 1- 7/8 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 3/8 1/2 1/2 1/2 1/8 1/8 1/8 1/8 1/8,3/8, 1/8 1/8 3/8 3/8 1/8 1/8 3/8 3/8 1/8 1/8 3/8,5/8, 1/8 3/8 5/8,5/8, 48,000 7/8 1- 1- 1 7/8 1- 1- 1- 1 1- 1 1 1 1 1 1 1 1- 1 1 1 1- 1- 1 1- 1 1/2 1/2 1/2 1/2 1/8 1/8 1/8 1/8 1/8 3/8 1/8 1/8 3/8.3/8 1/8 3/8 3/8 5/8 1/8 3/8 3/8 5/8 1/8 3/8 518 5/8 54,000 7/8 1- 1- 2- 1/2 1/2 1/2 5/8 1/8 1/8 3/8 1/8 1/8 3/8 3/8 1/8 3/8 3/8 5/8 1/8 3/8 3/8,5/8 1/8 3/8 5/8 5/8 3/8 3/8 5/8 1/8 60,000 7/8 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 2- 1/2 1/2 5/8 5/8 1/8 1/8 3/8 1/8 1/8 3/8 3/8 1/8 3/8 3/8 5/8 1/8.3/8 5/8 5/8 1/8 3/8 5/8 5/8 3/8 3/8 5/8 1/8 66,000 7/8 1- 1 1 1- 1- 1 1- 1- 1- 1 1- 1 1- 1 1- 1 1 1 1- 1- 1- 1- 2- 1/2 1/2 5/8 5/8 1/8 3/8 3/8,1/8, 1/8 3/8 3/8 1/8 3/8 3/8,5/8 1/8 3/8 5/8 5/8 3/8 3/8 5/8 5/8 3/8 5/8 5/8 1/8 72,000 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 2- 1- 1- 1- 2- 1- 1- 2- 2- 1/2 1/2 5/8 5/8 1/8 1/8 3/8 3/8 1/8 3/8,3/8 5/8 1/8 3/8 5/8 5/8 3/8 3/8.5/8, 1/8 3/8 3/8 5/8 1/8 3/8 5/8 1/8 1/8 78,000 1- 1- 1- 1- 1- 1- 1 1- 1- 1- 1- 1- 1- 1- 1- 2- 1- 1- 1 2 1- 1- 2- 2- 1/2 1/2 5/8 5/8 1/8 1/8,3/8 3/8 1/8 3/8 3/8 5/8 1/813/8 5/8 5/8 3/8 3/8 5/8 1/813/8 5/8 5/8 1/8 3/815/8 1/8 1/8 84,000 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 2- 1- 1- 2- 2- 1- 1- 2- 2- 1/2 5/8 5/8 5/8 1/8 1/8 3/8 3/8 1/8 3/8 3/8 5/8.3/8 3/8 5/8 5/8 3/8 5/8 5/8 1/8 3/8 5/8 1/8 1/8 3/8 5/8 1/8 1/8 90,000 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 1- 2- 1- 1- 2- 2- 1- 1- 2- 2- 1- 1- 2- 2- 1/2 5/8 5/8 7/8 1/8 3/8 3/8 5/8 1/8 3/8,5/8 5/8 3/8 3/8 5/8 1/8 3/8 5/8 1/8 1/8 3/8 5/8,1/8 1/8 3/8 5/8 1/8 1/8 120,000 1- 1- 1- 1- 1- 1- 1- 2- 1- 1- 2- 2- 1- 1- 2- 2- 1- 1- 2- 2- 1- 2- 2- 2- 5/8 5/8 7/8 7/8 1/8 3/8 5/8 5/8 3/8 3/8 5/8 1/8 3/8,5/8 1/8 1/8 5/8 5/8 1/8 1/8,5/8 5/8 1/8 1/8.5/8 1/8 1/8 5/8 150,000 1- 1- 1- 2- 1- 1- 2- 2- 1- 1- 2- 2- 1- 2- 2- 2- 1- 2- 2- 2- 2- 2- 2- 2- 5/8 7/8 7/8 7/8 3/8 3/8 5/8 1/8 3/8 5/8 1/8 1/8.5/8 5/8 1/8 1/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8 1/8 1/8,5/8 5/8 180,000 1- 1- 2- 2 1- 1 1- 2- 2- 1- 2- 2- 2- 1- 2- 2- 2- 1- 2- 2- 2- 2- 2- 2- 2- 5/8 7/8 7/8 7/8 3/8 5/8 1/8 1/8 3/8 5/8 1/8 1/8 5/8 1/8 1/815/8 5/8 1/8 1/8 5/8 5/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 210,000 1- 1- 2- 2- 1- 2- 2- 2- 1- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 3- 7/8 7/8 7/8 7/8 3/8,5/8, 1/8 1/8 5/8 1/8 1/8 1/8 5/8 1/8 1/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8,5/8 5/8.1/8 5/8 5/8 1/8 240,000 1- 1- 2- 2- 1- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 3- 7/8 7/8 7/8 1 1- 5/8 5/8 1/8 1/8 5/8 1/8 1/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8,5/8 1/8 1/8 5/8 5/8 1/8 5/8 5/8 1/8 1/8 300,000 1- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 3- 2- 2- 2- 3- 2- 2- 3- 1 3- 7/8 7/8 '- 1- 5/8 1/8 1/8 5/8,1/81 1/8,5/8 5/8 1/8 1/8 5/8 5/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8 1/8 1/8 1/8 1/8 360,000 2 2- 2- 2- 2- 1 2- 2- 2- 2- 2- 2- 3- 2- 2- 3- 3- 2- 2- 3- 3- 2- 3- 3 3- 7/8 7/8 1- 1- 1/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 1/8 5/8 5/8 1/8 1/8 5/8 1/8 1/8 1/8 5/8 1/8 1/8 5/8 1/8 1/8 5/8 1/8 1/8 480,000 2- 2- 2- 2- 2- 2- 1 2- 3- 1 2- 2- 3- 3- 2- 2- 3- 3- 2- 3- 3- 3- 2- 3- 3- 3- 1- 1- 1 1- 1- 1/8 1/8 5/8 5/8 1/8 5/8 5/8 1/8 1/8 5/8 1/8 1/8 5/8 5/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 1/8 5/8 5/8 1/8 1/8 1/8 3/8 600,000 2 2 2 3- 2- 2- 3- 3- 2- 2- 3- 3- 2- 3- 3- 3- 2- 3- 3- 3- 3- 3- 3- 4- 1/8 5/8 5/8 1/8 1/8 5/8 1/8 1/8 5/8 5/8 1/8 5/8 5/8 1/8 5/8 5/8 5/8 1/8 5/8 5/8 1/8 1/8 5/8 1/811/8 1/8 3/8 3/8 NOTES: 1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size. Properly placed suction traps must also be used for adequate oil return. All sizes shown are for O.D. Type L copper tubing. 2. Suction line sizes selected at pressure drop equivalent to 2°F. Reduce estimate of system capacity accordingly. 3. Recommended liquid line size may increase with reverse cycle hot gas systems. 4. If system load drops below 40% of design, consideration to installing double suction risers should be made. Table 8. Recommended Line Sizes for R -404A and R507* * NOTES: 1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size. Properly placed suction traps must also be used for adequate oil return. All sizes shown are for O.D. Type L copper tubing. 2. Suction line sizes selected at pressure drop equivalent to 2'F. Reduce estimate of system capacity accordingly. 3. Recommended liquid line size may increase with reverse cycle hot gas systems. 4. If system load drops below 40% of design, consideration to installing double suction risers should be made. Receiver to ExpansionValve Equivalent Lengths ► ►► ► ► to ► ► ►► ► ► ►► ► ► ►► ► ► ►► ► ► ►► ► 1,000 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 1/2 1/2 3/8 3/8 1/2 1/2 3/8 3/8 1/2 1/2 3/8 1/2 1/2 5/8 3/8 3/813/8 3/8 3,000 3/8 3/8 1/2 1/2 3/8 1/2 1/2 5/8 1/2 1/2 5/8 5/8 1/2 1/2 5/8 7/8 1/2 1/2 5/8 7/8 1/2 1/2 5/8 7/8 3/8 3/8 3/8 3/8 4,000 3/8 1/2 1/2 11 5/8 t/2 1/2 5/811 S/8 1/2 5/8 5/8 111 7/8. 1/2 5/8,17/8 7/8 5/8 5/8 7/8 7/8 1/2 5/8 7/8 7/8 3/8 3/8 3/8 3/8 6,000 1/2 1/2 5/8 7/811/2 1/2 5/8 7/8 1/2 5/8 7/8 7/8 5/8 5/8 7/8 7/8 5/8 5/8 7/8 7/8 5/8 5/8 7/8 17/813/8 3/8 3/813/81 9,000 5/8 5/8 7/8 7/8 5/8 5/8 7/8 7/8 5/8 7/8 7/8 7/8 5/8 7/8 7/8 5/8 7/8 7/8 5/8 7/8 7/8 3/8 3/8 3/8 3/8 1/8 1/8 1/8 12,000 5/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 7/8 1 7/8 7/8 1- 1- 7/8 7/8 1- 1- 7/8 7/8 1- 1- 3/8 3/8 3/8 3/8 1/8 1/8 1/8 1/8 1/8 1/8 1/8 15,000 5/8 7/8 7/8 7/8 7/8 7/8 7/8 1 7/8 7/8 1- 1- 7/8 7/8 1- 1- 11/811/8 7/8 7/8 1 1 '- 1- 7/8 7/8 1- 1- 3/8 3/8 3/8 1/2 1/8 1/8 1/8 /8 1/8 1/8 1/8 18,000 7/8 7/8 7/8 1- 7/8 7/8 1- 1- 7/8,7/8, 1- 1- 7/8 1- 1- 1- 7/8 1- 1- 1- 7/8 1- 1- 1- 3/8 3/8 1/2 1/2 1/8 1/8 1/8 1/8 1/8 1/8 1/8 3/8 1/8 1/8 3/8 1/8 1/8 3/8 24,000 7/8 7/8 1- 1- 7/8 1- 1- 1- 7/8 1- 1 1 1 1 1 1 1 1 1- 1 1- 1- 1- 1 3/8 3/8 1/2 1/2 1/8 1/8 1/8 1/8 1/8 1/8 1/8 3/8 1/8 1/8 3/8 3/8 1/8 1/8 3/8 3/8 1/8 1/8 3/8 3/8 30,000 7/8 7/8 1- 1- 7/8 1- 1- 1- 1- 1- 1- 1 1- 1 1 1 1 1 1 1 1 1 1 1- 3/8 1/2 1/2 1/2 1/8 1/8 1/8 1/8 3/8 1/8 1/8 3/8 3/8 1/8 1/8 3/8 3/8 1/8 1/8 3/8 3/8 1/8 1/8 3/8 3/8 36,000 7/8 1 1- 1 1- 1- 1 1 1- 1 1 1- 1- 1- 1 1 1 1 1 1- 1- 1- 1 1- 1/2 1/2 1/2 1/2 1/8 1/8 3/8 1/8 1/8 3/8 3/8 1/8 1/8 3/8 3/8 1/8 1/8 3/8 3/8 1/8 3/8 3/8 3/8 1/8 3/8 3/8 5/8 1- 1 1/2 1/2 1/2 5/8 1/8 1/8 3/8 3/8 1/8 1/8 3/8 3/8 1/8 3/8 3/8 5/8 1/8 3/8 5/8 5/8 1/8 3/8 3/8 5/8 1/8 3/8 3/8 5/8 1/8 1/8 3/8 3/8 1/8 1/8 3/8 5/8 1/8 3/8 3/8 5/8 1/8 3/8 5/8 5/8 1/8 3/8 3/8 5/8 1/8 3/8 3/8 5/8 1/2 1/2 5/8 5/8 54,000 1 1- 1 1 1 1 1 1 1- 1- 1 1 1- 1 1 1- 1 1- 1 1 1- 1 1- 1 1/2 1/2 5/8 5/8 1/8 1/8 3/8 3/8 1/8 3/8 3/8 5/8 3/8 3/8 5/8 5/8 3/8 3/8 5/8 5/8 3/8 3/8 5/8 5/8 3/8,3/8 5/8 5/8 60,000 1- 1- 1- 1- 1- 1- i- 1- 1 1 1 1 1- 1-1 1- 1- 1- 1- 1- 1- 1- 1- 1- 1/811/8 3/8 5/8 1/8 3/8 5/8 5/8 3/8 3/8 5/8 5/8 3/8 3/8 5/8 5/8 3/8 3/8 5/8 5/8 3/8 3/8 5/8 5/8 1/2 1/2 5/8 5/8 66,000 1- 1 1 1- 1 1 1 1- 1- 1/2 1/2 5/8 5/8 1/8 3/8 3/8 5/8 1/813/8 5/8 5/8 3/8 5/8 5/8 5/8 3/8 5/8 5/8 5/8 3/8 5/8 5/8 5/8 3/8 5/8.5/8 5/8 72,000 1 1 1- 1- 1 1 1 1 1 1 1 1- 1 1 1 1 1 1 1- 1 1 1- 1 1 1/8 3/8 5/8 5/8 1/8 3/8 5/8 5/8 3/8 5/8 5/8 5/8 3/8 5/8 5/8 5/8 3/8 5/8 5/8 5/8 3/8,5/8 5/8 5/8 1/2 5/8 5/8 5/8 78,000 1 1 1- 1 1 1 1 1 1- 1 1 1- 1 1- 1- 2- 1- 1- 1- 2- 1- 1- 1- 2- 5/8 5/8 5/8 5/8 1/8 3/8 5/8 5/8 3/8 3/8 5/8 5/8 3/8 5/8 5/8 5/8 5/8 5/8 5/8 1/8 5/8 5/8 5/8 1/8 5/8 5/8 5/8 1/8 84,000 1- 1- 1- 1- 1- 1- 1- 2- 1- 1- 1- 2- 1- 1- 2- 2- 1- 1- 2- 2- 1- 1- 2- 2- 5/8 5/8 5/8 7/8 1/8,3/8 5/8 5/8 3/8 3/8 5/8 1/8 3/8 5/8.5/8, 1/8 5/8 5/8 1/8,1/8 5/8 5/8,1/8 1/8 5/8 5/8.1/8 1/8 90,000 1- 1- 1- 2- 1- 1- 1- 2- 1- 1- 2 2- 1- 1- 2- 2- 1- 2- 2- 2- 1- 1- 2- 2- 3/8 3/8 5/8 1/8 3/8 5/8 5/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8 1/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 7/8 7/8 120,000 1- 1- 2- 2- 1- 1- 2- 2- 1- 2- 2- 2- 1- 2- 2- 2- 1- 2- 2- 2- 1- 2- 2- 2- 5/8 5/8 7/8 7/8 3/8 5/8 1/8 1/8 3/8 5/8 1/8 1/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8 150,000 1- 1- 2- 2- 1- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 5/8 7/8 7/8 7/8 - 5/8.5/8 1/8 1/8 5/8 1/8 1/8 1/8 1/8 1/8,5/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/815/8 1/8 1/8 5/8,5/8 180,000 1- 2- 2- 2- 1- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 7/8 7/8 7/8 1- 5/8 1/8 1/8 1/8 5/8 1/8 1/8 5/8.1/8 1/8 5/8,5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 1/8 210,000 1- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 3- 2- 2- 2- 3- 2- 2- 2- 3 2- 2- 2- 3- 7/8 7/8 1- 1- 5/8 1/8 1/8 5/8 1/8 1/8 5/8,5/8 1/8 1/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 1/8 1/8 1/8 240,000 1- 2- 2- 2- 2- 2- 2- 2- 2- 2- 2- 3- 2- 2- 2- 3- 2- 2- 3- 3- 2- 2- 3- 3- 7/8 7/8 1- 1- 5/8 1/8 1/8 5/8,1/8 1/8 5/8 5/8 1/8 5/8 5/8 1/811/8 5/8 5/8 1/8 5/8 5/8 1/8 1/8 5/815/8 1/8 1/8 1/8 1/8 300,000 2- 2- 2- 2 2- 2- 2- 3- 2- 2- 3- 3- 2- 2- 3- 3 2- 2- 1 3- 1 3- 2- 2- 3- 3 1- 1- 1- 1/8 1/8 5/8 5/8 1/8 5/8 5/8 1/8 5/8 5/8 1/8 1/8 5/8 5/8 1/8 5/8 5/8 5/8 1/8 5/8 5/8 5/8 5/8 5/8 7/8 1/8 1/8 3/8 360,000 2- 2- 2- 3- 2- 2- 2- 3- 2- 2- 3- 3- 2- 2- 3- 3- 2- 3 3- 3- 2- 3- 3- 4- 1- 1- 1- 1- 1/8 1/8 5/8 1/8 1/8 5/8 5/8 1/8 5/8 5/8 1/8 5/8 5/8 5/8 5/8 5/8 5/8 1/8 5/8 5/8 5/8 1/8 5/8 1/8 1/8 1/8 3/8 3/8 480,000 2 2 3 3 2 2 2±/;85 3 3- 3 2- 3 3 3 3- 3 4- 4- 3 3- 4- 4- 1 1- 1- 1/8 5/8 1/8 1/8 5/8 5/8 1/8 5/8 5/8 5/8 1/85/8 5/8 1/8 5/8 1/8 1/8 1/85/8 1/8 1/8 /8 1/8 3/8 5/8 600,000 2 2- 3- 3- 2- 2- t 3- 3 4 3 3- 3- 3- 3 3- 4 4 3 3- 111- 4- 4 1 1- 1 1- 5/8 5/8 1/8 5/8 5/8 5/8 1/8 5/8 1/8 1/8 1/8 5/8 5/8 1/8 5/8 1/8 1/8 1/8 5/8 1/8 1/8 1/8 3/8 5/8 5/8 * NOTES: 1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size. Properly placed suction traps must also be used for adequate oil return. All sizes shown are for O.D. Type L copper tubing. 2. Suction line sizes selected at pressure drop equivalent to 2'F. Reduce estimate of system capacity accordingly. 3. Recommended liquid line size may increase with reverse cycle hot gas systems. 4. If system load drops below 40% of design, consideration to installing double suction risers should be made. Evacuation and Leak Detection Due to the smaller molecule size of HFC's, they will tend to leak more readily than CFCs. Consequently, it is of the utmost importance that proper system evacuation and leak detection procedures be employed. Copeland recommends a minimum evacuation to 500 microns. In addition, a vacuum decay test is strongly recommended to assure there is not a large pressure differential between the system and vacuum pump. Good evacuation processes include frequent vacuum pump oil changes and large diameter, short hose connections to both high and low sides of the system preferably using bronze braided hose. Leak detection can be carried out in the conventional manner. If HCFC or CFC tracer gas is used, care must be taken to completely remove all traces of the gas prior to introducing HFC's. Electronic leak detectors are now available that will sense HFC's. This is considered preferable since it removes the possibility of chlorine remaining in the system after leak testing with HCFC's and/or CFCs. There is a view that even small quantities of chlorine may act as a catalyst encouraging copper plating and/or corrosion and should therefore be avoided. HFC -134a has been shown to be combustible at pressure as low as 5.5 psig (at 350°F) when mixed with air at concentrations more than 60% air by volume. At lower temperature, higher pressures are required to support combustion. Therefore, air should never be mixed with HFC -134a for leak detection. Within the last several years, manufacturers have developed fluorescent dye leak detection systems for use with refrigerants. These dyes mix with the lubricant and, when exposed to an ultraviolet lig ht"fluoresce; indicates the location of leaks. Copeland has tested and approved the Rigid "System Safe" dye and found it to be compatible with the compressor materials in systems. Leak Testing After all lines are connected, the entire system must be leak tested. The complete system should be pressurized to not more than 150 psig with refrigerant and dry nitrogen (or dry CO2) The use of an electronic type leak detector is highly recommended because of its greater sensitivity to small leaks. As a further check it is recommended that this pressure be held for a minimum of 12 hours and then rechecked. For a satisfactory installation, the system must be leak tight. Line Insulation After the final leak test, refrigerant lines exposed to high ambient conditions should be insulated to reduce heat pickup and prevent the formation of flash gas in the liquid lines. Suction lines must always be insulated with 3/4" wall Armstrong "Armaflex" or equal. When required, Liquid lines should be insulated with 1/2 inch wall insulation or better. The insulation located in outdoor environments should be protected from LIV exposure to prevent deterioration of insulating value. Evacuation CAUTION: Do not use the refrigeration compressor to evacuate the system. Do not start the compressor while it is in a vacuum. A good, deep vacuum pump should be connected to both the low and high side evacuation valves with copper tube or high vacuum hoses (1 /4" ID minimum). If the compressor has service valves, they should remain closed. A deep vacuum gauge capable of registering pressure in microns should be attached to the system for pressure readings. A shut off valve between the gauge connection and vacuum pump should be provided to allow the system pressure to be checked after evacuation. Do not turn off vacuum pump when connected to an evacuated system before closing shut off valve. The vacuum pump should be operated until a pressure of 1,500 microns absolute pressure is reached — at which time the vacuum should be broken with the refrigerant to be used in the system through a drier until the system pressure rises above "0" psig. NOTE: Refrigerant used during evacuation cannot be vented. Reclaim all used refrigerant. EPA regulations are constantly being updated. Ensure your procedure follows correct regulations. Repeat this operation a second time. Open the compressor service valves and evacuate the entire system to 500 microns absolute pressure. Raise the pressure to 2 psig with the refrigerant and remove the vacuum pump. Refrigerant Charging Instructions 1. Install a liquid line drier in the refrigerant supply line between the service gauge and the liquid service port of the receiver. This extra drier will insure that all refrigerant supplied to the system is clean and dry. 2.. When initially charging a system that is in a vacuum, liquid refrigerant can be added directly into the receiver tank. 3. Check equipment catalog for refrigerant capacity. System refrigerant capacity is 90% of receiver capacity. Do not add more refrigerant than the data tag indicates, unless the line run exceeds 25ft. Then, add additional refrigerant as per the chart on page 30. Weigh the refrigerant drum before charging so an accurate record can be kept of the weight of refrigerant put in the system. 4. Start the system and finish charging until the sight glass indicates a full charge and the proper amount has been weighed in. If the refrigerant must be added to the system through the suction side of the compressor, charge in vapor form only. Liquid charging must be done in the high side only or with liquid metering devices to protect the compressor. Low Head Pressure Systems If you are charging the system by using a clear sight glass as an indication of proper charge the following must be considered. Check the condensing temperature. It must be above 1057. If not, it will be necessary to reduce the amount of air going through the condenser from fans still running. Simply reduce the effective condenser face area to raise the discharge pressure above the equivalent 1057 condensing temperature and then proceed to charge to clear the sightglass. Adjust evaporator superheat at this time. Return to full condenser face area and allow the system to balance. Field Wiring WARNING: All wiring must be done in accordance with applicable codes and local ordinances. The field wiring should enter the areas as provided on the unit. The wiring diagram for each unit is located on the inside of the electrical panel door. All field wiring should be done in a professional manner and in accordance with all governing codes. Before operating unit, double check all wiring connections, including the factory terminals. Factory connections can vibrate loose during shipment. 1. The serial data tag on the unit is marked with the electrical characteristic for wiring the unit. 2. Consult the wiring diagram in the unit cooler and in the condensing unit for proper connections. 3. Wire type should be of copper conductor only and of the proper size to handle the connected load. 4. The unit must be grounded. 5. For multiple evaporator systems, the defrost termination controls should be wired in series. Follow the wiring diagrams for multiple evaporator systems carefully. This will assure complete defrost of all evaporators in the system. 6. Multiple evaporator systems should operate off of one thermostat. 7. If a remote defrost timer is to be used, the timer should be located outside the refrigerated space. 8. For air cooled condensers, due to multiple low amp motors, we recommend using time delay fuse protection instead of circuit breakers. 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 spacers. Install the neoprene washers onto the compressor feet. Replace the upper mounting nuts and washers, allowing 1/16" space between the mounting nut and the neoprene spacer. d) Check high and low pressure controls, pressure regulating valves, oil pressure safety controls, and all other safety controls, and adjust if necessary. e) Check the room thermostat for normal operation and adjust. >7 Wiring diagrams, instruction bulletins, etc. attached to the condensing units should be read and filed for future reference. g) All fan motors should be checked for proper rotation. Fan motor mounts should be carefully checked for tightness and proper alignment. h) Electric and hot gas evaporator fan motors should be temporarily wired for continuous operation until the room temperature has stabilized. I) Observe system pressures during charging and initial operation. Do not add oil while the system is short of refrigerant unless oil level is dangerously low. j) Continue charging until system has sufficient refrigerant for proper operation. Do not overcharge. Remember that bubbles in a sight glass may be caused by a restriction as well as a shortage of refrigerant. k) Do not leave unit unattended until the system has reached normal operating conditions and the oil charge has been properly adjusted to maintain the oil level between 1/4 and bottom of the sight glass. 1) Make sure all Schrader valve caps are in place and tight. m) Make sure ALL service valves are properly back -seated and tighten valve packing if necessary. Extreme care must be taken in starting compressors for the first time after system charging. At this time, all of the oil and most of the refrigerant might be in the compressor creating a condition which could cause compressor damage due to slugging. Activating the crankcase heater for 24 hours prior to start-up is required. If no crankcase heater is present, then directing a 500 watt heat lamp or other safe heat source on the lower shell of the compressor for approximately thirty minutes will be beneficial in eliminating this condition which might never reoccur. WARNING: Scroll compressor is directional dependent. If noisy, change phase of input wiring. ,� Operational Check Out After the system has been charged and has operated for at least two hours at normal operating conditions without any indication of malfunction, it should be allowed to operate overnight on automatic controls. Then a thorough recheck of the entire system operation should be made as follows: a) Check compressor discharge and suction pressures. If not within system design limits, determine why and take corrective action. b) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is required, leak test all connections and system components and repair any leaks before adding refrigerant. c) Observe oil level in compressor crankcase sight glass. Add oil as necessary to bring level to bottom 1/4 of the sight glass. d) Thermostatic expansion valves must be checked for proper superheat settings. Feeler bulbs must be in positive contact with the suction line and should be insulated. Valves set at high superheat will lower refrigeration capacity. Low superheat promotes liquid slugging and compressor bearing washout. e) Using suitable instruments, carefully check line voltage and amperage at the compressor terminals. Voltage must be within 10% of that indicated on the condensing unit nameplate. If high or low voltage is indicated, notify the power company. If amperage draw is excessive, immediately determine the cause and take corrective action. On three phase motor compressors, check to see that a balanced load is drawn by each phase. f) The maximum approved settings for high pressure controls on our air cooled condensing equipment is 425 psig. On air cooled systems, check as follows: Disconnect the fan motors or block the condenser inlet air. Watch high pressure gauge for cutout point. Recheck all safety and operating controls for proper operation and adjust if necessary. g) Check defrost controls for initiation and termination settings, and length of defrost period. Set fail safe at length of defrost + 25%. Example: 20 minute defrost + 5 minutes = 25 minute fail safe h) Check drain pan for proper drainage. I) Check winter head pressure controls for pressure setting. j) Check crankcase heater operation if used. k) Install instruction card and control system diagram for use of building manager or owner. System Balancing - Compressor Superheat IMPORTANT: In order to obtain the maximum capacity from a system, and to ensure trouble-free operation, it is necessary to balance each and every system. This is extremely important with any refrigeration system. The critical value which must be checked is suction superheat. Suction superheat should be checked at the compressor as follows: 1. Measure the suction pressure at the suction service valve of the compressor and determine the saturation temperature corresponding to this pressure from a "Temperature -Pressure" chart. 2. Measure the suction temperature of the suction line about one foot back from the compressor using an accurate thermometer. 3. Subtract the saturated temperature from the actual suction line temperature. The difference is superheat. Too low a suction superheat can result in liquid being returned to the compressor. This will cause dilution of the oil and eventual failure of the bearings and rings or in the extreme case, valve failure. Too high a suction superheat will result in excessive discharge temperatures which cause a break down of the oil and results in piston ring wear, piston and cylinder wall damage. It should also be remembered that the system capacity decreases as the suction superheat increases. For maximum system capacity, suction superheat should be kept as low as is practical. Copeland mandates a minimum superheat of 20°F at the compressor. We recommend that the superheat at the compressor be between 20°F and 30'F. If adjustments to the suction superheat need to be made, the expansion valve at the evaporator should be adjusted. NOTE: All adjustable controls and valves must be field adjusted to meet desired operation. There are no factory preset controls or valve adjustments. This includes low pressure, high pressure, adjustable head pressure systems and expansion valves. Table 9. Recommended Low Pressure Control Settings for Outdoor Air Cooled Condensing Units Minimum 50 R-22 Cut -in PSI 70 Cut-OutTemp.'F 20 90 0, , Cut -Out 35 40 55 20 70 35 30 40 20 55 35 10 30 10 45 25 0 15 0 25 7 -10 15 0 20 1 -20 10 0 12 1 30 6 0 8 1"Hg. * Minimum ambient or box temperature anticipated, high pressure control setting: R-22, 360 PSI; R -404A, R-507,400 PSI *The standard preset low pressure switch used for pumpdown is set for 15 PSI cut in / 4 PSI cut out and is a good setting for most pumpdown systems * ZB Scroll compressors should be set for 25 PSI cut in / 17 PSI cut out (R -404A / R-507) General Sequence of Operation Electric Defrost Troubleshooting Refrigeration Cycle The electric defrost units are relatively simple and trouble-free in operation: 1. Power is supplied to the timer at terminals "1"and"N" Timer 2. The fan delay and the defrost termination thermostat is closed in the fan If the system does not go through its proper sequence, check timer delay position and open in the defrost termination position. operation through a defrost cycle. Check for loose wires or terminals. Before The unit cooler fans run continuously. replacing timer, check other components. 3. The defrost heaters are off. 4. The room thermostat closes when the temperature rises above the desired setting. 5. The liquid line solenoid is energized and opens, which allows liquid refrigerant to flow through the unit cooler. 6. The low pressure control closes when the suction pressure rises above the cutin setting of the control. 7. On systems with oil pumps, the oil safety control is closed. If the net oil pressure is less than 9 PSIG for more than 120 seconds, the oil safety opens, thus breaking the circuit to the compressor contactor holding coil.The compressor will not operate. This control is reset manually and must be reset before the compressor can be restarted. 8. The compressor contactor closes. The compressor and condenser fan start simultaneously. 9. The room temperature gradually decreases to the desired temperature. 10. Once the desired temperature is reached, the thermostat opens and the liquid line solenoid closes, stopping refrigerant flow through the evaporator. 11. Suction pressure decreases and the compressor contactor opens when the pressure drops below the cutout setting on the low pressure control. The compressor and condenser fan stop running. 12. This cycle is repeated as many times as necessary to satisfy the room thermostat. 13. Frost starts to form on the evaporator coil and continues to form until the defrost cycle is initiated. Defrost Cycle 1. The defrost cycle starts automatically by the timer at predetermined times. Typical settings are two to four defrost cycles per day for freezers. For heavier frost loads additional settings may be required. 2. Switch "2"to "4"opens in the timer which breaks the circuit to the room thermostat, liquid line solenoid, and evaporator fan motors, allowing the compressor to pump down and shut off. Simultaneously switch "1"to "3" closes in the timer allowing current to flow to one side of the defrost heater contactor. When the compressor shuts off, an auxiliary contact will send power to the contactor holding coil; thus, energizing the defrost heaters. 3. The heaters raise the temperature of the coil to 32'F causing the frost to melt off the coil. 4. When the coil warms to 45`F to 55°F, the defrost termination thermostat closes, which allows current to the switching solenoid in the timer allowing the refrigeration cycle to begin again. 5. The evaporator heaters are off. If the termination thermostat fails to close, the fail-safe set on the timer will terminate defrost. 6. The low pressure control closes and the compressor will start. 7. When the coil temperature reaches 237 to 30°F, the fan delay closes. This allows the current to flow to the fan motors. The fan motors start running. 8. The system will now operate in the refrigeration cycle until another defrost period is initiated by the timer. Operation of Paragon rimer To set time of day grasp knob which is in the center of the inner (fail-safe) dial and rotate it in a counter -clockwise direction. This will cause the outer (24 hour) dial to revolve. Line up the correct time of day on the outer dial with the time pointer. Do not try to set the time control by grasping the other (24 hour) dial. Place pins in the outer dial at the time of day that defrost is required. Operation of Grasslin Timer To set the time, turn the minute hand clockwise until the time of day (and AM or PM) on the outer dial is aligned with the triangle marker on the inner dial. Do not rotate minute hand counter -clockwise. Move the white tab (tripper) on the outer dial outward at each desired initiation time. Each white tab (tripper) is a 15 minute interval and provides 15 minutes of defrost. For longer defrost duration, move additional tabs (following in time) from the initiation tab. For example, if a 45 minute defrost is to start at 7:00 AM, move the tabs outward that lie between 7:00 - 7:15,7:15 - 7:30 and 7:30 - 7:45 on the AM side of the dial. The defrost will initiate at 7:00 AM and time terminate at 7:45 AM (if temperature termination does not occur first). For models with plastic cover on timer assembly; re -install cover after adjustment. NOTE: After correcting faulty condition it is essential that the coil and unit be free of ice before placing unit back on automatic operation. NOTES: 1. Lockout relays or normally closed switch of auxiliary contact on the compressor contactor may be wired to defrost contactor. Its purpose is to prevent energizing of the defrost heaters until the compressor has pumped down and stopped, thus keeping power demand to a minimum. 2. If the control voltage is to remain energized for any period of time with the compressor disabled, remove the defrost clock pins to prevent the defrost heaters from energizing. 3. A Preventative Maintenance schedule should be set up as soon as possible after start-up to maintain equipment integrity. TMJs 7 n Cvc*nr TrnnhlAchnn+inn Chart PROBLEM POSSIBLE CAUSESPOSSIBLECORRECT Compressor will not 1. Main switch open. 2. Fuse blown. 1. Close switch. 2. Check electrical circuits and motor winding for shorts or grounds. run 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. Defective contactor or coil. 5. System shut down by safety devices. 4. Repair or replace. 5. Determine type and cause of shutdown and correct it before resetting safety switch. 6. No cooling required. 6. None. Wait until calls for cooling. 7. Liquid line solenoid will not open. 7. Repair or replace coil. 8. Check motor for open windings, short circuit or burn out. 8. Motor electrical trouble. 9. Loose wiring. 9. Check all wire junctions. Tighten all terminal screws. 10. Phase loss monitor inoperative. 10. Refer to page 17. Compressor noisy or 1. Flooding of refrigerant into crankcase. 1. Check setting of expansion valves. vibrating 2. Improper piping support on suction or liquid line. 2. Relocate, add or remove hangers. 3. Worn compressor. 3. Replace. 4. Scroll compressor rotation reversed. 4. Rewire for phase change. High discharge 1. Non-condensables in system. 1. Remove the non-condensables. pressure 2. System overcharges with refrigerant. 2. Remove excess. 3. Discharge shutoff valve partially closed. 3. Open valve. 4. Fan not running. 4. Check electrical circuit. 5. Head pressure control setting. 5. Adjust. 6. Dirty condenser coil. 6. Clean. Low discharge 1. Faulty condenser temperature regulation. 1. Check condenser control operation. pressure 2. Suction shutoffvalve partially closed. 2. Open valve. 3. Insufficient refrigerant in system. 3. Check for leaks. Repair and add charge. 4. Low suction pressure. 4. See corrective steps for low suction pressure. 5. Variable head pressure valve. 5. Check valve setting. High suction 1. Excessive load. 1. Reduce load or add additional equipment. pressure 2. Expansion valve overfeeding. 2. Check remote bulb. Regulate superheat. Low suction pressure 1. Lack of refrigerant. 1. Check for leaks. Repair and add charge. 2. Evaporator dirty or iced. 2. Clean. 3. Clogged liquid line filter drier. 3. Replace cartridge(s). 4. Clogged suction line or compressor suction gas strainers. 4. Clean strainers. 5. Expansion valve malfunctioning. 5. Check and reset for proper superheat. 6. Condensing temperature too low. 6. Check means for regulating condensing temperature. 7. ImproperTXV. 7. Check for proper sizing. Little or no oil pressure 1. Clogged suction oil strainer. 2. Excessive liquid in crankcase. 1. Clean. 2. Check crankcase heater. Reset expansion valve for higher superheat. Check liquid line solenoid valve operation. 3. Low oil pressure safety switch defective. 3. Replace. 4. Worn oil pump. 4. Replace. 5. Oil pump reversing gear stuck in wrong position. 5. Reverse direction of compressor rotation. 6. Worn bearings. 6. Replace compressor. 7. Low oil level. 7. Add oil and/or through defrost. 8. Loose fitting on oil lines. 8. Check and tighten system. 9. Pump housing gasket leaks. 9. Replace gasket. Compressor loses oil 1. Lack of refrigerant. 1. Check for leaks and repair. Add refrigerant. 2. Excessive compression ring blow by. 2. Replace compressor. 3. Refrigerant flood back. 3. Maintain proper superheat at compressor. 4. Improper piping or traps. 4. Correct piping. Compressor thermal 1. Operating beyond design conditions. 1. Add components to bring conditions within acceptable limits (i.e., protector switch CPR/EPR valves, additional condenser surface, liquid injection, etc.). open 2. Discharge valve partially shut. 2. Open valve. 3. Blown valve plate gasket. 3. Replace gasket. 4. Dirty condenser coil. 4. Clean coil. 5. Overcharged system. 5. Reduce charge. Preventive Maintenance Unit Coolers At every six month interval, or sooner if local conditions cause clogging or fouling of air passages through the finned surface, the following items should be checked. 1) Visually inspect unit • Look for signs of corrosion on fins, cabinet, copper tubing and solderjoints. • Look for excessive or unusual vibration for fan blades or sheet metal panels when in operation. Identify fan cell(s) causing vibration and check motor and blade carefully. • Look for oil stains on headers, return bends, and coil fins. Check any suspect areas with an electronic leak detector. • Check moisture indicator/sightglass for flash gas. If found check entire system for refrigerant leaks and add refrigerant as needed after repairing any leaks. • Check compressor sightglass (if equipped) for proper oil level. • Check condition of condenser. Look for accumulation of dirt and debris (clean as required). • Check for unusual noise or vibration. Take corrective action as required. • Inspect wiring for signs of wear or discoloration and repair if needed. • Check and tighten all flare connections. Semi -Annually 2) Repeat all quarterly inspection items. • Check drain pan to insure that drain is clear of debris, obstructions or ice buildup and is free draining. 3) Clean condenser coil and blades 2) Clean evaporator coil and blades • Periodic cleaning can be accomplished by using a brush, pressurized water or a commercially available evaporator coil cleaner or mild detergent. Never use an acid based cleaner. Follow label directions for appropriate use. Be sure the product you use is approved for use in your particular application. • Flush and rinse coil until no residue remains. • Pay close attention to drain pan, drain line and trap. 3) Check the operation of all fans and ensure airflow is unobstructed • Check that each fan rotates freely and quietly. Replace any fan motor that does not rotate smoothly or makes an unusual noise. • Check all fan set screws and tighten if needed. • Check all fan blades for signs of stress or wear. Replace any blades that are worn, cracked or bent. • Verify that all fan motors are securely fastened to the motor rail. • Lubricate motors if applicable. 4) Inspect electrical wiring and components • Visually inspect all wiring for wear, kinks, bare areas and discoloration. Replace any wiring found to be damaged. • Verify that all electrical and ground connections are secure, tighten if necessary. • Check operation/calibration of all fan cycle and defrost controls when used. • Look for abnormal accumulation of ice patterns and adjust defrost cycles accordingly • Compare actual defrost heater amp draw against unit data plate. •Visually inspect heaters to ensure even surface contact with the coil. If heaters have crept, decrease defrost termination temperature and be sure you have even coil frost patterns. Re -align heaters as needed. • Check drain line heat tape for proper operation (supplied and installed by others). 5) Refrigeration Cycle • Check unit cooler superheat and compare reading for your specific application •Visually inspect coil for even distribution Air -Cooled Condensing Units Quarterly 1) Visually inspect unit • Look for signs of oil stains on interconnection piping and condenser coil. Pay close attention to areas around solder joints, building penetrations and pipe clamps. Check any suspect areas with an electronic leak detector. Repair any leaks found and add refrigerant as needed. • Check condition of moisture indicator/sightglass in the sight glass if so equipped. Replace liquid line drier if there is indication of slight presence of moisture. Replace refrigerant, oil and drier if moisture concentration is indicated to be high. • Periodic cleaning can be accomplished by using a brush, pressurized water and a commercially available foam coil cleaner. If foam cleaner is used, it should not be an acid based cleaner. Follow label directions for appropriate use. • Rinse until no residue remains. 4) Check operation of condenser fans • Check that each fan rotates freely and quietly. Replace any fan motor that does not rotate smoothly or makes excessive noise. • Check all fan blade set screws and tighten as required. • Check all fan blades for signs of cracks, wear or stress. Pay close attention to the hub and spider. Replace blades as required. • Verify that all motors are mounted securely. • Lubricate motors if applicable. Do not lubricate permanently sealed, ball bearing motors. 5) Inspect electrical wiring and components • Verify that all electrical and ground connections are secure, tighten as required. • Check condition of compressor and heater contactors. Look for discoloration and pitting. Replace as required. • Check operation and calibration of all timers, relays pressure controls and safety controls. • Clean electrical cabinet. Look for signs of moisture, dirt, debris, insects and wildlife. Take corrective action as required. • Verify operation of crankcase heater by measuring amp draw. 6) Check refrigeration cycle • Check suction, discharge and net oil pressure readings. If abnormal take appropriate action. • Check operation of demand cooling, liquid injection or unloaders if so equipped. • Check pressure drop across all filters and driers. Replace as required. • Verify that superheat at the compressor conforms to specification. (30°F to 45°F) • Check pressure and safety control settings and verify proper operation, Annually 7) In addition to quarterly and semiannual maintenance checks, submit an oil sample for analysis • Look for high concentrations of acid or moisture. Change oil and driers until test results read normal. • Investigate source of high metal concentrations, which normally are due to abnormal bearing wear. Look for liquid refrigerant in the crankcase, low oil pressure or low superheat as a possible source. 8) Inspect suction accumulator (if equipped) • If the accumulator is insulated remove insulation and inspect for leaks and corrosion. • Pay close attention to all copper to steel brazed connections • Wire brush all corroded areas and peeling paint. • Apply an anticorrosion primer and paint as required. Re -insulate if applicable. Diagram 3. Typical Wiring Diagram for Single Evaporator with and without Defrost Timer Air Defrost with Defrost Timer (OPTIONAL) FACTORY -MOUNTED IN CONDENSING UNIT �1 DEFROST av rnm TIMER airPM 7M -------------------- ------I tEF)Wgir 4 I I 1 Wi / (REFER TO UVIT DATAPLATE) I •--------------------------- I �_----__ L-- - - - - ------------� i POWER SUPPLY FAN --------- east FAN RT v 'dam (OPTIONAL) FIELD -MOUNTED WIRE NUTS OR SUPPLIED BY OTHERS SUPPLIED BY OTHERS. UNIT COOLER Air Defrost without Defrost Timer (REFER TO UNIT DATAPLATE) �-----rlAAw +unrest ------------- -,SCLEMID POWER SUPPLY \ FAN Z. ----LPUPIC MY Si7TCHY — — — — — — — — — — — — — • , ACTOR i. RT------ROOI THMOSTAT r-------------� 5. NN ------WIRE NUr 6. — =FACTORY WIRING 7. — — — =FIELD WIRrm PAN L AVO PART Na. 29613714 RT (OPTIONAL) FIELD -MOUNTED OR SUPPLIED BY OTHERS UNIT COOLER Diagram 4. Typical Wiring Diagram for Single Evaporator with Defrost Timer Only (OPTIONAL) FACTORY -MOUNTED IN CONDENSING UNIT DEFROST m �w TIMER TV 3 L6V 4 ---T-r----- 1 1 1 1 I 1 I i 1 e.----- 4/ 1 I I 1 1 1 L----- �. j 1 I 1 I I I I 1 0 0 o bob 0 0 3—b, 0 0 O . N OJ X Fl F2 FO3 4 3 ~ FIELD SLmPLIE0 V {LSV} J JfMiPER_(12 OAJ FROM �2 TO '4' RT (OPTIONAL) MATERS / FIELD -MOUNTED OTFD MOVE cauZCTZO14 OR SUPPLIED PROW •4' TO "r1 BY OTHERS FAN FIELD !E A40TOR LEGETD+ I .AAPER� (12 &A /. TAI ------TIMER AKlTO4 FROM '712" r0 N' 2. OTFD----DEFROST TISWIMATION IFAN DELAY PAN 3. LSI -LV- W.ATER LIMIT 4. LSV -----LIQUID SOLENOID VALVE S. PDS -----PLOP DONN SWITCH 8. RT ------ROOM TFE%wrAT L--------------- FIELD SCPPLIEEpp 7. NIV------WIRE MJT — _ ROPER (12 OA) B. =FACTORY WIRING _ FIM "Fit' TO '3- 9. - - =FIELD WIRING MOVE (0M N NL NOT 10. --FACTCRY WIRIM3. OPTICNAL CTII7Y NL ( WEN SIM) SWLOYED) Cit FIELD MWIFIED FRM -- N' TO 'Hl- Unit Cooler "A" PART NO. 29e6137O7 Diagram 5. Typical Wiring Diagram for Multiple Evaporators with Defrost Timer Only FACTORNALMOUNTED IN CONDENSING LN1T i DEFROST TIMER I \ r 1 TM I 1 1 x j� ; -♦ I � 1 1 I �_____J -_-_-1 1 1 I 1 1 1 1 1 1 1 z 1 1 1 1 -1--1 i --_-________♦ 1 --________'---____-- 0— 1i_�----_-__� 1 11 T -1------------�---------- ------------ ------------ --------- i 1 1 1 1 1 LF--+ 1 1 1 1 1 ------------ 1 I ------------J-r.l-+ 1( I O D D aaa-F1 D C N/ N2 iQ N J X FI P7 FJ f 3 O 0 O FIEU) mFL161 Rr (LNtT aRs. A sal (OPTIONAL) FIELD -MOUNTED OR SUPPLIED BY OTHERS i 1/01E' CYvECTICV FRAI/ IN, NEATERS I ,10VE CONI�ECTIW D7F'D �,� �T LEGEIID� 7. TM -_____TITER Aorm 2. DTFD----DEPRDST TEAMMATIOV/FAN DELAY FIE1D Stil^LI D pµ 3. FL ------{EMR LIMIT z� f. LSV -----L SNOID VALVE 5. Fir, --- -PUIP ODYNw rAT (WIT MRS. A 6 H) 7.6. w-'--- TAT I., B. - �FAnow WIRRF MU ING ♦--------��-��__ 9. - -- =FIELD WIRIN9 10. - �FAC70RY WIRIM, LPTIQMAL DQ FIELD TROIFIED FIELD SfiR_IED AMER (17 DA) PART NO. 78613705 C1N�EC7ICY!'TION 'NI' TO '3' W, TO 9i1' K (WMY SLPPLIEDI (MFS K NOT QFLOYED) T CLAS. A 6 9) t1 �l UNIT C.RS. A 6 81 Unit Cooler B L ----------------- J T---- - 6 Ir N. two SNWLI®) Aaff Unit Cooler "A" ""' Diagram 6. Typical Wiring Diagram for Single Evaporator / Single Phase Defrost and Evaporator Fan Contactors Way DEFROST PART ND. 29613715 SUPPLIED TIMER "M" ON OPS(WI-ov SUPPLIED) OH) EF OR "N" ON DEFROST TIMER TM l ) OFR 4 MS ar FACTORY MOUNTED IN AaH) COAVENSING UNI T CPU II II0 0 o 0 N 3A � 4 O 4 JB S 36 7 O REJUMPER WIRE Y ( 1 1 1 1 "3A" TO "N" (� I (WHEN HL EMPLOYED) I� LL L _ _ _ _ _ 1 1 j 1 1 1 L--------------------+ L --------1 1 I I 1 1 1 1 1 1 1 1 1 L ---- ------------'� 1 I i 1 1 1 1 O b 0-6- o (OPTIONAL) FIELD -MOUNTED H1 Hz H3 F1 Fz F3 N ✓ x 4 s OR SUPPLIED BY OTHERS O O 0 WIRE "3" TO "3A" WHEN HL EMPLOYED. Unit Cooler "A" VALVE M" (W£N SLFPLIED) RELAY hEA TE7PS t OTFD t i L (WHEN SEPPL1EDl Unit Cooler "A" VALVE M" (W£N SLFPLIED) RELAY Diagram 7. Typical Wiring Diagram for Single Evaporator Defrost and Evaporator Fan Contactors �wer)m DEFROST M TIMER PART ND. 29613703 ^M^ ON OPS(WHEN SUPPLIED) OR ^N^ ON DEFROST TIMER oh¢ cwr EF TM 1 a� PDS 4 ff �ACTORY-LMOUNTED x aw MIER COM)ENSING UNIT III I { { { I o I I I I 1 1 I I I N 3A -X 4 d6 09 ±11 REMOVE FACTORY 1_ 1 1 III I I I I I I JUMPER WIRE MOVE CONNECTION FROM N^ TO ^3A^ ^3A^ TO ^N^ 1 -'J --F-_--+ (WHEN HL AND DH2 EMPLOYED) (WHEN HL EMPLOYED) I (I III III 1 16--_ •___—+ 1 1 1 I I I I I __- 1 1 1 1 I I LLL— --------- 1, j I I 1 L-------------------- i I I L—_ = ---- I I LL -L —_—_—_----_--, � ,, IIII 1 1 1 ------ 1, I I I I I I 1 1 1 1 L-------------- �- 1 1 1 RT 4� OL 1 1 1 (OPTIONAL) FIELD -MOUNTED Tf TZ T3 Hl IleH3 �_N O X 4 3 OR SUPPLIED BY OTHERS WIRE ^3^ TO ^3A^ WHEN HL EMPLOYED. HEATERS /EATERSWGN I DTFD StPM r'ED FAN WrOR AN A/OTQR __ (WEEN 9PPL7®) IN Unit Cooler "A" M Y 'TCF/ (WEEN SUPPLIED) RELAY Diagram B. Typical Wiring Diagram for Multiple Evaporators with Evaporator Fan Contactors/without Heater Limit Defrost WeN aZW DEFROST TIMER M. ON OPS(WHEN SUPPLIED) N^ ON DEFROST TIMER PART h0. 29613702 PDS (OPTIONAL) FACTORY -MOUNTED IN a41 d¢ EF Cwf X M&LrFD CONDENSING UNIT _0j ffIII O N 3A 4 3H 017 141�ulilll -9 — 7 ( _ I 1 1 I L--------------------+ L `------------- — — — — + ! I {III I L � _ — L -F-- �--� 1 ! III T I L-�-L-1 I�L — -4— —1— — — — — �— L——t—--�--�----—,� I11 III I II I e -----------I- 4—I-44--+ I 1 1 bimbo 0 0 1 I I 1 1 b4 -bo oG Rr H! FB kC3 Fr f7 F3 N J X 4 3 HI W H3 F1 FZ F3 N J X 4 3 O O O O (OPTIONAL) FIELD -MOUNTED OR SUPPLIED BY OTHERS MOVE CONNECTION FROM N^ TO ^J^ ' yAN DELAY 'ALVE TcH (WHEN SLPPLIED) Unit Cooler "A" Unit Cooler "Bo O4 FIELD MObI kED I r FE'ATERS DTI FEATEAS DTFD PAN FAN MOTOR FAN FAN MOTOR MOTs: ' yAN DELAY 'ALVE TcH (WHEN SLPPLIED) Unit Cooler "A" Unit Cooler "Bo O4 FIELD MObI kED Diagram 9. Typical Wiring Diagram for Multiple Evaporators with Heater Limit Defrost and Evaporator Fan Contactors DEFROST TIMER M" ON OPS(WHEN SUPPLIED) OR N" ON DEFROST TIMER PART NO. 29613701 TM DL, 1Ow PAS tEn 4 EF (OPTIONAL) FACTORY -MOUNTED IN CHI OW EF AN/ hlFP1 ZED CONDENSING, UNI T x O U4 X 4 3B 5 6 7 19 1-1_ --9� VE FACTORY JUMPER WIRES "3A" TO "N" -r7-rm-FTT 1 _i_ ANO ^3B" TO ^N- (WHEN HL EMPLOYED) r------h'-� 1 1 r--, ( L----------..---------• 1 1 1 1 1 1 1 L L —I— — —rte-= == F= — I L-------------, I III I L L rt —s– =P -_= _ L- {- -1--I- f 1 I I I I r -L -f ---------I• "J-+-�.�-I•J-, I I--� 1 1 1{ 1 1 1 1 o�-a-a� H! H2 H3 FI F2 F3 N J X 4 3 H! H2 H3 F/ F2 F3 N. J X 04 3 RT (OPTIONAL) FIELD -MOUNTED OR SUPPLIED BY OTHERS MOVE CONNECTION 1 111 111 FROM "N" TO "J" NEATERs I OTFO OTFO FAN I FAN MOTOR ACTOR K - K FAN FAN MOTOR MOTOR Unit Cooler "A" Unit Cooler "B� DELAY 'TCH foeN S.PPLIED) RELAY Diagram 10. Typical Wiring Diagram for Multiple Evaporators Defrost and Evaporator Fan Contactors with Unit Cooler Holdout Relay DEFROST PART NO. 296137/3 TIMER ^M^ ON OPS(WHEN SUPPLIED) n OR N" ON DEFROST TIMER l LiR way E7A E}R2 PDS sr® 4 fir (OPTIONAL) FACTORY -MOUNTED IN CHI &W x / EF CONDENSING UNIT Avr N JA x 4 38 5 6 7 30C 300 X2 J EtR/ 0W -9 O j O 0-9-0 O REMOVE FACTORY JAFER WIRES I L - - - - - - (I fN N.�EAPI�OYmJ ' TO®, ' - 1 r------L-j I I L---��J 1 I I I l_ r- 1_---4--- 1 I 1 L -_-,-_ _ -1 - - - r- 1 1 RT 1 (STI IED BY rHERS L--�- - I- T-- r--------------------- LL , -1 11 1 r -4--r'-----.& ------ ry • I I WIRE "3" TO W. •3" TO I I E33aFLorm K N! 14 H3 FI F2 F3 N J X 4 3 H/ H2 H3 FI F2 F3 N J X 4 3 OO WATERS I DTFD HEATERSFAN I 07FD MOTOR I MDTDa ,: N SIK.PPLIED) &A. (Wev S7K.-FLIED) Unit Cooler "A" Unit Cooler "B" DELAY Replacement Parts by IrlterL NK Commwd Repigeacon Fmn InterLink'' Comercial Refrigeration Parts is your link to a complete line of dependable and certified commercial refrigeration parts, accessories and innovative electronic controls for all Heatcraft Refrigeration Products (HRP) brands - including Bohn, Larkin, Climate Control and Chandler. At InterLink, we provide our wholesalers with a comprehensive selection of product solutions and innovative technologies for the installed customer base. And every product is built to ensure the same high performance standards with which all HRP brands are built — backed by a dedicated team to serve every customer need, delivering at the best lead times in the industry. Replacement parts should be obtained from your local InterLink wholesaler. Replacement parts, which are covered under the terms of the warranty statement on page 2 of this manual, will be reimbursed for total part cost only. The original invoice from the parts supplier must accompany all warranty claims for replacement part reimbursement. Heatcraft Refrigeration Products reserves the right to adjust the compensation amount paid on any parts submitted for warranty reimbursement when a parts supplier's original invoice is not provided with a claim. For more information, call 800-686-7278 or visit www.interlinkparts.com. For our complete Refrigeration Systems Installation and Operations Manual (H -IM -64L), please visit http-//heatcraftrpd.com/service/publibrary.asp. Since product improvement is a continuing effort, we reserve the right to make changes in specifications without notice. Replaces None. Information formerly included in H -IM -64L Table of Contents GeneralSafety Information..................................................................2 Inspection................................................................................................ 2 WarrantyStatement...............................................................................2 Placement.............................................................................................3-4 DefrostTroubleshooting.......................................................................4 FieldWiring..............................................................................................4 CondensateDrain Lines........................................................................5 H -IM -UC -0812 I Version 000 Unit Coolers �e . CheckOut and Start Up.........................................................................5 OperationalCheck Out..........................................................................5 EvaporatorSuperheat...........................................................................6 SlimContour Features...........................................................................6 ExpansionValve Selection....................................................................7 EvaporatorTroubleshooting................................................................8 Interl-ink Replacement Parts................................................................8 0 General Safety Information 1. Installation and maintenance to be performed only by qualified personnel who are familiar with this type of equipment 2. Some units are pressurized with dry air or inert gas. All units must be evacuated before charging the system with refrigerant. 3. Make sure that all field wiring conforms to the requirements of the equipment and all applicable national and local codes. 4. Avoid contact with sharp edges and coil surfaces. They are a potential injury hazard. 5. Make sure all power sources are disconnected before any service work is done on units. WARNING: Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly. Failure to follow this warning may result in personal injury or death. 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. Check carefully for concealed damage. Any shortage ordamages should be reported tothe 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 its shipping base until it has been moved to the final location. Check the serial tag information with invoice. Report any discrepancies to your Heatcraft Refrigeration Products Sales Representative. Warranty Statement Seller warrants to its direct purchasers that products, including Service Parts, manufactured by SELLER shall be of a merchantable quality, free of defects in material or workmanship, under normal use and service for a period of one (1) year from date of original installation, or eighteen (18) months from date of shipment by SELLER, whichever first occurs. Any product covered by this order found to Seller's satisfaction to be defective upon examination at Seller's factory will at SELLER's option, be repaired or replaced and returned to Buyer via lowest common carrier, or SELLER may at its option grant Buyer a creditforthe purchase price of the defective article. Upon return of defective product to SELLER's plant, freight prepaid, by Buyer, correction of such defect by repair or replacement, and return freight via lowest common carrier, shall constitute full performance by SELLER of its obligations hereunder. SELLER shall have no liability for expenses incurred for repairs made by Buyer except by prior, written authorization. Every claim on account of breach of warranty shall be made to SELLER in writing within the warranty period specified above - otherwise such claim shall be deemed waived. Seller shall have no warranty obligation whatsoever if its products have been subjected to alteration, misuse, negligence, free chemicals in system, corrosive atmosphere, accident, or if operation is contrary to SELLER's or manufacturer's recommendations, or if the serial number has been altered, defaced, or removed. Seller makes no express warranties except as noted above. All implied warranties are limited to the duration of the Express Warranty. Liability for incidental and consequential damages is excluded. Theforgoing is in lieu of all other warranties, express or implied, notwithstanding the provisions of the uniform commercial code, the Magnuson -Moss Warranty - Federal Trade Commission Improvement Act, or any other statutory or common law, federal or state. SELLER makes no warranty, express or implied, of fitness for any particular purpose, or of any nature whatsoever, with respect to products manufactures or sold by seller hereunder, except as specifically set forth above and on the face hereof. It is expressly understood and agreed that SELLER shall not be liable to buyer, or any customer of buyer, for direct or indirect, special, incidental, consequential or penal damages, or for any expenses incurred by reason of the use or misuse by buyer or third parties of said products.To the extent said products may be considered "consumer products," As defined in Sec. 101 of the Magnuson -Moss Warranty- FederalTrade Commission Improvement Act, SELLER makes no warranty of any kind, express or implied, to "consumers," except as specifically set forth above and on the face hereof. 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. (c) The power supply to the unit must meet the following conditions: A. Three phase voltages must be +/- 10% of nameplate ratings. Single phase must be within +10% or -5% of nameplate ratings. B. Phase imbalance cannot exceed 2%. (d) All control and safety switch circuits must be properly connected according to the wiring diagram. (e) The factory installed wiring and piping must not be changed without written factory approval. (f) All equipment is installed in accordance with Heatcraft Refrigeration Products specified minimum clearances Recommended Unit Cooler Placement Some general rules for evaporator placement which must be followed are: 1. The air pattern must cover the entire room. 2. NEVER locate evaporators over doors. 3. Location of aisles, racks, etc. must be known. 4. Location relative to compressors for minimum pipe runs. 5. Location of condensate drains for minimum run. The size and shape of the storage will generally determine the type and number of evaporators to be used and their location. The following are some typical examples: NOTE: Leave space equal to unit height between bottom of unit and product. Do not stack product In front of fans. O 2012 Heatcraft Refrigeration Products LLC Minimum Unit Clearances Figure 1. Medium Profile and Large Unit Coolers FA Pin 112 W / One evaporator Figure 2. Low Profile Unit Coolers One evaporator Figure 3. Center Mount Unit Coolers NOTE: W =Total width of evaporator coil surface. NOTE: H =Total height of evaporator coil surface. 41 1122W > 112w F W W F W - grew E Two evaporators 1112H 1112H 1112M I<- 3H 11121.1 F Two evaporators Recommended Maximum - Minimum Dimensions for Cantor Mount Unit Cenler Installations. E I S I M S Max. 25' E Min. I Max. 3' 40' I Min. 3' I Max. 40' E S Recommended Maximum - Minimum Dimensions for Cantor Mount Unit Cenler Installations. E I S I M I T Max. 25' Min. Max. 1 2' 20' Min. I Max. 3' 40' I Min. 3' I Max. 40' Min. 6' Figure 3A. Slim Contour Unit Coolers Min 3 A [At, e Min 3 Unit Cooler Mounting Most evaporators can be mounted with rod hangers, lag screws, or bolts. Use 5/16' bolt and washers or rod for up to 250 pounds, 3/8" for up to 600 pounds and 5/8" for over 600 pounds. Care should betaken to mount the units level so that condensate drains properly. Note that some unit cooler designs achieve drain pan slope by using different height mounting brackets. In this situation, the top of the mounting brackets should be level. Adequate support must be provided to hold the weight of the unit. cleaning without the use of tools. When lagging or bolting the unit flush to the ceiling, seal the joint between the top and the ceiling with an NSF listed sealant and ends of open hanger channels must be sealed to prevent accumulation of foreign matter. When locating unit coolers in a cooler or freezer, refer to Figures 1 through 4 for guidelines. When using rod hangers, allow adequate space between the top of the unit NOTE: Always avoid placement of Unit Coolers direct above and the ceiling for cleaning. To comply with NSF Standard 7, the area above doors and door openings. the unit cooler must be sealed or exposed in such a way to facilitate hand Figure 4. Large Coolers and Freezers Placement. Cooler or Freezers where one wall will not 0 accommodate all required Baffle evaporators or where air t; Cooler or Freezer with Glass throw distance must be y Display Doors Glass considered. Display 0 Door � y y Baffled Unit - Allow sufficient Where one wall evaporator 0 space between rear of Unit Cook. ll d anwall to permit free return of Elevation view of glass display mounting is satisfactory. �' y y' air. Refer to Figures 1 through 3 door cooler or freezer. Be sure O (page 3) for proper space. air discharge blows above, not directly at doors. Provide baffle door extends above blower leve Defrost Troubleshooting Fan Motor If the motor does not operate or it cycles on thermal overload, remove motor leads from terminal block and apply correct voltage across the leads. If motor still does not operate satisfactorily, it must be replaced. Before starting the unit, rotate fan blades to make sure they turn freely and have sufficient clearance. Fan Delay & Defrost Termination Control This control is a single pole double throw switch. The red lead wire is wired to common. The black wire is wired in series with the fan motors. The brown wire is wired in series with the defrost termination solenoid in the timer. The brown and red contacts close and the black and red contacts open when the temperature is above 55°F. The black and red contacts close and the brown and red contacts open when the temperature is below 35°F. On initial"pulldown"ofa warm boxthefan will not start until the coil temperature reaches approximately 35°F. If the box is still comparatively warm (60°F) when the fan starts, then blowing this warm air over the coil may cause it to warm up to 55°F and thus stop the fan. Therefore, the fan may recycle on initial"pull down" This control cannot be adjusted. If the fan motor fails to start when the control is below 35°F, disconnect the fan motor leads and check the motor as described for fan motors. Also check whether current is being supplied at"N"and"4"from the timer. The fan delay control must be below 35°F when checking for a closed circuit. Defrost Heater If unit shows very little or no defrosting and does not heat, disconnect heater and checkto find if it is burned out. To test, apply correct voltage across heater or use continuity flashlight battery tester. 4 Drain Pan If drain pan has an ice build-up, drain line may be frozen. The drain line should be pitched sharply and exit cabinet as quickly as possible. Sometimes location and ambient at the drain outside of cabinet may cause freeze-up. A drain line heater may be required to correct the freeze-up. Any traps in the drain line must be located in a warm ambient. Field Wiring The field wiring should enter the areas as provided on the unit. The wiring diagram for each unit is located on the inside of the electrical panel door. All field wiring should be done in a professional manner and in accordance with all governing codes. Before operating unit, double check all wiring connections, including the factory terminals. Factory connections can vibrate loose during shipment. 1. The serial data tag on the unit is marked with the electrical character- istic for wiring the unit. 2. Consult the wiring diagram in the unit cooler and in the condensing unit for proper connections. 3. Wire type should be of copper conductor only and of the proper size to handle the connected load. 4. The unit must be grounded. 5. For multiple evaporator systems, the defrost termination controls should be wired in series. Follow the wiring diagrams for multiple evaporator systems carefully. This will assure complete defrost of all evaporators in the system. 6. Multiple evaporator systems should operate off of one thermostat. 7. If a remote defrost timer is to be used, the timer should be located outside the refrigerated space. WARNING: All wiring must be done in accordance with applicable codes and local ordinances. Condensate Drain Lines Either copper or steel drain lines should be used and properly protected from freezing. In running drain lines, provide a minimum 1/4 inch perfoot pitch for proper drainage. Drain lines should be at least as large as the evaporator drain connection. All plumbing connections should be made in accordance with local plumbing codes. All condensate drain lines must be trapped, and run to an open drain. They must never be connected directly to the sewer system. Traps in the drain line must be located in a warm ambient. We recommend a trap on each evaporator drain line prior to any tee connections. Traps located outside, or extensive outside runs of drain line must be wrapped with a drain line heater.The heater should be connected so that it operates continuously. It is recommended that the drain line be insulated to prevent heat loss. A heat input of 20 watts per linear foot of drain line for 0°F (-18°C) room applications and 30 watts per linear foot for -20°F (-29'C) rooms is satisfactory. In freezers, the evaporator drain pan fitting should be included when heating and insulating the drain line. Inspect drain pan periodically to insure free drainage of condensate. If drain pan contains standing water, checkfor proper installation.The drain pan should be cleaned regularly with warm soapy water. WARNING: All power must be disconnected before clean- ing. Drain pan also serves as cover of hazard- ous moving parts. Operation of unit without drain pan constitutes a hazard. Traps on low temperature units must be outside of refrigerated enclosures. Traps subject to freezing temperatures must be wrapped with heat tape and insulated. NOTE: Always trap single evaporator system drain lines individually to prevent humidity migration. Figure 5. Condensate Drain Lines DRAIN LINE MIN. PITCH -1/4"/ FT. VAPOR SEAL 000 TRAP V OPEN DRAIN Check Out and Start Up NOTE: All adjustable controls and valves must be field adjusted to meet desired operation. There are no factory preset controls or valve adjustments. This includes low pressure, high pressure, adjustable head pressure systems and expansion valves. 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) Check the room thermostat for normal operation and adjust. (c) Wiring diagrams, instruction bulletins, etc. attached to the condensing units should be read and filed for future reference. (d) All fan motors on evaporators should be checked for proper rotation. Fan motor mounts should be carefully checked for tightness and proper alignment. (e) Electric and hot gas evaporator fan motors should be temporarily wired for continuous operation until the room temperature has stabilized. (f) Do not leave unit unattended until the system has reached normal operating conditions and the oil charge has been properly adjusted to maintain the oil level between 1/4 and bottom of the sight glass. (g) Make sure all Schrader valve caps are in place and tight. Operational Check Out After the system has been charged and has operated for at least two hours at normal operating conditions without any indication of malfunction, it should be allowed to operate overnight on automatic controls. Then a thorough recheck of the evaporator operation should be made as follows: (a) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is required, leak test all connections and system components and repair any leaks before adding refrigerant. (b) Thermostatic expansion valves must be checked for proper superheat settings. Feeler bulbs must be in positive contact with the suction line and should be insulated. Valves set at high superheat will lower refrigeration capacity. Low superheat promotes liquid slugging and compressor bearing washout. (c) Check defrost controls for initiation and termination settings, and length of defrost period. Set fail safe at length of defrost + 25%. Example: 20 minute defrost + 5 minutes = 25 minute fail safe (d) Check drain pan for proper drainage. (e) Install instruction card and control system diagram for use of building manager or owner. Evaporator Superheat Check Your Superheat. After the box temperature has reached or is close to reaching the desired temperature, theevaporatorsuperheat should bechecked and adjustments made if necessary. Generally, systems with a design TO of 10 F should have a superheat value of 6to 10 F for maximum efficiency. For systems operating at higherTD's, the superheat can be adjusted to 12'to 15' `F as required. NOTE: Minimum compressor suction superheat of 207 may override these recommendations on some systems with short line runs. To properly determine the superheat ofthe evaporator, thefollowing procedure is the method Heatcraft recommends: WARNING: If the condensing unit has no flooded condenser head pressure control, the condensing unit must have the discharge pressure above the equivalent 1057 condensing pressure. 1. Measure the temperature of the suction line at the point the bulb is clamped. 2. Obtain the suction pressure that exists in the suction line at the bulb location by either of the following methods: a. A gauge in the external equalized line will indicate the pressure directly and accurately. b. A gauge directly in the suction line near the evaporator or directly in the suction header of the evaporator will yield the same reading as 2a above. 3. Convert the pressure obtained in 2a or 2b above to saturated evaporator temperature by using a temperature -pressure chart. 4. Subtract the saturated temperature from the actual suction line temperature. The difference is Superheat. Figure 6. Bulb and Contact Location 8:00 a:a Figure 7. Multiple Evaporators Above and Below Main Suction Line Flow frmn upper valve cannot effect W@ ... the free &aWn9 Alternative Superheat Method The most accurate method of measuring superheat is found by following the previous procedure, Temperature/Pressure method. However, that method may not always be practical. An alternative method which will yield fairly accurate results is the temperature /temperature method: 1. Measure the temperature of the suction line at the point the bulb is clamped (outlet). 2. Measure the temperature of one of the distributor tubes close to the evaporator coil (inlet). 3. Subtract the inlet temperature from the outlet temperature. The difference is Superheat. This method will yield fairly accurate results as long as the pressure drop through the evaporator coil is low. Slim Contour Exclusive Information The Slim Contour has several exclusive features that improve the servicability. . Cassette Removal/Replacement Removal of modular cassettes in the Slim Contour improve access and the speed required to service the unit cooler. 1. Turn off electrical feed to the unit. 2. Remove the fan guard (2 Screws). 3. Remove screws from modular cassette and pull cassette forward, but do not fully remove cassette. (Figure 8) 4. With the cassette slightly removed, reach behind the cassette and unplug wired connection. This will separate the cassette from unit cooler. (Figure 9) S. Once the cassette has been removed from the unit cooler, the cassette can be stored on the unit by using the service clip feature. (Figure 10) 6. To reinstall cassette, reconnect plug and slide cassette back into place. Re - secure the cassette by placing screws in place. 3:00 1:00 Figure 8. Figure9. Figure 10. Cassette Removal (Step 3) Cassette Removal (Step 4) Cassette Removal (Step 5) Invated trap to evokl W areNNg Wo We evaporaW Free dralnhT Service Clip Feature The Slim Contour features a service clip on all of its modular cassettes. The service clip is exclusive to Slim Contour cassettes and is designed to improve the serviceability of the unit cooler. The service clip features two separate hooks that can be used to aide in common maintenance. The service clip that is featured on top of the cassettes motor can be used to suspend the cassette while being removed to assist in removing the power connection of the cassette(Figure 11.). The Slim Contour cassette also can be suspended from the drain pan using the screw mounts (Figure 12.) . 4�o Figure 11. Figure 12. Service Clip (Feature 1) Service Clip (Feature 2) Table 1. Expansion Valve Selection For 100# Head Pressure Valve ,., , ,., 3,000-5,000 EGSE 1/2 ZP HFESC-1/2-RZ EGSE 1/2 C HFESC-1/2-RC R-22 EGVE 1/2 Z HFESC-I-HZ EGVE 1/2 C R-22 HFESC-1/2-HC 5,500-7000 EGSE 1/2 ZP HFESC-1/2412 EGSE 1 C HFESC-1/2-RC EGVE 1 ZP HFESC-I-HZ EGVE 1 C HFESC-I-HC 7500-8000 EGSE 1 ZP HFESC-1/2-RZ EGSE 1 C HFESC-I-RC EGVE 1 ZP HFESC-I 1/2 -HZ EGVE 1 C HFESC-I-HC 8500-10,000 EGSE 1 ZP HFESC-1-RZ EGSE 11/2 C HFESC-1 1/4 -RC EGVE 11/2 ZP HFESC-1 1/2 -HZ EGVE 1 C HFESC-I-HC 10,500-11,000 EGSE 1 ZP HFESC-1 1/4-RZ EGSE 11/2 C HFESC-1 1/4 -RC EGVE 11/2 ZP HFESC-2-HZ EGVE 11/2 C HFESC-I-HC 111500-13,000 EGSE 11/2 ZP HFESC-11/2-RZ EGSE 11/2C HFESC-11/4-RC EGVE 11/2ZP HFESC-2-HZ I EGVE 11/2C HFESC-1-HC 13,500-15,000 EGSE 11/2 ZP HFESC-2-RZ EGSE 2 C HFESC-I 1/2 -RC EGVE 2 ZP HFESC-2 1/2 -HZ EGVE 11/2 C HFESC-2-HC 15,500-17,000 EGSE 2 ZP HFESC-2-RZ EGSE 2 C HFESC-2-RC EGVE 2 ZP HFESC-21/2-HZ EGVE 2 C HFESC-2-HC 17,500-20,000 EGSE 2 ZP HFESC-3 1/2-RZ SSE 3 C HFESC-2-RC EGVE 3 ZP HFESC-3-HZ EGVE 2 C HFESC-21/2-HC 20,500-24,000 SSE 3 ZP HFESC-31/2-RZ SSE 3 C HFESC-3-RC SVE 3 ZP HFESC-3-HZ SVE 3 C HFESC-3-HC 24,500-28,000 SSE 3 ZP HFESC-3 1 /2-RZ SSE 4 C HFESC-3-RC SVE 4 ZP HFESC-51/2-HZ SVE 3 C HFESC-3-HC 28,500-34,000 SSE 4 ZP HFESC-S-RZ SSE 4 C HFESC-3-RC SVE 5 ZP HF'FSC-51/2-HZ SVE 4 C HFESC-51/2-14C 34,500-40,000 OSE 6 ZP HFESC-5-RZ SSE 6 C HFESC-5-RC SVE 8 ZP HFESC-5 1/2 -HZ SVE 4 C HFESC-5 1/2 -HC 40,500-50,000 OSE 8 ZP HFESC-7-RZ OSE 8 C HFESC-5-RC SVE 10 ZP HFESC-8-HZ SVE 5 C HFESC-51 /2 -HC 50,500-60,000 OSE 9 ZP HFESC-10-RZ OSE 9 C HFESC-7-RC SVE 10 ZP HFESC-8-HZ SVE 8 C HFESC-8-HC 60,500-70,000 1 OSE 9 ZP HFESC-I0-RZ OSE 9 C HFESC-I0-RC OVE 15 ZP HFESC-10-HZ SVE 8 C HFESC-&HC 70,500-80,000 OSE 12 ZP HFESC-10-RZ OSE 12 C HFESC-10-RC OVE 15 ZP HFESC-15-HZ SVE 10 C HFESC-10-HC 80,500-90AW OSE 12 ZP HFESC-I3-RZ OSE 12 C HFESC-I0-RC OVE 15 ZP HFESC 1 S -HZ SVE 10 C HFESC-I0-HC 90,500-100,000 OSE 12 ZP HFESC-I3-RZ OSE 12 C HFESC-I3-RC OVE 15 ZP HFESC-I5-HZ OVE 15 C HFESC-I5-HC 100,500-110,000 OSE 21 ZP TRAE-20-RZ I OSE 21 C HFESC-I3-RC I OVE 20 ZP I HFESC-20-HZ OVE 15 C HFESC-I5-HC 110,500-120,000 OSE 21 ZP TRAE-20-RZ OSE 21 C HFESC-I3-RC OVE 20 ZP HFESC-20-HZ OVE 15 C HFESC-I5-HC 120,500-130,000 OSE 21 ZP TRAE-20-RZ OSE 21 C TME -20 -RC OVE 20 ZP HFESC-20-HZ I OVE 15 C HFESC-I5-HC NOTES: 1. Valve selections assume standard conditions and 1007 vapor -free liquid. 2. Equivalent valve may be used in place of selection. 3. For "Medium Temp R-507;' valve designation will use"P" for refrigerant code. Table 2. Expansion Valve Selection 180# Head Pressure Valve BTU H at about O• 3,000-5,000 .. EGSE 1/2 ZP ,.. . HFESC-1/2-RZ , .. EGSE 1/2 C ,., . HFESC-1/2-RC R-22 .. EGVE 1/2 ZP . HFESC-1/2-HZ .. EGVE 1/2 C R-22 . HFESC-1/2-HC 5,500-7000 EGSE 1/2 ZP HFESC-I-RZ EGSE 1 C HFESC-1/2-RC EGVE 1 ZP HFBC-"Z EGVE 1/2 C HFESC-I-HC 7500-8000 EGSE 1 ZP HFESC-I-RZ EGSE 1 C HFESC-1/2-RC EGVE 1 ZP HFESC-I-HZ EGVE 1 C HFESC-I-HC 8500-10,000 EGSE 1 ZP HFESC-I-RZ EGSE 1 C HFESC-I-RC EGVE11/2 ZP HFESC-1 1/2 -HZ EGVE 1 C HFESC-I-HC 10,500-11,000 EGSE 1 ZP HFESC-1 1/4-RZ EGSE 11/2 C HFESC-I-RC EGVE 11/2 ZP HFESC-1 1/2 -HZ EGVE 1 C HFESC-I-HC 11,500-13,000 1 EGSE 11/2 ZP HFESC-1 1/4-RZ EGSE 11/2 C HFESC-1 1/4 -RC EGVE 11/2 ZP HFESC-2-HZ EGVE 1 C HFESC-1 1/2 -HC 13,500-15,000 EGSE 2 ZP HFESC-1 1/2-RZ EGSE 11/2 C HFESC-1 1/4 -RC EGVE 2 ZP HFESC-2-HZ EGVE 11/2 C HFESC-1 1/2 -HC 15,500-17,000 EGSE 2 ZP HFESC-2-RZ EGSE 2 C HFESCA 1/2 -RC EGVE 2 ZP HFESC-212-HZ EGVE 11/2 C HFESC-1 12 -HC 17,500-20,000 EGSE 2 ZP HFESC-2-RZ EGSE 2 C HFESC-1 1/2 -RC EGVE 3 ZP HFESC-21/2-HZ EGVE 11/2 C HFESC-2-HC 20,500-24,000 SSE 3 ZP HFESC-3-RZ SSE 3 C HFESC-2-RC SVE 3 ZP HFESC-3 HZ SVE 2 C HFESC-2-HC 24,500-28,000 SSE 4 ZP HFESC-3-RZ SSE 3 C HFESC-2-RC SVE 4 ZP HFESC-3-HZ SVE 3 C HFESC-21/2-HC 28,500-34,000 SSE 4 ZP HFESC-5-RZ SSE 4 C HFESC-31/2-RC SVE 4 ZP HFESC-512-HZ SVE 3 C HFESC-3-HC 34,500-40,000 SSE 6 ZP HFESC-5-RZ SSE 6 C HFESC-3 1/2 -RC SVE 5 ZP HFESC-51/2-HZ SVE 3 C HFESC-3-HC 40,500-50,000 OSE 9 ZP HFESC-7-RZ SSE 6 C HFESC-31/2-RC SVE 8 ZP HFESC-512-HZ SVE 4 C HFESC-512-HC 50,500-60,000 OSE 9 ZP HFESC-7-RZ OSE 9 C HFESC-5-RC SVE 10 ZP HFESC-8-HZ SVE 5 C HFESC-51 /2 -HC 60,500-70,000 OSE 9 ZP I HFESC-I0-RZ OSE 9 C HFESC-7-RC OVE 15 ZP HFESC-8-HZ SVE 5 C HFESC-S 1/2 -HC 70,500-80,000 OSE 12 ZP HFESC-10-RZ OSE 12 C HFESC-7-RC OVE 15 ZP HFESC-10-HZ SVE 8 C HFESC-8-HC 80,500-90,000 OSE 12 ZP HFESC-10-RZ OSE 12 C HFESC-10-RC OVE 15 ZP HFESC-10-HZ SVE 8 C HFESC-8-HC 90,500-100,000 OSE 12 ZP HFESC-I3-RZ OSE 12 C HFESC-10-RC OVE 15 ZP HFESC-I5-HZ SVE 10 C HFESC-8-HC 100,500-110,000 OSE 12 ZP HFESC-13-RZ OSE 12 C HFESC-10-RC OVE 20 ZP HFESC-15-HZ SVE 110C HFESC-10-HC 110,500-120,000 OSE 12 ZP HFESC-I3-RZ OSE 12 C HFESC-10-RC OVE 20 ZP HFESC-I5-HZ SVE 10 C HFESC-10-HC 1120,500-130,0001 OSE 21 ZP I HFESC-I3-RZ OSE 12 C HFESC-I3-RC OVE 20 ZP HFESCA 5 -HZ OVE 15 C HFESC-I O -HC Table 3. Evaporator Troubleshooting Chart r iilllik�', SYMPTOMS POSSIBLE CAUSE ww E CORRECT.IVE STEPS Fan(s) will not operate. 1. Main switch open. 1. Close switch. 2. Blown fuses. 2. Replace fuses. Check for short circuits or overload conditions. 3. Defective motor. 3. Replace motor. 4. Defective timer or defrost thermostat. 4. Replace defective component. 5. Unit in defrost cycle. 5. Wait for completion of cycle. 6. Coil does not get cold enough to reset thermostat. 6. Adjust fan delay setting of thermostat. See Defrost Thermostat Section of this bulletin. Room temperature too high. 1. Room thermostat set too high. 1. Adjust thermostat. 2. Superheat too high. 2. Adjust thermal expansion valve. 3. System low on refrigerant. 3. Add refrigerant. 4. Coil iced -up. 4. Manually defrost coil. Check defrost controls for malfunction. 5. Unit cooler located too close to doors. 5. Relocate unit cooler or add strip curtain to door opening. 6. Heavy air infiltration. 6. Seal unwanted openings in room. Ice accumulating on ceiling 1. Defrost duration is too long. 1. Adjust defrost termination thermostat. around evaporator and/or on 2. Fan delay not delaying fans after defrost period. 2. Defective defrost thermostat or not adjusted properly. fan guards venturi or blades. 3. Defective defrost thermostat or timer. 3. Replace defective component. 4. Too many defrosts. 4. Reduce number of defrosts. Coil not clearing of frost during 1. Coil temperature not getting above freezing point 1. Check heater operation. defrost cycle. during defrost. 2. Not enough defrost cycles per day. 2. Adjust timer for more defrost cycles. 3. Defrost cycle too short. 3. Adjust defrost thermostat or timer for longer cycle. 4. Defective timer or defrost thermostat. 4. Replace defective component. Ice accumulating in drain pan 1. Defective heater. 1. Replace heater. 2. Unit not pitched properly. 2. Check and adjust if necessary. 3. Drain line plugged. 3. Clean drain line. 4. Defective drain line heater. 4. Replace heater. 5. Defective timer or thermostat. 5. Replace defective component. Uneven coil frosting 1. Defective heater. 1. Replace heater. 2. Located too close to door or opening. 2. Relocate evaporator. 3. Defrost termination set too low. 3. Adjust defrost termination setting higher. 4. Incorrect or missing distributor nozzle. 4. Add or replace nozzle with appropriately sized orifice for conditions. Replacement Parts byI rater LININ Commercial Refrigeration Parts InterLink is your linkto a complete line of dependable and certified commercial refrigeration parts, accessories and innovative electronic controls for all Heatcraft Refrigeration Products (HRP) brands - including Bohn, Larkin, Climate Control and Chandler. At InterLink, we provide our wholesalers with a comprehensive selection of product solutions and innovative technologies for the installed customer base. And every product is built to ensure the same high performance standards with which all HRP brands are built - backed by a dedicated team to serve every customer need, delivering at the best lead times in the industry. Replacement parts should be obtained from your local InterLink wholesaler. Replacement parts, which are covered under the terms of the warranty statement on page 2 of this manual, will be reimbursed for total part cost only. The original invoice from the parts supplier must accompany all warranty claims for replacement part reimbursement. Heatcraft Refrigeration Products reserves the right to adjust the compensation amount paid on any parts submitted for warranty reimbursement when a parts supplier's original invoice is not provided with a claim. For more information, call 800-686-7278 or visit www.interlinkparts.com. For more detailed information on the following topics, please visit http://heatcraftrpd.com/service/publibrary.asp for our complete Refrigeration Systems Installation and Operation Manual (H -IM -64L). Defrost Thermostat Expansion Valves & Nozzles Refrigerant Oils Recommended Refrigerant Piping Practices Line Sizing Charts Hot Gas Defrost Systems Evacuation and Leak Detection Refrigerant Charging Instructions System Balancing - Compressor Superheat General Sequence and Operation Troubleshooting Guides Preventive Maintenance Guidelines Typical Wiring Diagrams Since product improvement is a continuing effort, we reserve the right to make changes in specifications without notice.