Condensing Unit - Hussmann...Hard mounting is standard on all units. All piping was carefully design...

Condensing UnitInstallation and

Operation Manual

PN 0708232_DOctober 2016

®

Æ

MANUAL 1/O H-SERIES CONDENSING UNIT

PN 0708232_D Condensing Unit Installation and Operation Manual 2

2

TABLE OF CONTENTSMODEL NUMBERING SYSTEM................................................................................................... 4INSTALLATION INSTRUCTIONS ................................................................................................ 5 SHIPPING DAMAGE ................................................................................................................ 5 Apparent Loss or Damage ..................................................................................................... 5 Concealed Loss or Damage .................................................................................................... 5 RIGGING AND LIFTING ......................................................................................................... 5 MACHINE ROOM REQUIREMENTS .................................................................................... 6 UNIT PLACEMENT .................................................................................................................. 7 Minimum Allowable Clearances ............................................................................................. 7 Maximum Allowable Clearances ............................................................................................ 7 SHIPPING BLOCK REMOVAL ............................................................................................... 7 TWO-TIER APPLICATION ...................................................................................................... 8 RECEIVER CAPACITY ............................................................................................................. 8 PRESSURE RELIEF ................................................................................................................. 8 WATER COOLED CONDENSER ............................................................................................ 8REFRIGERATION PROCESS ........................................................................................................ 9 OVERVIEW ................................................................................................................................ 9 REFRIGERATION CYCLE ......................................................................................................10 HEAT RECLAIM VALVE .........................................................................................................11 DEMAND COOLING ...............................................................................................................12 The System Parts .................................................................................................................12 Component Testing ...............................................................................................................13 Alarm Circuit .......................................................................................................................13 Alarm Relay .........................................................................................................................13 Operational Notes ................................................................................................................14COMPONENT PIPING ..................................................................................................................15 OVERVIEW ...............................................................................................................................15 REFRIGERATION LINE RUNS ..............................................................................................15 Through Walls or Floors .......................................................................................................15 From Machine to Solid Object ..............................................................................................16 P-Trap Construction .............................................................................................................16 Reduced Riser .......................................................................................................................16 Factory Supplied Stubs .........................................................................................................16 Protecting Valves and Clamps ...............................................................................................16 Connecting Remote Condenser ..............................................................................................16 Purge Valve Location ............................................................................................................16 MERCHANDISER PIPING .....................................................................................................18 Suction Line .........................................................................................................................18 Liquid Line – Off Time and Electric Defrost .........................................................................18 Field Connections of Heat Reclaim .......................................................................................18 SPECIAL PIPING FOR OPEN ROOMS ................................................................................18 RUN LENGTHS AND EQUIVALENT FEET ..........................................................................18 INSULATION ...........................................................................................................................18 REFRIGERANT LINE SIZING ...............................................................................................19 General Information .............................................................................................................19 Refrigeration Line Stubs Out ................................................................................................19 Condenser Line Sizing ..........................................................................................................19

Condensing Unit Installation and Operation Manual 3

PN 0708232_D 3

ELECTRICAL ................................................................................................................................ 20 OVERVIEW .............................................................................................................................. 20 GUIDELINES FOR FIELD WIRING ..................................................................................... 20 Unit Cooler Fan Wiring ....................................................................................................... 20 Evaporator Mounted Liquid Line Solenoid ........................................................................... 20 Cooler Door Switch Wiring ................................................................................................. 20 Sizing Wire and Overcurrent Protectors ............................................................................... 20 Defrost Controls .................................................................................................................. 20 Other Controls .................................................................................................................... 20 ABOUT THESE ELECTRICAL DIAGRAMS ........................................................................ 21 Electrical Diagrams ............................................................................................................. 22START-UP .................................................................................................................................... 30 Leak Testing ...................................................................................................................... 30 Test Charge ......................................................................................................................... 30 Oil Levels................................................................................................................................... 30 Evacuation ....................................................................................................................................... 31 Setup ................................................................................................................................... 31 Procedure ................................................................................................................................... 31 Pre-Charge Check List ........................................................................................................ 31 Charging ............................................................................................................................. 31 Winter Charge ........................................................................................................................... 31 Compressor Motor Rotation (Scroll) .......................................................................................... 31 Final Checks ........................................................................................................................ 31MAINTENANCE ............................................................................................................................ 34 COMPRESSOR REPLACEMENT ......................................................................................... 34 REPLACING DRIER AND FILTER CORES ......................................................................... 34APPENDIX A – DIMENSION DRAWINGS ................................................................................. 35 AIR COOLED / WATER COOLED CONDENSING UNITS ................................................. 36TROUBLESHOOTING INFORMATION .................................................................................... 52TROUBLESHOOTING GUIDE .................................................................................................... 53


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PN 0708232_D 5

SHIPPING DAMAGE

All equipment should be thoroughly examined for shipping damage before and while unloading. This equipment has been carefully inspected at our factory and the carrier has assumed responsibility for safe arrival. If damaged, either apparent or concealed, claim must be made to the carrier.

Apparent Loss or DamageIf there is an obvious loss or damage, it must be noted on the freight bill or express receipt and signed by the carrier’s agent, otherwise, carrier may refuse claim. The carrier will supply the necessary claim forms.

Concealed Loss or DamageWhen loss or damage is not apparent until after equipment is uncrated, a claim for concealed damage is made. Upon discovering damage, make request in writing to carrier for inspection within 15 days and retain all packing. The carrier will supply inspection report and required claim forms.

RIGGING AND LIFTING

Under no circumstances should the manifolds, piping return blends or control panel be used for lifting or moving the unit. Use lifting eyes provided on two tier units. On singles tier units, secure lifting hooks to the under side of the base, or use the holes provided in the base. The installer is responsible to see that equipment used to move the unit is operated within its limits.

Figure 1-1 Rigging and Lifting

INSTALLATION INSTRUCTIONS

1 ½ times overall unit height minimum

Spreader bar = unit width + 1 in.

Secure lifting hooks on underside of base where

sheet metal ends.


6

Figure 1-2 Machine Room Requirements (Side View)

MACHINE ROOM REQUIREMENTS

The equipment room floor must solidly support the compressor unit as a live load. Ground level installation seldom presents problems, but a mezzanine installation must be carefully engineered.

When a Remote Condenser Unit, Satellite Unit or a Water Cooled Condensing Unit is installed, the ventilation should be 100 cfm per compressor unit horsepower. The air inlet should be sized for a maximum of 600 fpm velocity (0.5 ft² of air intake per compressor unit horsepower).

The Indoor Condensing Unit ventilation should be 750 to 1,000 cfm with 2 to 2.5 ft² of air intake per compressor unit horsepower.

The ventilation fans should cycle by thermostatic control.

All machine room ventilation equipment must be field supplied. Check local codes for variances.

Proper ventilation provides airflow across the compressors. Duct work may be necessary.

Provide a floor drain for disposal of condensate that may form on the compressor unit or header defrost assembly.

Equipment must be located in the machine room to provide enough working space for service personnel, and to meet electrical codes.

Consult NEC National Fire Handbook, particularly “Installation of Switch Boards” and “Working Space Requirements.” Figures 1-2 and 1-3 illustrate some suggested distances. Refer to local codes for each installation.

Exhaust Fan

Exhaust Fan

Baffle

9 ft min

4 ft min

2 ft min

11 ft min

4 ft min

2 ft min

L o u v e r s

L o u v e r s


PN 0708232_D 7

UNIT PLACEMENT

When setting the units, plan in relation to the rest of the equipment to be installed and existing structures. Some minimum and maximum distances are listed. Note: Piping equivalent is not the same as linear distance.

Minimum Allowable ClearancesBetween an Outdoor Condensing Unit and any vertical structure (except open chain link fence) the minimum allowable distance is 4 feet.

Between one Outdoor Condensing Unit exhaust and another Outdoor Condensing Unit intake the minimum allowable distance is 15 feet.

Between the sides of two Outdoor Condensing Units the minimum allowable distance is 5 feet.

On Indoor Condensing Unit, Satellite Unit, Remote Condenser Unit and Water Cooled Condensing Unit, the minimum distance between the Control Panel and the wall is 3 feet.

On Indoor Condensing Unit, Satellite Unit, Remote Condenser Unit and Water Cooled Condensing Unit, the minimum distance between the Control Panel and another live panel is 4 feet.

On Indoor Condensing Units the minimum distance between the Condenser Air Intake and a louvered wall is 2 feet.

Maximum Allowable ClearancesWhen piping a suction riser the maximum vertical distance between P-traps is 20 feet.

When piping from Remote Condenser Unit to a Condenser, the maximum allowable piping equivalent is 100 feet.

SHIPPING BLOCK REMOVAL

Hard mounting is standard on all units. All piping was carefully design to absorb the vibration that is generated by the compressor and fan motors.

When the spring mounting kit (optional) is installed, the unit is shipped with blocks under each compressor foot to prevent transit damage. Loosen the mounting spring nuts at least one full turn and remove the blocks.

Adjust the torque on the mounting spring nuts so that the compressor feet are 1 inch above the unit’s base.

Figure 1-4 Shipping Block Removal

Figure 1-3 Machine Room Requirements (Top View)

4 ft min3 ft

min

3 ft max

2 ft min

2 ft min

Baffle

Shipping Block


8

TWO-TIER APPLICATION

The two-tier unit is only an option when it is installed on the heavy duty base (option) and it is designed for indoor, water-cooled, remote condenser or satellite application.

WARNING:Two Tier Remote Condenser Units

Are Front Heavy.

Take appropriate precautions during shipment and moving of unit. Fasten to floor upon final placement.

Figure 1-5 Two Tier Remote Condenser Units

RECEIVER CAPACITY

The receiver capacity is listed on the table below.

PRESSURE RELIEFIt is standard that a fusible plug is installed on all the receivers. The connection size for piping from the fusible plug to outside is 3/8” NPT.

It is also available as an option a relief valve, which replaces the fusible plug, and has the same connection size for piping (3/8” NPT).

WATER COOLED CONDENSER

Flush the water lines before connecting them to the water-cooled condenser.

Consult Water Cooled Condensing Unit Catalog for pressure drop, recommended inlet water temperature and water flow through the condenser.

H-series Receivers

R22 R404a/R507 R448a/449a R407a R407F

6x12 12.8 11.1 11.7 12.2 11.96x18 19.2 16.7 17.6 18.4 18.06x23 24.6 21.4 22.5 23.6 23.06x30 32 27.9 29.3 30.7 30.0

8-5/8x30 62 53.9 56.6 59.4 57.910-3/4x30 94.6 82.3 86.5 90.7 88.510-3/4x38 122 106.2 111.6 117.0 114.212-3/4x30 115 100.1 105.2 110.3 107.6

5x12 9.1 7.9 8.3 8.7 8.56x15 16.8 14.6 15.3 16.1 15.76x12 13.1 11.4 12.0 12.6 12.36x36 41.6 36.1 37.9 39.8 38.8

Capacity - 90%


PN 0708232_D 9

OVERVIEW

This section details the refrigeration process by tracking the refrigerant flow through the system components. Heat Reclaim, Demand Cooling, Oil separation and return is explained. See Piping for piping guidelines.

Typically, refrigeration falls into low or medium temperature ranges. An average low temperature condensing unit maintains a suction temperature of -20F with a low-temp Satellite operating at -33F. A common medium temperature condensing unit operates at +25F with a low-temp Satellite operating at +7.

In these instructions the following constants are maintained to assist the reader.

In the diagrams refrigerant flow direction is generally clockwise and indicated by directional arrows.

Electric solenoid valves carry the same initial abbreviations as in the electric schematics.

Refrigeration lines not actually in the cycle being discussed are shown closed or removed. Pressure in oil lines will also retain a fixed pattern.

Figure 2-1 Refrigeration Cycle

REFRIGERATION PROCESS

Check Valve

Check Valve

Heat Reclaim Coil

Heat Reclaim Valve

EvaporatorOil SeparatorOil Return

Line

Condenser

Condenser

Receiver

Receiver

Fixed Flooding Valve

Liquid DryerSight Glass

Suction Filter

CompressorAccumulator

Oil Line Solenoid

Liquid Line Solenoid

Sensor

Demand Cooling Module

Injection Valve

Differential Check Valve

Adjustable Flooding Valve

High Pressure Hot Vapor

High Pressure Warm Vapor

High Pressure Warm Liquid

Low Pressure Cool Vapor


10

REFRIGERATION CYCLE

Beginning with the Compressor, refrigerant vapor is compressed and flows to the Oil Separator, which separates the oil from the discharge gas by centrifugal force and screen baffles. The oil is stored in the bottom of the Oil Separator and returned to the compressors through the oil return line.

Figure 2-2 Oil Separator

When an Oil Separator is installed the following components are required:• Check Valve on the discharge line after the

Oil Separator, to prevent refrigerant migration during low ambient temperatures from the condenser to the Oil Separator, and from that to the Compressor.

• Oil Line Solenoid on the oil return line, to prevent the oil to return from the compressor when the compressor is not running. The excessive oil in the carter when the compressor starts, could cause damage to the compressor such as broken valve plate or piston, etc.

A 3-Way Heat Reclaim Valve directs the superheated discharge gas to either the condenser or a Heat Reclaim device when energized. When the reclaim solenoid is de- energized the valve directs the refrigerant to the condenser.

Figure 2-3 Heat Reclaim Valve

The Condenser rejects the heat that must be removed from refrigerant to cause it to condense.

For Low Ambient Conditions, Fan Cycling or Flooding Valves are required. These valves may be fixed or adjustable. The adjustable flooding valve works in parallel with a 20 pound differential check valve.

The Flooding Valve maintains head pressure in low ambient conditions by restricting liquid refrigerant flow from the Condenser. This causes liquid refrigerant to be backed up in the condenser thus reducing available heat transfer surface and causing the discharge pressure to rise.

Adjustable Flooding Valve and Differential

Check Valve


Figure 2-4 Flooding Valves

The Receiver is a holding vessel for liquid refrigerant that compensates for fluctuations in


PN 0708232_D 11

liquid requirements due to changing load, defrost, and weather.

A Liquid Line Drier removes moisture and contaminants from the refrigerant.

The Sight Glass allows service personnel to view refrigerant flow inside the liquid line.

The Liquid Line Solenoid Valve closes off refrigerant supply to the evaporator.

Figure 2-5 Liquid Line Solenoid Valve

The Thermostatic Expansion Valve (TEV), located in the merchandiser, meters liquid refrigerant through its orifice to the low pressure side of the system where it absorbs heat from the coil causing the liquid to evaporate.

Figure 2-6 Thermostatic Expansion Valve

The Accumulator catches liquid refrigerant in the suction line and provides a means for it to boil off before it reaches the compressor.

A Suction Filter is placed upstream of the compressor to remove system contaminants from the refrigerant vapor.

At critical locations along the refrigerant path, service valves or ball valves allow isolation of components.

HEAT RECLAIM VALVE

A 3-Way Heat Reclaim Valve directs the refrigerant to either the Condenser or a Heat Reclaim Coil. When the solenoid is de- energized the valve directs the refrigerant to the condenser.

When the solenoid is de-energized the high- pressure inlet is stopped and the passage between suction and valve chamber is open. When the solenoid is energized the suction outlet is stopped and the passage between high pressure and the valve chamber is open.

“B” version of the valve has a bleed port through the drive piston to the suction manifold. The bleed port provides a vent for fluids trapped in the Heat Reclaim circuits during normal operation.

Figure 2-7 Heat Reclaim Valve Normal Operation

De-energized

From Discharge Manifold

To Heat Reclaim

To Suction Manifold

Bleed Port

To Condenser Valve in Normal Operation


12

Figure 2-8 Heat Reclaim Valve Heat Reclaim Mode

DEMAND COOLING

The Demand Cooling System is designed to inject saturated refrigerant into the suction cavity when the compressor internal head temperature exceeds 292°F. Injection continues until the temperature is reduced to 282°F. If the temperature remains above 310°F for one minute the control shuts down the compressor. After correcting the cause of shutdown, manual reset is required.

The System PartsTemperature SensorControl ModuleInjection Valve

The Temperature Sensor uses a Negative Temperature Coefficient (NTC) Thermistor to provide signals to the Control Module. The NTC resistance drops on temperature rise.

Temperature Approximate Ohm°F Reading77 90,000282 2,400292 2,100310 1,700

The Control Module responds to the Temperature Sensor input by energizing the Injection Valve Solenoid when 292°F is exceeded. Too high or too low a resistance from the thermistor circuit will cause the Module to shutdown the compressor after one minute.

The Injection Valve meters saturated refrigerant into the suction cavity of the compressor. The valve orifice is carefully sized to meet the requirements of a specific compressor. Valve sizes correspond to the four compressor bodies- 2D, 3D, 4D.

Probe test readings between 100,000 Ohms and 1,600 Ohms usually indicate an operating probe.

Figure 2-9 Demand Cooling Components

Energized

From Discharge Manifold

To Heat Reclaim

To Suction Manifold

To Condenser Valve in Heat Reclaim Mode

Injection Valve

Temperature Sensor Module

Temperature Sensor

Module

Injection Valve Solenoid


PN 0708232_D 13

Component Testing

Remove power to the system. Unplug the Temperature Sensor from the Module. The Sensor should ohm out between 1,600 Ohms and 100,000 Ohms.

Leave the Sensor unplugged and restart the system. There should be no voltage between terminals “S” and “L2” on the Module. The inlet and outlet sides of the Injection Valve should feel the same temperature. After one minute the alarm relay should trip. Remove power to the system. Press the manual reset on the Module.

Using a small piece of wire, jump the Sensor circuit at the female plug in the Module. Restart the system. There should be voltage between terminals “S” and “L2” on the Module. The outlet side of the Injection Valve should feel colder than the inlet side. After one minute the alarm relay should trip.

Remove power to the system. Press the manual reset on the Module.

Remove the jumper wire and plug in the Temperature Sensor.

Restart the System.

Alarm CircuitThe Alarm Circuit has three terminals in the Control Module.

“L” – Common“M” – Normally Closed “A” – Normally Open

“L” and “M” are wired into the compressor control circuit so an alarm condition removes the compressor from the line and power to the Module. A manual reset is required to call attention the alarm condition.

Figure 2-10 Demand Cooling Alarm Connections

Figure 2-11 Demand Cooling Wiring

Alarm RelayThe Alarm Relay is activated after a one minute delay under the following three conditions:

• Compressor discharge temperature exceeds 310°F.

Injection Valve

To Control Panel

Temperature Sensor

Compressor Terminal BoxNot all wires shown


14

• A shorted circuit or very low Thermistor Resistance.

• An open circuit or very high Thermistor Resistance.

Operational NotesDemand Cooling does NOT replace head cooling fans, which may be required on low temperature applications.

On indoor and outdoor condensing units, the condenser fans replace the head cooling fan.

When fan cycling is applied, at least one condenser fan MUST always be ON with the compressor, so head cooling fan will be not necessary.

Temperature Sensor cables must not touch any hot surfaces or the cable will be damaged.


PN 0708232_D 15

OVERVIEW

This section deals with the information necessary for installing the refrigeration lines for a condensing unit. The components are piped as completely as practical at the factory.

Use only clean, dehydrated, sealed refrigeration grade copper tubing. Use dry nitrogen in the tubing during brazing to prevent the formation of copper oxide. All joints should be made with silver alloy brazing material, and use 45% silver solder for dissimilar metals.

WARNINGAlways use a Pressure Regulator on the

nitrogen tanks.

REFRIGERATION LINE RUNS Liquid Lines and suction lines must be free to expand and contract independently of each other. Do not clamp or solder them together. Run supports must allow tubing to expand and contract freely. Do not exceed 100 feet without a change of direction or/and offset. Plan proper pitching, expansion allowance, and P-traps at the base of all suction risers. Use long radius elbows to reduce line resistance and breakage.

Avoid completely the use of 45 degree elbows. Install service valves at several locations for ease of maintenance and reduction of service costs. These valves must be UL approved for 410 psig minimum working pressure.

Figure 3-1 Supporting Refrigeration Lines

Through Walls or FloorsRefrigeration lines run through walls or floors must be properly insulated. Avoid running lines through the refrigeration cases. When this is done the lines must be adequately insulated.

Figure 3-2 Insulating a Riser

COMPONENT PIPING

Floor Run

Ceiling Run

Support Detail

Riser

Insulation 2nd LayerInsulation


16

From Machine to Solid ObjectWhen mounting lines from machinery to a solid object allow line freedom for vibration to prevent metal fatigue.

Figure 3-3 Vibration Allowance

P-Trap ConstructionA P-Trap must be installed at the bottom of all suction risers to return oil to the compressors.

Figure 3-4 P-Trap Construction

Reduced RiserWhen a reduced riser is necessary, place the reduction coupling downstream of the P-Trap.

Figure 3-5 Reduced Riser

Factory Supplied StubsStub sizes provided do not automatically correspond to the line sizes necessary. It is the installer’s responsibility to supply reduction couplings.

Protecting Valves and ClampsWhen brazing near factory installed clamps or valves be sure to protect them with a wet rag to avoid overheating.

Connecting Remote Condenser• Discharge Line will be routed directly to the

condenser inlet stub with a purge valve at the highest point.

• Liquid Return line will be pitched downstream and provide trap less drainage to the Receiver.

Purge Valve LocationThe purge valve will be installed at the highest point of an inverted P-Trap, with at least a 6” rise. (Use with approved recovery vessel.)

WARNINGVent the Receiver Safety Relief Device

properly.

Clamp Here

Factory Clamp 10 X Pipe Diameter

Using Elbows Riser

Using P-Trap Riser

Keep this distance as short as possible

Reduced Riser


PN 0708232_D 17

Figure 3-6 Remote Condensing Unit Piping

Note: The Heat Reclaim Valve could be factory or field installed and depends on the customer request.

Receiver

Liquid Return Line


Fixed Flooding Valve Piping

Header End of Condenser

3” Min Rise

12” Min

All Piping and Valves in this box are field supplied and Installed.

Heating Coil

To Heat ReclaimFrom

Heat Reclaim

Pitch ¼” per Foot

Receiver

Heat Reclaim Valve

Adjustable Flooding Valve

Differential Check Valve

Liquid Return Line

Liquid Return Lines

Purge Valve

Discharge Lines Ball Valve

Check Valve

Service Valve

Bleed Line to Suction

Heat Reclaim ValveBleed Line to Suction


18

MERCHANDISER PIPING

Suction Line• Pitch in direction of flow.• May be reduced by one size at one third of run

load and again after the second third. Do not reduce below evaporator connection size.

• Suction returns from evaporators enter at the top of the branch line.

Figure 3-7 Line Piping Inside Merchandisers

Liquid Line – Off Time and Electric Defrost• May be reduced by one size after one half of the

case load run. Do not reduce below evaporator connection size.

• Take-offs to evaporators exit the bottom of the liquid line. Provide an expansion loop for each evaporator take-off (Minimum 3 inch diameter).

Field Connections of Heat ReclaimEach circuit of the heat reclaim coil is tagged to correspond with a specific condensing unit and must be connected only to that unit.

The supply and return lines are to be installed as shown in Figure 3-6.

Notice that heat reclaim could be factory or field installed, and depends on customer order.

SPECIAL PIPING FOR OPEN ROOMS

An open preparation room allows heat infiltration from the rest of the store at a rate which may jeopardize total refrigeration performance. To protect the rest of the refrigeration system, open preparation evaporators must be piped with a Crankcase Pressure Regulating Valve (CPR).

The CPR is field installed in the suction line(s) from the evaporator(s). And the installer is responsible for proper adjustment of the Valve. (See: Control Valve Section for adjustment procedures.)

RUN LENGTHS AND EQUIVALENT FEET

When figuring run lengths, angle valves and 90 degrees elbows are figured as additional straight pipe. The chart below gives equivalent lengths for these components.

Tubing Size Angle Valve Long Radius Elbow 90°

1/2 6 0.95/8 7 1.07/8 9 1.4

1 1/8 12 1.71 3/8 15 2.31 5/8 18 2.62 1/8 24 3.32 5/8 29 4.13 1/8 35 5.03 5/8 41 5.94 1/8 47 6.7

Table 3-1 Equivalent Feet for Angle Valve and Elbow 90º

(ASHARE 1994 Refrigeration Handbook)

INSULATION

Additional insulation for the balance of the liquid and suction lines is recommended wherever condensation drippage is objectionable or the lines are exposed to ambient conditions.

3” LoopLiquid Line Take Off

Suction Line Return


PN 0708232_D 19

REFRIGERANT LINE SIZING

General InformationThis document supersedes all previously published line sizing data – including planning data, installation instructions, or other stand- alone documents.

Refer to ASHARE standards for line sizing. The installer is responsible for sizing the piping for each application.

Refrigeration Line Stubs OutStub sizes do not match line sizes. Reduction fittings are field supplied and installed. These are general guidelines. The installer is responsible to account for any factors which may affect the system.

Condenser Line SizingA Condenser Line Sizing chart is established for an equivalent pipe run of 100 feet. For longer runs use the following formula:

Table Capacity * √100/Longer Length = Longer

Line Capacity

Note: This formula applies only to remote condenser lines, and only to longer runs of these lines. A 25 ft run does not necessarily have double the capacity of a 100 ft. run.


20

ELECTRICAL

OVERVIEW

The scope of this section is limited to main field wiring connections, and to the control panel.

The standard Condensing Unit is available wired for 208-230/1/60, 208-230/3/60, 460/3/60, 575/3/60 or 380/3/50 compressors (note that some compressors may be available in all voltages). In either case, the control circuit is 208-230V.

The standard 460V and 575V Condensing Unit require two single point connections, one for the compressor (460V or 575V) and one for the control and defrost circuits (208-230V). When a single point connection is specified for 460V and 575V condensing units, the factory will install a transformer to supply 208-230V for just the control circuit.

Refer to the serial plate located on the control panel to determine wire size (MCA) and overcurrent protection (MOPD).

GUIDELINES FOR FIELD WIRING

Condensing Unit components are wired as completely as possible at the factory with all work completed in accordance with UL file. All deviations required by governing electrical codes will be the responsibility of the installer.

The main lugs in the compressor control panel are sized for copper wire only, with 75° C insulation. All wiring must be in compliance with governing electrical codes.• For 208-230/1/60 Condensing Units:To each condensing unit provide; one

208-230/1/60 branch circuit,

• For 208-230/3/60 Condensing Units:To each condensing unit provide; one

208-230/3/60 branch circuit,

• For 460/3/60 Condensing Units:

To each condensing unit provide; one 460/3/60 branch circuit, one 208/3/60 circuit – see Note 1

• For 575/3/60 Condensing Units:To each condensing unit provide; one 575/3/60 branch circuit, one 208/3/60 circuit – see Note 1• For 380/3/50 Condensing Units:To each condensing unit provide; one 380/3/50 branch circuit, one Neutral

Note 1 – Omit when single point connection kit is used.

Unit Cooler Fan WiringOff Time Defrost: the unit cooler fan should be wired from the condensing unit panel or an outside panel.

Electric Defrost: the unit cooler fan should be wired from the condensing unit panel.

Evaporator Mounted Liquid Line SolenoidPower for a liquid line solenoid can be picked up from the fan circuit.

Cooler Door Switch WiringThe switch must be mounted to the cooler door frame, and must be wired to control the field installed liquid line solenoid and evaporator fans. Door switches are wired in series.

Sizing Wire and Overcurrent ProtectorsCheck the serial plate for Minimum Circuit Ampacity (MCA) and Maximum Overcurrent Protective Devices (MOPD), follow NEC guidelines.

Defrost ControlsThe basic defrost circuits are shown on the wiring diagrams in this section.


PN 0708232_D 21

Other ControlsWhen other controls are used, refer to the manual included with that control.

ABOUT THESE ELECTRICAL DIAGRAMS

All diagrams show the electrical system DE-energized and in refrigeration mode. Diagrams emphasize individual circuit continuity and logic. They aid troubleshooting and testing by identifying point-to-point connections. Color coding wires allows easy transfer to the control panel. The diagrams normally move from left to right so the user can read the series of components and their terminals which make up a circuit.

Generally, in a control circuit the loads are limited to coils, lights, and bells. By identifying one control circuit load and “reading” the schematic to the load, the sequence of operation becomes obvious. Troubleshooting that circuit then breaks into test point terminals. Take only one circuit at the time.

Important Note:The electrical diagrams in this section show circuit logic. They are not intended for troubleshooting or design work. For unit cooler fan power, electric defrost sub circuit balance, and other location specific circuits refer to the schematics on control panel.


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0

REVISION HISTORY

1 1 MATERIAL-----

Hu 5 5

m n n n

®� I MODEL BY / DWG BY-

RAM �

REVISION DESCRIPT

ION REV

BY

CHKD BY

H-DIAGRAM MAJ


AIL BLOCKS.RA

M WAYNE

APPR BY

CRAIG

CHECKED BY-WAYNE

� APPROVED BY-

CRAIG REF-

SUPERSEDES DIAGRAM -TI

MER 460!575V-3/60 SUPPL

Y �

DATE DRAWN -30SEPl6 SHEET I

OF 121

UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES. �

TOLERANCES ARE r,

{\ rl

THIRD

� DECIMALS .xx ±.03, .xxx ±.0 IO

\ �p / �

IANGLE

O 701c:46 9

I

H �

ANGLES ± 2°

'-V

�

PROJECTION

/

1

..J•

�


PN 0708232_D 27

SMALL MEDIUM LARGE UNITS

0-l �

1N-2Y

FAN CON

TACTOR

0-l �

FAN

CONTACTOR BFAN

S

0-l �

FAN

CON

TACTOR BFANS

0-l �

FAN

CONTACTOR BFAN

S

0-l �

FAN

CONTACTOR B

B

FANS 1 N-2Y-

3N-4N

1 N-2Y-3Y-4N

1 N-2Y-

3Y-4Y

1 N-2Y-34Y

FANS

H1 H2

H3 H4

REV

ECN

H ECN-

CAP-

0002 691 -A

DATE

11 MAY1 6

0-l �FAN

CON

TACTOR B

FANS

0-l �FAN

CON

TACTOR B

FANS

X-LARGE UNITS

1N-2Y-3Y-4Y-5Y-6N

HB

1N-2Y-3Y-4N-5N-6N

0-l �FA

N CON

TACTOR B

FAN

S

0-l �FA

N CON

TACTOR B

1 N-23Y-45Y-6Y

H1 H2

H3 H4

H5 HB

1 N-234Y-5N-6N

POWER

SUPPLY: 208V/

1PH

CONDENSER FAN ARRANGEMENTS

G)

SMALL

FAN

S H1

H2 H3

H4 H5

HB

Ww

0-l �FAN

CON

TACTOR B

FANS

0-l �FAN

CON

TACTOR B

1N-2N-3N-4Y-5N-6N

HB

1N-2Y-

3Y-4Y-

5N-6N

FANS H1

H2 H3

H4 H5

# 6

0-l �FAN

CON

TACTOR B

FANS

1N-2Y-3Y-4Y-5Y-6Y

0-l �FAN

CONTA

CTOR BFANS

0-l �

FAN

CONTACTOR B

FAN

S

0-l �FA

N CON

TACTOR B

1 N-23Y-4N-5N-6N MEDIUM

H1 12

H3 H4

H5 HB

1 N-23Y-45Y-6N IW

wlQ)

w

LARGE

H1 H2

H3 #4

H5 HB

X-LARGE

1 N-23Y-456Y

SMALL UNITS = 1

FAN

FAN

S H1

H2 H3

H4 H5

HB MED UNITS =

1 OR 2

FANS LARGE UNITS =

4 FANS X-

LARGE UNITS = 6

FANS

REVISION HISTORY

NOTE: NOT ALL COMPONENTS ARE USED ON A SPECIFICAPPLICAT

ION. DELETION OR ADDITION OF COMPONENTS MUST MAINTAIN CIRCUIT INTEGRITY

AND PHASE BALA

NCE. PROTECTORS MAY

BE EITHER CIRCUIT BREAKER OR FUSES.

REVISION DESCRIPT

ION

REV BY

CHKD BY

H-DIAGRA

M MAJ

OR RE-

DESIGN. ADDED SHEET DWG H3 01 0445

FOR DET

AIL BLOCKS. RAM

WAYNE

APPR BY

CRAIG

0

MATERIAL-----Hu

ss

mn

nn®

F8 I MODEL BY / DWG BY-

RAM �

CHECKED BY-WAYNE

� APPROVED BY-

CRAIG REF-

SUPERSEDES DIA

GRAM -FAN CYWNG

208V/1 PH SUPPLY

�DATE DRAWN -I IMAYl6

SHEET I OF 1

� UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES.

� TOLERANCES ARE

f;f::\

r"i

THIRD i

DECIMALS .xx ±.03, .xxx ±.010 \ �p /

i.__

I ANGLE

1H81161001 I H

� 1

1 1

1 1

1 1

1 1

1 ANGLES ± 2·

'-V

--..i

PROJECTION

�


28

SMALL MEDIUM LARGE UNITS

FAN CONTA

CTOR FA

NS

FAN CONTA

CTOR

FAN

CONTACTOR

FAN CONTA

CTOR

FAN

CONTACTOR FANS

FANS

FANS

1N-2Y

#1

#2

1 N-2Y-3N-4N

1 N-2Y-3Y-4Y

FANS

#1 #2

#3 #4

REV

ECN

H ECN-

CAP-

0002691-A

DATE

X-LARGE UNITS

FAN CONT ACTORFANS

FAN CONT ACTOR

1N-2Y-3Y-4Y-5Y-6N

#6

1N-2Y-3Y-4N-5N-6N

FANS Jf

#2

#3 #4

#5 # 6

FAN CONTA

CTOR

1N-2N-3N-4Y-5N-6N

FAN CONT ACTOR

FANS

FAN

CONTACTOR

FANS

FAN

CONTACTOR

#1

1 N-23Y-45Y-6Y

#2 #3

#4

1 N-234Y-5N-6N

#5 #6

#5 #6

POWER

SUPPLY: 208V-

575V /3PH CONDENSER FAN ARRANGEMENTS

G)

SMALL

G)w

MEDIUM

FANS

#1 #2

#3 #4

#5 #6

FANS

#1 #2

#3 #4

#5 #6

IG)wlQ)

w1N-2Y-3Y-4Y-5N-6N

FAN CONT ACTORFANS

1N-2Y-3Y-4Y-5Y-6Y

FAN CONT ACTORFA

NS

NOTE: NOT ALL COMPONENTS ARE USED ON A SPECIFIC APPLICAT

ION. DELETION OR ADDITION OF COMPONENTS MUST MAINTAIN CIRCUIT INTEGRITY AND PHASE BALANCE.

FAN CONTACTOR

FANS #1

FAN CONTACTOR

FANS #1

PROTECTORS MAY BE EITHER CIRCUIT BREAKER OR FUSES.

REVISION

HISTORY

1 N-23Y-45Y-6N

#2 #3

#4 #5

#6

1 N-23Y-456Y

#2 #3

#4 #5

#6

LARGE

X-LARGE

SMALL UNITS = 1

FAN MED UNITS =

1 OR 2

FANS LARGE UNITS =

4 FANS X-

LARGE UNITS = 6

FANS

MATERIAL-----

Hus

sm

nnn

®� I M

OD

EL BY / DWG BY-

RAM

Dj REV

ISION DESCRIPTION REV

BY CHKD BY

APPR BY C

HECKED

BY-W

AYNE �

11MAY16 H-

DIAGRAM MAJOR RE-

DESIGN. ADDED SHEET DW

G #3010445 FOR DETAIL BLOCKS.

RAM WAYNE

CRAIG APPRO

VED BY-

CRAIG

REF-SU

PERSEDES

DIAGRAM -FA

N CYWNu

� DATE D

RAWN -

1 IMAYl6

SHEET I

OF 1

208!460!5

75V-3-60 SUPPLY

� U

NLESS OT

HERWISE SPEC

IFIED D

IMENSIO

NS ARE IN INCHES.

� TO

LERANCES ARE

r,:

t\ r"I

THIRD

i

DEC

IMALS .XX ±.0

3, .xxx ±.010

\ ��

J l.__

I ANGLE

1LJ81162001 I H

� ANGLES + 2

° '--

I./

--.i

PROJEC

TION

// /

�


PN 0708232_D 29

DIAG INSERT

COPELA

ND DISCUS , SEMI HERMITIC (COPELAMETIC), SCROLL

BITZER ECOLINE COMPRESSOR

BLOCK DESCRIPTION CO

PELAND SCRO

LL ZF/ZB**K5E

RE

FER

TO

TE

RM

INA

L B

OX

&

TE

RM

INA

L P

LATE

FO

R

MO

TOR

CO

NN

EC

TION

A-

CO

MP

RE

SS

OR

TER

MIN

AL W

IRIN

GB

-S

OLID

S

TATE

MO

DU

LE

WIR

ING

C-

TRAX

-O

IL W

IRIN

G

WITH NEW CO

RESENSE DIAG

NOSTICS

BAS

ED

O

N

MO

TOR

VO

LTAG

E.

y FOR

COPruND RECP, CO

MPRESSOR.

-

--

--

FOR IIIZER

-WITH

Ollf OI.CK

1 MOOUl£:

y NO VOLTAGE MUST COME IN CONTACT WITH TERMINALS

1, 2, 3, 4, 81, 82

�1

-8

BLOCK

8-

TOL.2

TERM

BLOCK

OL

208-230/24VTRANSFORMER

��

1�--+-B

BLOCK

R

��

�

�-

-(IF USED)

SCROLL COMPRESSOR 0MB (IF USED) ORl

UNIT COOLER FA

N CONNECTION

TO TR TERM

INAL BLOCK

COPELAND SCROLL

3-6 HP LIQUID INJECTION SOLE

NOID p

CURRENT SENSING RELAY

(WHEN REQ'D)

B

LIQUID INJECTOR

SOLEN

OID

COPELAND SCROLL

7 1/2 HP AND UP LIQUID INJECTION SOLE

NOID

W/0 PROJECTI

ON

W7 PROTECTION

INSERT NEUTRAL

WH

ITE WIRE

INTO NEUTRAL

LU

G ON BREAK

ER

p t8

LIQUID INJECTOR SOUENOID

IS

p

y

& �

�

D-

UN

IT C

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N

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NN

ECTIO

NE-

SC

RO

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UID

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JECTIO

NF-

HEA

T TAP

E W

IRIN

G

FAN/O

IL RELA

Y 208V

TO "M" ON

OIL FAIUJRE

OR

TO L1 SIDE OF

MOTOR COIIT

ACTOR

OR

R BL

2 OR MORE CON. FANS

�SINGLE CON. FAN

UNIT COOUER

p

� 1�

-0-1

FAN DELAY

T'STAT

CASES

UNIT COOLER

DC

t--¢Ej:--ffi I -

�HEA

TER SAFETY

FROM "I! " ON

PHASE MO

NITOR

TO L1 !ER

M. BLOCK

R B TO

L2 !ERM. BLOCK

---I 2

NO

TIME DELAY RELA

Y

AUXILIARY PRO

TECTOR

CONTROL BREA

KER

"t-1

-1

/ -

--

PDB c, �

�

PDB or

Terminal Blac

kl �

L!:!J..!!J T .......

Blackl

NOTES: c,.

nooded)

c,. nooded

)

SE-83

OR

G-

LIQU

ID

INJEC

TION

-

CO

PE

LAN

D

REC

IPH

-C

ON

DE

NS

ER

FAN

I-U

NIT

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-

FAN

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IT C

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TER

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TIME

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LAN

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SC

RO

LL Z

L/Z

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E

WITH

NE

W

CO

RE

SE

NS

E

DIAG

NO

STIC

S

N-

CO

ND

EN

SER

FAN

W

IRIN

GP

-EC

M

MO

TOR

W

IRIN

G

REFERANCE-EATON ADJU

STABLE TIME DELAY

ORANGE WIRE CONNECT TO BLUE WIRE FROM HIGH PRESSURE CONTROL OR IF OIL FA

ILURE CONTROL IS USED CUT INTO ORANGE WIRE FROM "M" CONNECTION. SSPC1, XPRT1 & CPC IPC JR RED WIRE CONNECT TO BLUE WIRE FROM HIGH PRESS. CTL.

TO L1<>---(CO

M)

EATO

N

TIMER

A 1 (L 1) C A2(L2)

15 18

J.. TIM

E D

ELAY

16 {NC) I

B1

ADJUSTABLE

REFERENCE HEAT RECLA

IM WIRING

B

l �B

�SHOWN

R M

C

S

24V YELLOW

PUMP

::

23

0V

RED SOLENOID

81�

-

t@/�

HEAT RECLA

IMSOLENOID

TO L2 LINE ON AUXILIARY PROTECTOR

NON SCROLL COMPRESSORS

STANDARD APPLICATION ORA

NGE WIRE TO LM TERMINAL BLOCK

SSPC1, XPRT1 & CPC IPC JR RED WIRE CONNECT TO MOTOR CONTACTOR

SCROLL COMPRESSORS STANDARD TIMER, SPPC1 XPRT1 AND CPC IPC JR

RED WIRE TO DISCHARGE T-STAT

OR IF NO T-STAT RUN RED WIRE

TO CONNECT WITH BROWN WIRE FROM TRAX

OIL

CONDENSER BREA

KER VOLTAGE PHASE TAPE OR CONDUCTOR COLOR

'\ FANS

#2 #3

#4 #5

#6

s1�f o;rfi

B r CONDENSER FAN

�-

--

--

--

-G RA

Y HEA

D COOLING FAN(WHEN REQ'D)

208V =

460V =

575

V =

L1 L2

L3

BLAC

K

RED

BLUE

BROW

N

ORAN

GE YELLO

W

RED

BLAC

K

BLUE

NOTES:

Liquid Injection Shut-O

ff (W

HEN USED)

BR

1 . Remove dem

and signal wire from term

inal "D" when E2 Controller is applied. (Dem

and Thru RS-485)

CONDENSER FAN W

IRING 17

7 7

7 :;I FROM

CONDENSER FAN

r , , , , 1 CONTACTOR �µ��µ� FAN

FAN

FA

N FA

N FA

N

FAN

*FO

R THIS APPLICATIO

N SIN

GLE CO

NDEN

SER FAN

REQUIRES

CON

TACTOR ALSO

.NO

TE: FO

R FAN CYCLE CO

NTR

OL SEE FA

N CYCLING

DRAWING

S #1H

81161001, #1 H

81162001, #1 H81163001

RELAY OR CONTR

COIL COIL IDENTIFICA

TION MC

= COMPRESSOR

FC = COND FAN

CH

= CRANKCAS

E HEATE

R r

R = HEA

T RECLAIM LOCKOUT

UCF = UNIT COOLE

R FANS

DC • DEFR

OST

DT

= DEFROST

THERMOST

AT R

= HEAT RECLA

IM LOCKOUT

CIRCUIT BREAK

ER SIZE (A)

15

MINIMUM WIRE SIZE

(AWG)

LEGEND: TE

RMINAL

o. BLO

CK FU

SE �

THERMAL

O'XrO

OV

ERLOAD

SPLICE •

WIRE CAP

� RELA

Y CONTACTS

0-;tfo

NORMAl.l.

Y CLOSED PRES

SURE °);-?

CONTR

OL CLO

SE ON RISE COMPRES

SOR MOTOR 0

CONTACTOR COIL

COMPRESSOR COOLING§

FAN MOTO

R

WIRE COLOR CODE R = RED

Y = YELLOW BL= BLUE

W = WHITE OR= ORANGE

BR= BROWN P = PURPLE

B = BLACK

NORMALl. Y CLOSED

�

CONTACTS

NORMALL

Y OPEN o-H-o

CONTACTS

POWER WIRING

--

CONTROL W

IRING -

-

BROKEN LINE INDICATE

S FIELD

INSTAUA

TION ----

0PRES

SURE T

CONTROL

OPEN ON RISE RELA

Y COIL 0

TERMINAL

BLOCK D

POW

ER DISTRIBUTION �

BLO

CK (PDB) L 1 L2

L3

FIELD WIRING --

-FACT

ORY WIRING -

-HOUSE WIRING -

HW -USE ON

LY W

HEN USING 4 OR

MORE ECM

FANS.

PK= PINK GR= G RA

Y FIELD OR HOUSE WIRING

ONLY USED ON

SINGLE POINT 208V POW

ER SUPPLY

OR 380V W

ITH 120V CONTROL


30

STARTUPWARNING

Know whether a circuit is open at the power supply or not. Remove all power before opening control panels. Note: Some equipment has more than one power supply.

Always use a pressure regulator with a nitrogen tank. Do not exceed 2 pounds of pressure and vent lines when brazing. Do not exceed 350 pounds of pressure for leak testing high side. Do not exceed 150 pounds of pressure for leak testing low side.

Always follow current EPA regulations and guidelines.

STARTUP

Leak Testing - Visually inspect all lines and joints for proper piping practices.Isolate - Compressors – Front Seat Service Valves on Suction and Discharge

Pressure Transducers - Close Angle Valves.

Open - Valves – to condenser, heat reclaim and receiver.

Liquid Line Solenoid Valve - Solenoid should be energized.

Disconnect - Defrost Time Clock – Disconnect power to the clock.

Verify - Refrigerant requirements for System, Compressors, and TEV’s in merchandisers and coolers.

Electrical supply and component requirements.

WARNINGAlways recapture test charge in approved

recovery vessel for recycling.

Oil LevelsCheck oil levels for the compressor: Compressor sight glass 1/8 to 1/2 full.

Note: Check the oil sticker on the condensing unit before adding oil.

Test ChargeUsing properly regulated dry nitrogen and R22 pressurize the system with vapor only. Add dry nitrogen to bring the system pressure up to 150 psig. Using an electronic leak detector inspect all connections. If a leak is found, isolate, repair, and retest. Be sure system is at 150 psig and all valves closed to isolate the leak are opened. After the last leak is repaired and retested, the system must stand unaltered for 12 hours with no pressure drop from 150 psig.

*Any H-Series Condensing Units selected with Bitzer Compressors will not have oil pre-charged or included as standard, but can be ordered as an option (ship loose).

Compressors with Pre-Charged Oil as Standard

H-Series Condensing UnitsKrack C Series Condensing Units

Compressors Shipped Dry

*H-Series Condensing Units with Bitzer Compressors


PN 0708232_D 31

EvacuationNitrogen and moisture will remain in the system unless proper evacuation procedures are followed. Nitrogen left in the system may cause head pressure problems. Moisture causes TEV ice blockage, wax build up, acid oil, and sludge formation.

Do not simply purge the system – this procedure is expensive, harmful to the environment, and may leave moisture and nitrogen behind.

Do not run the compressors to evacuate – this procedure introduces moisture into the compressor’s crankcase oil and does not produce adequate vacuum to remove moisture from the rest of the system at normal temperatures.

SetupUsing all copper lines and packless valves, connect an 8 CFM or larger vacuum pump to suction or liquid line. Connect one-micron vacuum gauge at the pump. Plan procedures so breaking the vacuum with refrigerant will not introduce contaminates into the system. The vacuum pump must be in good condition filled with fresh oil to achieve desired results.

ProcedurePull a vacuum to 1500 microns. If the vacuum fails to hold, determine the cause and correct. Begin again with the first of the three required evacuations.

Break the vacuum with refrigerant vapor to a pressure of about 2psig. Do not exceed the micron gauge transducer’s maximum pressure limit. Liquid refrigerant may cause damage to components through thermal shock or a pressure surge to the transducer of the micron gauge.

Repeat first two steps.

Install the suction and liquid drier cores, if applicable.

Pull a vacuum to 500 microns. Close vacuum header valves and allow system to stand for a minimum of 12 hours. If the 500-micron vacuum holds, charging may begin. If not the cause must be determined and corrected. Repeat the entire evacuation procedure from the first step.

WARNINGNever trap liquid refrigerant

between closed valves.A hydraulic explosion may result.

Pre-Charge Check ListWhile the system is being evacuated preparation for charging can begin. During any of the pull downs check:

Check controller Program if applicable.

Merchandisers Electrical requirements and power supply Electrical connections tight and clean Proper fan operation Thermostat setting.

Walk-in coolers and freezers Electrical requirements and power supply Electrical connections tight and clean Proper fan operation Thermostat setting.

Condensing Unit Electrical requirements and power supply Electrical connections tight and clean Proper fan operation Pressure settings Defrost settings Adjust head pressure valve


32

Air Cooled Condenser Electrical requirements and power supply Electrical connections tight and clean Proper fan operation Thermostat or pressure settings Damper operation, if equipped.

Water Cooled Condenser Flush water lines before connecting them to

water-cooled condenser.

Heat Reclaim and other systems Electrical requirements and power supply Electrical connections tight and clean Component operation.

Note: Remember to reinstate control to unit components jumpered to make test.

Set all mechanical pressure controls. Compressor should still be isolated from the rest of the system.

During the last evacuation look up and make a list of the required control settings for the system. High and low pressure, heat reclaim lockout, winter control settings, and other controls on the system should be noted.

ChargingUse standard procedures for charging while watching for possible problems. Check: Suction and discharge pressure Oil level Voltage differential and balance Ampere draw and balance

Shut down the unit at first indication of unusual operation, locate and correct cause.

Leak testing, evacuation and initial charging are now completed.

Note: With non-azeotropic refrigerants, it is best to charge the entire contents of the cylinder to prevent fractionalization of the refrigerant when charging vapor.

Winter ChargeWhen charging the condensing unit equipped with winter head pressure control valve, additional refrigerant is required for winter operation. [See Table Below]

Compressor Motor Rotation (Scroll)To check compressor rotation, use the following procedure:

Install gauges on suction and discharge side of compressor. A momentary compressor run should cause a drop in suction header and a rise in discharge header pressure.

With main disconnect OFF, switch OFF all breakers or fuses in the control panel.

Turn ON main disconnect.

Coil Kit Summer Charge (pounds) Winter Charge (pounds) A 1 6 B 3 13 C 3 13 D 4 17 E 6 26 F 8 34 J 13 56 K 7 30

*Charges Based on R407a


PN 0708232_D 33

Look for the light on the single phase protector. If it is not lit, turn OFF the main disconnect. Have the field connections to the main breaker of the unit corrected so the phase protector indicates phase alignment (The light is lit).

Turn ON the main disconnect.

Momentarily turn ON the compressor and verify correct pumping direction. If the compressor is rotating backwards, change two legs on the load side of the compressor contactor.

Note: DO NOT run compressors for more than 10 seconds during test.

Final ChecksOnce the system is up and running it is the responsibility of the installer to see that all the fine adjustments are made so the Condensing Unit delivers maximum temperature performance and efficiency for the customer. These include:

Defrost scheduling and timing Condenser controlsWinter controlsTEV superheat adjustmentHigh and low pressure controls Thermostat settingsAdjustments to electronic controlsInlet / Outlet water temperature (water cooled units only)

Thoroughly inspect all field piping while the equipment is running and add supports where line vibration occurs. Be sure additional supports do not conflict with pipe expansion and contraction.

When condition space is completely stocked, check the operation of the system again.

At 48 hours of operation replace the liquid drier and suction filter cores (if applicable).

At 90 days recheck the entire system, including all field wiring.


34

This Procedure is not designed to cover system changeover to a different refrigerant.

COMPRESSOR REPLACEMENT

Since each machine room tends to be unique, plan carefully as to how you will move the compressor without harming personnel, equipment or the building. Before beginning removal of old compressor make replacement unit ready to install:

Verify:Replacement compressor

Electrical requirementsRefrigerant applicationCapacityPiping hookup location and designSuction and discharge gasketsMounting requirements

Have compressor in an easily accessible position, uncrated and unbolted from shipping pallets.

Disconnect Electrical Supply:Turn off motor and control panel power supplies to the Condensing Unit.

Turn off control circuit and open all compressor circuit breakers or fuses.

Tag and remove electrical wires and conduit from the compressor.

Isolate Compressor:Front seat Suction and Discharge Service Valves. Close oil supply and equalizing lines.

Bleed compressor pressure through both discharge and suction access ports into an approved recovery vessel.

Remove externally mounted components which will be re-used on the replacement compressor.

Plug holes to compressor manufacturer’s specifications.

Remove bolts from suction and discharge service valves.

Remove mounting bolts.

When moving the compressor, use a come-along, hoist or hydraulic lift to carry the weight.

Do not use the piping or panel to support a hoist or come-along.

Do not use ceiling trusses to support a hoist or come-along.

The rear support channel on the rack or a properly constructed ceiling rail may be used to support a hoist or come-along.

To make hookup and lifting easier, an eyebolt may be installed in the rear top of the compressor head.

If a compressor removal table is used, slide the compressor fully on to the table, then roll table to overhead hoist or hydraulic lift area.

When the old compressor has been removed, clean the suction and discharge service valve gasket surfaces to shiny metal. Clean the gasket surfaces on the new compressor to shiny metal. Be careful not to groove or round the surfaces. Gasket surfaces must be clean to prevent leaking.

Install the new compressor in reverse order of removal. Do not open the new compressor to the system until after it has been leak tested and triple evacuated.

REPLACING DRIER AND FILTER CORES

Shut down the system. Isolate the core to be replaced and bleed off pressure into an approved recovery vessel. Open housing, replace core and close up. Pressurize, leak test and bring back into line.


PN 0708232_D 35

APPENDIX A – DIMENSION DRAWINGS


36

AIR COOLED / WATER COOLED CONDENSING UNITS

0712528B

DRAW

ING -

SM

ALL ID

STD L

EGS

LEFT S

IDE V

IEW

FRONT V

IEW

RIG

HT S

IDE V

IEW

TOP V

IEW

ISO V

IEW

CONTROL P

ANEL

BASE A

SSEMBLY

SMALL S

IZE

INDOOR U

NIT

STANDARD LE

GS

"HNSx-

xxxxxxx-xx-

A"

CONDENSER

32.057

28.000

MOUNTIN

G

DIM

ENSIO

NS

40.250

MOUNTIN

G

DIM

ENSIO

NS

41.7

50

32.000

24.424


PN 0708232_D 37

0712529B

DRAW

ING -

SM

ALL

OD S

TD L

EGS

LEFT S

IDE V

IEW

FRONT V

IEW

RIG

HT S

IDE V

IEW

TOP V

IEW

ISO V

IEW

CONTROL P

ANEL C

OVER

BASE A

SSEMBLY

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38

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DRAW

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PN 0708232_D 39

0712531B

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MEDIU

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40

0712532B

DRAW

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PN 0708232_D 41

0712533B

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42

0712534B

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PN 0708232_D 43

0712535B

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44

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PN 0708232_D 45

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PN 0708232_D 47

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PN 0708232_D 49

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PN 0708232_D 51

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52

SERVICE

TROUBLE SHOOTING INFORMATION

SPORLAN http://www.sporlanonline.com

EMERSON Fault Finder app http://www.emersonclimate.com/en-us/Resources/Mobile_Apps/Pages/mobileapps.aspx

SQUARED HOTLINE 888-SQUARED (888-778-2733) Tech Support Line. Level One provides product initial Tech Support and can connect the Caller to Level 2, if required.


PN 0708232_D 53

U.S. & Canada 1-800-922-1919 • Mexico 01-800-890-2900 • WWW.HUSSMANN.COM

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To obtain warranty information or other support, contact your

Hussmann representative.Please include the model and serial number of the product.

Hussmann Corporation, Corporate Headquarters: Bridgeton, Missouri, U.S.A. 63044-2483 01 October 2012

Condensing Unit - Hussmann...Hard mounting is standard on all units. All piping was carefully design...

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Transcript of Condensing Unit - Hussmann...Hard mounting is standard on all units. All piping was carefully design...