FL AC Scroll
Refrigeration Systems
Part No. 25006901
H-IM-FL1A
December, 2004
Table of Contents
Installation and
Operation Manual
General Safety Information ...................................................... 2
Inspection................................................................................. 2
Warranty Statement.................................................................. 2
Air Cooled Condensing Unit and Condenser Space and Location
Requirements .................................................................. 3
Condensing Unit Rigging and Mounting................................... 4
Ambient Fan Cycle Control ...................................................... 4
Condensing Unit Accessories .................................................. 5
Suction Filters, Driers, Sight Glasses....................................... 5
Refrigerant Oils ........................................................................ 6
Phase Loss Monitor.................................................................. 7
Recommended Refrigerant Piping Practices ........................... 7
Refrigeration Pipe Supports .................................................... 7
Suction Lines............................................................................ 8
Suction Line Risers .................................................................. 8
Liquid Lines .............................................................................. 8
Evacuation and Leak Detection...............................................11
Refrigerant Charging Instructions........................................... 12
Field Wiring............................................................................. 12
Check Out and Start Up ......................................................... 12
Operational Check Out........................................................... 13
System Balancing - Compressor Superheat .......................... 13
System Troubleshooting Guide .............................................. 14
Preventive Maintenance Guidelines....................................... 15
Replacement Parts................................................................. 15
Wiring Diagrams................................................................ 16-18
Submittal .......................................................................... 19, 20
Service Record....................................................................... 21
Space and Location Requirements for
Air Cooled Condensing Units and Remote Condensers
Another consideration which must be taken is that the unit should
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.
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 and Remote Condensers
Multiple Units
Walls or Obstructions
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.
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.
Units in Pits
Decorative Fences
The top of the unit should be level with the top of the pit,
and side distance increased to “2W”.
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”.
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.
* “W” = Total width of the condensing unit or condenser.
3
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.
Figure 2. Solid Mount for Mobile or Deep
Sump Application.
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.
Ambient Fan Cycle Control
Roof Mounting
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 90˚F.
Table 2 on page 5 lists approximate settings for several system
T.D.ʼs. These settings are approximate as they do not take into
account variations in load.
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.
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
Spring Mounted Compressor
condenser motor nearest the inlet
header should remain on whenever the
compressor is operating.
Compressors are secured rigidly to make sure there is no transit
damage. Before operating the unit, it is necessary to follow
these steps:
a.
b.
c.
Remove the upper nuts and washers.
Discard the shipping spacers.
Install the neoprene spacers. (Spacers located
in the electrical panel or tied to compressor.)
Replace the upper mounting nuts and washers.
Allow 1/16 inch space between the mounting nut/
washer and the neoprene spacer.
d.
e.
Rigid Mounted Compressor
Some products use rigid mounted compressors. Check the
compressor mounting bolts to insure they have not vibrated
loose during shipment.
4
Condensing Unit Accessories
Suction Filters, Driers, Sight Glasses
There are two types of suction and liquid filter/driers used
on Heatcraft Refrigeration Products units. Replaceable core
and/or sealed units are used, dependent upon the option
package ordered.
stream of the liquid line solenoid valve (if supplied). Liquid line
driers may or may not have an access valve, dependent on the
size and application. The basic servicing of these units is similar
to suction filters. Liquid line driers should be replaced whenever
there is evidence of excessive pressure drop across the filter,
or the system becomes contaminated due to system leaks,
compressor burnouts, acid formation, or moisture accumulation
as indicated by the liquid line sight glass.
Suction filters, regardless of type, are always installed
upstream of the compressor suction service valve, and
any accumulators or other options that may be installed.
Suction filters are equipped with “Schrader” type access
valves to allow field measurement of pressure drop across
the device. This allows plugged filters and elements to be
identified very quickly and easily so they can be replaced
when the pressure drop is excessive. Refer to the specific
manufacturersʼ recommendation on servicing these units by
make and model.
The sight glass is installed in the main liquid line assembly,
downstream from the receiver outlet service valve, and
immediately after the liquid line drier. The sight glass is
designed to give a visual indication of moisture content in the
system. Generally, it requires no field service. However, in
cases of extreme acid formation in a system after a compressor
burnout, the acid may damage the sensing element or etch the
glass. This would require that the sight glass be replaced, along
with the liquid line drier after any compressor motor burnout.
Liquid filter/driers, regardless of type, are always installed
downstream of the receiver outlet service valve, and up-
Table 1. Recommended Low Pressure Control Settings for Outdoor Air Cooled Condensing Units
R-22
R-404A/R-507
Cut-In Cut-Out
R-134a
Cut-Out
*Minimum
Cut-In
PSI
70
Cut-Out
Cut-In
PSI
45
Temp. ˚F
50
PSI
20
20
20
10
0
PSI
90
70
55
45
25
20
12
8
PSI
35
35
35
25
7
PSI
15
10
10
0
40
55
35
30
40
25
10
30
13
0
15
8
0
-10
-20
-30
15
0
1
---
---
---
---
10
0
1
---
6
0
1"Hg.
---
* Minimum ambient or box temperature anticipated, Hi pressure control setting: R-22, 360 PSI; R-404A, R-507, 400 PSI; R-134a, 225 PSI.
Table 2. Thermostat Settings
Design
Thermostat Settings
T2
Models
T.D.
30
25
20
15
30
25
20
15
30
25
20
15
T1
60
65
70
75
60
65
70
75
60
65
70
75
T3
2-fan units:
4-fan units:
3-fan units:
6-fan units:
8-fan units:
40
55
60
65
50
55
65
70
30
40
50
60
NOTE: Cycle pairs of fans on double wide units.
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 +10°F SST must have air flowing
over the compressor at all times when the compressor is
running.
5
Refrigeration Oils*
Color
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 CFC-12, HCFC-22 or
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
lubricantʼ s protective additive.
Oil Level
R502. This “backward compatibility” has been achieved with the During Copelandʼ s testing of Polyol ester oil, it was found that
introduction of the Polyol ester lubricants.
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.
Table 3 below summarizes which oils/lubricants are approved
for use in Copeland compressors:
A crankcase heater is required with condensing units and it
must be turned on several hours before start-up.
Polyol Ester Lubricants
Oil level must not exceed 1/4 sight glass.
Hygroscopicity
Ester lubricants (POE) have the characteristic of quickly
absorbing moisture from the ambient surroundings. This is
shown graphically in Figure 3 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
AVOIDED!
Figure 3.
Mineral Oil
Table 3. Refrigeration Oils
Interims
Traditional Refrigerants R401A, R401B, R402A
HFCʼs
HFC-134a,
R404A, R507
Refrigeration Oils
Mobil EAL ARCTIC 22 CC
ICI (Virginia KMP) EMKARATE RL 32CF
Suniso 3GS
HCFC-22
A
(MP-39, MP-66, HP-80)
A
POEʼs
P
P
A
A
P
P
P
PM
PM
PM
Mineral
Oils
Texaco WF32
NOT
ACCEPTABLE
Calumet RO15 (Witco)
Sontex 200-LT (White Oil)
Witco LP-200
(BR & Scroll Only)
P
A/B
Zerol 200TD
Soltex Type AB-200
AM
PM
PM
NOT
ACCEPTABLE
P = Preferred Lubricant Choice A = Acceptable Alternative M = Mixture of Mineral Oil and Alkyl Benzene (AB) with minimum 50% AB.
* (Reprinted with permission from Copeland)
Mineral Oils
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. These lubricants are compatible with one another
and can be mixed.
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 200TD
is permissible, as long as at least 50% of the total oil charge
remains Sontex 200.
Alkyl Benzenes
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.
Zerol 200TD 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-401A, R-401B
and R-402A (MP39, MP66 and HP80). A minimum of 50% AB is
required in these mixtures to assure proper oil return.
Polyol Ester Lubricants
The Mobil EALARCTIC 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
isnotavailable.ThesePOEʼsmustbeusedifHFCrefrigerantsare
used in the system. They are also acceptable for use with any
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.
6
Phase Loss Monitor
Refrigerant Pipe Support
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.
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.
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:
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.
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.
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. Observe motors for correct rotation.
Recommended Refrigerant Piping Practices
4. Do not use short radius ells. Short radius elbows have
points of excessive stress concentration and are subject
to breakage at these points.
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.
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.
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 interconnecting pipe size is not necessarily the same size
as the stub-out on the condensing unit or the evaporator.
Figure 4. Example of Pipe Support
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 5. Condensing Unit / Compressor to Wall Support.
(d) Suitable P-type oil traps should be located at the base of
each suction riser of four (4) feet or more 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) If isolation valves are installed at the evaporator, full port
ball valves should be used.
7
Suction Lines
Suction Line Risers
NOTE: If the suction line must rise to a point
higher than the suction connection on the
evaporator, a suction line trap at the outlet
of the evaporator must be provided.
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 6 below for methods of
constructing proper suction line P-traps.
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 11 for more
information.
Figure 6. Su
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.
8
Table 4. Pressure Loss of Liquid Refrigerants in Liquid Line Risers
(Expressed in Pressure Drop, PSIG, and Subcooling Loss, ˚F).
Liquid Line Rise in Feet
10ʼ
15ʼ
PSIG
7.3
20ʼ
PSIG
9.7
25ʼ
30ʼ
40ʼ
50ʼ
75ʼ
100ʼ
Refrigerant PSIG
˚F
˚F
˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F
3.1 12.1 3.8 14.5 4.7 19.4 6.2 24.2 8.0 36.3 12.1 48.4 16.5
4.1 12.3 5.2 14.7 6.3 19.7 8.8 24.6 11.0 36.8 17.0 49.1 23.7
2.1 10.2 2.7 12.2 3.3 16.3 4.1 20.4 5.6 30.6 8.3 40.8 11.8
R22
R134a
4.8
4.9
4.1
1.6
2.0
1.1
2.3
2.9
1.6
7.4
9.8
R507, R404A
6.1
8.2
Based on 110˚F liquid temperature at bottom of riser.
Table 5. Equivalent Feet of Pipe Due to Valve and Fitting Friction
Copper Tuber, O.D., Type “L”
1/2
14
7
5/8
16
9
7/8
22
12
5
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)
28
36
18
8
42
21
9
57
28
12
69
34
14
83
42
17
99
49
20
118
57
138
70
168
83
Angle Valve (Open)
15
90˚ Turn Through Tee
Tee (Straight Through)
or Sweep Below
3
4
6
22
28
34
.75
1
1
2
1.5
2
2
3
2.5
4
3
4
3.5
5
4
7
5
8
6
7
9
11
16
90˚ Elbow or Reducing
Tee (Straight Through)
10
12
14
9
Table 6. Weight of Refrigerants in Copper Lines During Operation
(Pounds per 100 lineal feet of type “L” tubing).
Line Size
O.D.
Suction Line at Suction Temperature
Liquid
Line
4.0
Hot Gas
Line
.15
in Inches
Refrigerant
134a
-40˚F
.01
-20˚F
.01
0˚F
.02
+20˚F
.04
+40˚F
.06
3/8
1/2
22
3.9
.22
.02
.03
.04
.06
.08
R507, 404A
134a
3.4
.31
.03
.04
.06
.09
.13
7.4
.30
.01
.03
.04
.07
.11
22
7.4
.41
.03
.05
.07
.11
.15
R507, 404A
134a
6.4
.58
.04
.07
.13
.16
.24
11.9
11.8
10.3
24.7
24.4
21.2
42.2
41.6
36.1
64.2
63.5
55.0
90.9
90.0
78.0
158
156
134
244
241
209
348
344
298
471
465
403
612
605
526
.47
.02
.05
.07
.12
.17
5/8
22
.65
.05
.08
.12
.17
.25
R507, 404A
134a
.93
.07
.11
.17
.25
.35
.99
.05
.10
.15
.24
.36
7/8
22
1.35
1.92
1.70
2.30
3.27
2.57
3.50
4.98
3.65
4.96
7.07
6.34
8.61
12.25
9.78
13.70
18.92
13.97
18.95
27.05
18.90
25.60
36.50
24.56
33.40
47.57
.10
.16
.24
.36
.51
R507, 404A
134a
.15
.23
.37
.51
.72
.08
.17
.26
.41
.60
1 1/8
1 3/8
1 5/8
2 1/8
2 5/8
3 1/8
3 5/8
4 1/8
22
.17
.28
.42
.61
.87
R507, 404A
134a
.26
.39
.63
.86
1.24
1.91
1.33
1.87
1.30
1.88
2.64
2.24
3.26
4.58
3.47
5.03
7.07
4.96
7.18
9.95
6.69
9.74
13.67
8.75
12.70
17.80
.14
.26
.40
.61
22
.27
.42
.64
.93
R507, 404A
134a
.40
.58
.95
1.32
.87
.20
.37
.57
22
.37
.59
.90
1.33
1.86
1.51
2.30
3.23
2.32
3.54
5.00
3.31
5.05
7.14
4.48
6.83
19.65
5.84
8.90
12.58
R507, 404A
134a
.56
.82
1.35
.98
.34
.64
22
.65
1.03
1.43
.99
1.57
2.35
1.51
2.42
3.62
2.16
3.45
5.17
2.92
4.67
6.97
3.81
6.08
9.09
R507, 404A
134a
.98
.52
22
1.01
1.51
.75
1.59
2.21
1.41
2.28
3.15
1.91
3.08
4.25
2.49
4.01
5.55
R507, 404A
134a
22
1.44
2.16
.99
R507, 404A
134a
22
1.94
2.92
1.29
2.53
3.80
R507, 404A
134a
22
R507, 404A
10
Evacuation and Leak Detection
Evacuation
CAUTION: Do not use the refrigeration compressor
to evacuate the system. Do not start the
compressor while it is in a vacuum.
Due to the smaller molecule size of HFCʼs, they will tend to
leak more readily than CFCʼs. Consequently, it is of the utmost
importance that proper system evacuation and leak detection
procedures be employed.
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.
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.
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.
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
HFCʼs.
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.
Electronic leak detectors are now available that will sense
HFCʼs. This is considered preferable since it removes the
possibility of chlorine remaining in the system after leak testing
with HCFCʼs and/or CFCʼs. 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.
NOTE: Refrigerant used during evacuation cannot
be vented. Reclaim all used refrigerant.
EPA regulations are constantly being
updated to ensure your procedure follows
correct regulations.
WARNING: HFC-134a has been shown to be combus-
tible at pressure as low as 5.5 psig (at
350˚F) when mixed with air at concen
trations 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.
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.
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 light “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 should be insulated with 3/4" wall Armstrong
“Armaflex” or equal. Liquid lines should be insulated with 1/2
inch wall insulation or better. The insulation located in outdoor
environments should be protected from UV exposure to prevent
deterioration of insulating value.
11
Refrigerant Charging Instructions
Check Out and Start Up
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.
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.
2. When initially charging a system that is in a vacuum, liquid
refrigerant can be added directly into the receiver tank.
(b) Check high and low pressure controls, pressure
regulating valves, oil pressure safety controls, and all
other safety controls, and adjust if necessary.
3. Check serial data tag attached to the unit for refrigerant
capacity. System refrigerant capacity is 90% of receiver
capacity. Do not add more refrigerant than the data tag
indicates. Weigh the refrigerant drum before charging so
an accurate record can be kept of the weight of refrigerant
put in the system.
(c) Check the room thermostat for normal operation
and adjust.
(d) Wiring diagrams, instruction bulletins, etc. attached
to the condensing units should be read and filed for
future reference.
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.
(e) All fan motors on air cooled condensers, evaporators,
etc. should be checked for proper rotation. Fan motor
mounts should be carefully checked for tightness and
proper alignment.
(f) Electric and hot gas evaporator fan motors should be
temporarily wired for continuous operation until the room
temperature has stabilized.
Field Wiring
WARNING: All wiring must be done in accordance with
applicable codes and local ordinances.
(g) 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.
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 profes-
sional 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.
(h) 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.
1.The nameplate on the unit is marked with the electrical
characteristic for wiring the unit.
(i) 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 at the
center of the sight glass.
2.Consult the wiring diagram in the unit cooler and in the
condensing unit for proper connections.
CAUTION: 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.
3.For air cooled condensers, due to multiple low amp motors,
we recommend using time delay fuse protection instead of
circuit breakers.
WARNING: Scroll compressor is directional dependent.
If noisy, change phase of input wiring.
12
Operational Check Out
System Balancing - Compressor Superheat
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:
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.
(a) Check compressor discharge and suction pressures.
If not within system design limits, determine why and
take corrective action.
Suction superheat should be checked at the compressor
as follows:
(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.
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.
(c) 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.
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.
(d) 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.
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. Heatcraft Refrigeration Products
recommends that the superheat at the compressor be
between 30˚F and 45˚F.
(e) The maximum approved settings for high pressure
controls on Heatcraft air cooled condensing equipment
is 400 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.
If adjustments to the suction superheat need to be made,
the expansion valve at the evaporator should be adjusted.
(f) Check winter head pressure controls for pressure
setting.
(g) Check crankcase heater operation if used.
(h) Install instruction card and control system diagram for
use of building manager or owner.
NOTE: All adjustable controls and valves must be field
adjusted to meet desired operation. There are no
factory preset controls or valve adjustments.
13
Table 7. System Troubleshooting Chart
PROBLEM
Compressor will not run
POSSIBLE CAUSES
1. Main switch open.
2. Fuse blown.
POSSIBLE CORRECTIVE STEPS
1. Close switch.
2. Check electrical circuits and motor winding
for shorts or grounds. Investigate for possible
overloading. Replace fuse after fault is corrected.
3. Overloads are automatically reset. Check
unit closely when unit comes back on line.
4. Repair or replace.
3. Thermal overloads tripped.
4. Defective contactor or coil.
5. System shut down by safety devices.
5. Determine type and cause of shutdown and
correct it before resetting safety switch.
6. None. Wait until calls for cooling.
7. Repair or replace coil.
6. No cooling required.
7. Liquid line solenoid will not open.
8. Motor electrical trouble.
8. Check motor for open windings, short circuit
or burn out.
9. Loose wiring.
9. Check all wire junctions. Tighten all
terminal screws.
10. Refer to page 18.
10. Phase loss monitor inoperative.
Compressor noisy or vibrating
High discharge pressure
1. Flooding of refrigerant into crankcase.
2. Improper piping support on suction or
liquid line.
1. Check setting of expansion valves.
2. Relocate, add or remove hangers.
3. Worn compressor.
4. Scroll compressor rotation reversed.
3. Replace.
4. Rewire for phase change.
1. Non-condensables in system.
2. System overcharges with refrigerant.
3. Discharge shutoff valve partially closed.
4. Fan not running.
1. Remove the non-condensables.
2. Remove excess.
3. Open valve.
4. Check electrical circuit.
5. Adjust.
6. Clean.
5. Head pressure control setting.
6. Dirty condenser coil.
Low discharge pressure
1. Faulty condenser temperature regulation.
2. Suction shutoff valve partially closed.
3. Insufficient refrigerant in system.
4. Low suction pressure.
1. Check condenser control operation.
2. Open valve.
3. Check for leaks. Repair and add charge.
4. See corrective steps for low suction
pressure.
5. Variable head pressure valve.
5. Check valve setting.
High suction pressure
Low suction pressure
1. Excessive load.
2. Expansion valve overfeeding.
1. Reduce load or add additional equipment.
2. Check remote bulb. Regulate superheat.
1. Lack of refrigerant.
2. Evaporator dirty or iced.
1. Check for leaks. Repair and add charge.
2. Clean.
3. Clogged liquid line filter drier.
4. Clogged suction line or compressor
suction gas strainers.
3. Replace cartridge (s).
4. Clean strainers.
5. Expansion valve malfunctioning.
6. Condensing temperature too low.
5. Check and reset for proper superheat.
6. Check means for regulating condensing
temperature.
7. Improper TXV.
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.
4. Worn oil pump.
3. Replace.
4. Replace.
5. Reverse direction of compressor rotation.
5. Oil pump reversing gear stuck in wrong
position.
6. Worn bearings.
6. Replace compressor.
7. Add oil and/or through defrost.
8. Check and tighten system.
9. Replace gasket.
7. Low oil level.
8. Loose fitting on oil lines.
9. Pump housing gasket leaks.
Compressor loses oil
1. Lack of refrigerant.
1. Check for leaks and repair. Add refrigerant.
2. Replace compressor.
2. Excessive compression ring blowby.
3. Refrigerant flood back.
4. Improper piping or traps.
3. Maintain proper superheat at compressor.
4. Correct piping.
Compressor thermal protector
switch open.
1. Operating beyond design conditions.
1. Add facilities so that conditions are within
allowable limits.
2. Open valve.
2. Discharge valve partially shut.
3. Blown valve plate gasket.
4. Dirty condenser coil.
3. Replace gasket.
4. Clean coil.
5. Reduce charge.
5. Overcharged system.
14
Preventive Maintenance
Air Cooled Condensing Units
Quarterly
• Clean electrical cabinet. Look for signs of moisture, dirt,
debris, insects and wildlife. Take corrective action as
required.
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.
• Verify operation of crankcase heater by measuring amp
draw.
6) Check refrigeration cycle
• 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.
• 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.
• Check moisture indicator/sightglass for flash gas. If found
check entire system for refrigerant leaks and add refrigerant
as needed after repairing any leaks.
• Verify that superheat at the compressor conforms to
specification. (30°F to 45°F)
• Check compressor sightglass (if equipped) for proper oil level.
• Check pressure and safety control settings and verify
proper operation.
• Check condition of condenser. Look for accumulation of dirt
and debris (clean as required).
Annually
• Check for unusual noise or vibration. Take corrective action
as required.
7) In addition to quarterly and semiannual maintenance checks,
submit an oil sample for analysis
• Inspect wiring for signs of wear or discoloration and repair
if needed.
• Look for high concentrations of acid or moisture. Change oil
and driers until test results read normal.
• Check and tighten all flare connections.
• 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 super-
heat as a possible source.
Semi-Annually
2) Repeat all quarterly inspection items.
3)Clean condenser coil and blades
• 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.
Replacement Parts
Whenever possible, replacement parts are to be obtained
from a local wholesaler authorized to sell one of Heatcraft
Refrigeration Productsʼ brands. 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
supplierʼ s original invoice is not provided with a claim.
You may obtain information regarding local authorized
wholesalers by calling the Heatcraft Refrigeration Products
Replacement Parts Center at 1-800-686-7278 between the
hours of 7:30 AM to 4:30 PM Central Time.
• 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.
15
Wiring Diagram for BACU51D2CHPQ
MINIMUM WIRE #18 AWG UNLESS OTHERWISE SPECIFIED.
USE COPPER CONDUCTORS ONLY.
DISCONNECT BY OTHERS.
PLM
208V/3ÿ/60HZ
POWER SUPPLY
L1 L2 L3
L1 L2 L3
14 AWG
#
F1
TRANSFORMER
14 AWG
#
15 A
GND
W
TO
B
SHEET 2
208V
120V
6 AWG
6 AWG
#
#
4 AWG
4 AWG
#
#
CB5
CB6
15 A
15 A
14 AWG
14 AWG
14 AWG
14 AWG
14 AWG
14 AWG
#
#
#
#
#
#
CB1
CB2
CB3
CB4
70 A
90 A
80 A
80 A
C5
C9
C12
25
C6
C7
C8
C10
25 A
C11
25 A
25 A
25 A
25 A
25 A
25 A
A
8 AWG
6 AWG
6 AWG
6 AWG
#
#
#
#
C4
60 A
C1
50 A
C2
75 A
C3
60 A
M1
M3
M5
M7
M2
M4
M6
M8
COMPRESSOR 1
ZR12
COMPRESSOR 2
ZR19
COMPRESSOR 3
ZR16
COMPRESSOR 4
ZR16
ALL COMPRESSORS THERMALLY PROTECTED
SEE COMPRESSOR ELECTRIC BOX
LEGEND
COVERS FOR PROPER CONNECTION
M1-M8 --- CONDENSER FANS(TP)
PLM ----- PHASE LINE MONITOR
PDS ----- PUMPDOWN SWITCH
R1-R4 --- RELAYS
C1-C4 --- COMPRESSOR CONTACTORS
C5-C12 -- CONDENSER FAN CONTACTORS
C1A1-C4A1--- C1 - C4 AUXILIARY CONTACTS
CCH ----- CRANKCASE HEATERS
ELECTRICAL
ENTRANCE
SSM1-4 -- SOLID STATE MODULE
CB1-CB7 - CIRCUIT BREAKERS
w/ 30 MIN TIME DELAY
M8
M7
M6
M5
M4
M3
M2
M1
F1 ------ FUSE (CLASS CC)
SW ------ TOGGLE SWITCHES
TD1-TD4 --- STAGE START TIMER
TD7-8 --- START TIMER
FCT ----- FAN CYCLE TEMP CONTROL
HPS ----- HIGH PRESSURE SWITCH
LSV ----- LIQUID LINE SOLENOID VALVE
LPS ----- LOW PRESSURE SWITCH
COMP-4
COMP-3
COMP-2
COMP-1
BACU51D2CHPQ
FAN ARRANGEMENT
FACTORY WIRING
FIELD WIRING
16
Wiring Diagram for BACU59D2CHPQ
MINIMUM WIRE #18 AWG UNLESS OTHERWISE SPECIFIED.
USE COPPER CONDUCTORS ONLY.
DISCONNECT BY OTHERS.
PLM
208V/3ÿ/60HZ
POWER SUPPLY
L1 L2 L3
L1 L2 L3
14 AWG
#
F1
TRANSFORMER
14 AWG
#
15 A
GND
W
TO
B
SHEET 2
208V
120V
4 AWG
4 AWG
#
#
4 AWG
4 AWG
#
#
CB5
CB6
15 A
15 A
14 AWG
14 AWG
14 AWG
14 AWG
14 AWG
14 AWG
#
#
#
#
#
#
CB1
CB2
CB3
CB4
90 A
70 A
90 A
90 A
C5
C9
C6
C7
C8
C10
25 A
C11
C12
25 A
25 A
25 A
25 A
25 A
25 A
25 A
8 AWG
6 AWG
6 AWG
6 AWG
#
#
#
#
C4
75 A
C1
50 A
C2
75 A
C3
75 A
M1
M3
M5
M7
M2
M4
M6
M8
COMPRESSOR 1
ZR12
COMPRESSOR 2
ZR19
COMPRESSOR 3
ZR19
COMPRESSOR 4
ZR19
ALL COMPRESSORS THERMALLY PROTECTED
SEE COMPRESSOR ELECTRIC BOX
LEGEND
COVERS FOR PROPER CONNECTION
M1-M8 --- CONDENSER FANS(TP)
PLM ----- PHASE LINE MONITOR
PDS ----- PUMPDOWN SWITCH
R1-R4 --- RELAYS
C1-C4 --- COMPRESSOR CONTACTORS
C5-C12 -- CONDENSER FAN CONTACTORS
C1A1-C4A1--- C1 - C4 AUXILIARY CONTACTS
CCH ----- CRANKCASE HEATERS
ELECTRICAL
ENTRANCE
SSM1-4 -- SOLID STATE MODULE
CB1-CB7 - CIRCUIT BREAKERS
w/ 30 MIN TIME DELAY
M8
M7
M6
M5
M4
M3
M2
M1
F1 ------ FUSE (CLASS CC)
SW ------ TOGGLE SWITCHES
TD1-TD4 --- STAGE START TIMER
TD7-8 --- START TIMER
FCT ----- FAN CYCLE TEMP CONTROL
HPS ----- HIGH PRESSURE SWITCH
LSV ----- LIQUID LINE SOLENOID VALVE
LPS ----- LOW PRESSURE SWITCH
COMP-4
COMP-3
COMP-2
2
BACU59D2CHPQ
FAN ARRANGEMENT
COMP-1
FACTORY WIRING
FIELD WIRING
17
Control Circuit Wiring Diagram for BACU51 and BACU59
18
Submittal
19
Submittal
20
Service Record
A permanent data sheet should be prepared on each If another firm is to handle service and maintenance, additional
refrigerationsystemataninstallation,withacopyfortheowner copies should be prepared as necessary.
and the original for the installing contractorʼ s files.
System Reference Data
The following information should be filled out and signed by Refrigeration Installation Contractor at time of start-up.
Date System Installed:
Installer and Address:
_____________________________________________________
_____________________________________________________
_____________________________________________________
_____________________________________________________
Condensing Unit
Unit Model#:
________________________________________
Unit Serial #: ________________________________________
____________________ Compressor Model #: _________________
____________________ Compressor Serial #: __________________
_________________ Volts __________________ Phase _______
Compressor Model #:
Compressor Serial #:
Electrical
Voltage at Compressor
Amperage at Compressor
L1__________ L2 ___________
L1__________ L2 ___________
L3 ___________
L3 ___________
21
Notes
22
Notes
23
Since product improvement is a continuing effort,
we reserve the right to make changes in specifications without notice.
Visit us online at www.heatcraftrpd.com.
HEATCRAFT REFRIGERATION PRODUCTS LLC
2175 WEST PARK PLACE BOULEVARD • STONE MOUNTAIN, GA 30087 USA
770-465-5600 • FAX: 770-465-5990 WWW.HEATCRAFTRPD.COM
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