Heatcraft Refrigeration Products Air Compressor H IM 72A User Manual

Parallel

Compressor

Systems

Installation

Part No. 25000102

H-IM-72B

October 1999

Replaces H-IM-72A

Installation, Operation and

Maintenance Guide

Parallel Compressor Systems

HEATCRAFT INC. REFRIGERATION PRODUCTS DIVISION

2175 W EST P ARK P LACE B LVD ., S TONE M OUNTAIN , GA 30087 • 770-465-5600 • F AX 770-465-6016

WWW.HEATCRAFTRPD.COM • E-MAIL: HRPD.FEEDBACK@HEATCRAFT.COM

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Model definition:

HEATCRAFT INC.

1st digit - Brand (B, C, H, or L)

Parallel Compressor Units

2nd digit - Compressor Type

H - Hermetic

INTRODUCTION

R - Reciprocating

S - Screw

O - Open

Z - Scroll

C - Compound

Parallel Compressor systems are central refrigeration units

employing 2 to 8 parallel piped compressors, a control

panel, and receiver mounted on one common base frame.

The system may be designed for either Indoor or Outdoor

use. The Outdoor design may include the condenser

mounted and piped.

3rd digit - Unit Construction

R - Remote Condenser

The selection and design of the system is based on the

needs of the individual customer. The most important point

in planning an installation of the Heatcraft parallel system is

the proper selection of the system components for the

particular application.

U - Attached Condenser

H - Hybrid

M - Multi-compressor Platform

F - Frame Hybrid (Frame + Standard Unit)

4th digit - Compressor Quantity

2 - 2 compressor

3 - 3 compressor

4 - 4 compressor

Etc.

Component parts have been selected for their dependability

and availability to keep service problems to a minimum.

Simplicity of design has also made the Heatcraft parallel

system one of the easiest to service and install. The

simplicity and compactness of the Heatcraft design make

the addition of hot gas defrost and/or heat reclaim a simple

and economical feature.

5th, 6th, & 7th digit - Horsepower

030 - 30 HP

075 - 75 HP

100 - 100 HP

Etc.

In the following pages will be found explanations of system

components, wiring and piping diagrams, control settings,

and operational guides.

8th digit - Condenser Type

A - Air

INSPECTION

Unit inspection should be assigned to a dependable

individual. Inspect the parallel system and any accessories

shipped with them for damages or shortages before and

during unloading. All items on bill of lading should be

accounted for prior to signing the shipping receipt. Note any

shortages or damage on carrier’s delivery receipt (Specify

the extent and type of damage found). Unit should be

inspected carefully for concealed damage. Notify the

Heatcraft sales representative and the carrier of the damage

immediately. Request an immediate joint inspection with the

carrier (Do not repair the unit until inspected by carrier’s

representative). Care should be exercised when uncrating

units to prevent damage.

W - Water

E - Evaporative

9th digit - Control Voltage

A - 115/1/60

B - 208-230/1/60

C - 24/1/60

10th digit - Defrost Type

A - Air / Off Cycle

E - Electric

G - Hot Gas

M - Multiple

W - Water

The system is shipped with a holding charge of dry nitrogen.

Check to see that pressure is still in the unit upon receipt.

Report lack of pressure immediately to the Heatcraft service

department.

11th digit - Temperature Range

L - Low

M - Medium

H - High

C - Combination

X - Ultra Low

NOTE: Accessory items such as drier cores,

mounting pads, modems, etc. may be packaged

in a separate carton. Be sure that you receive

all items.

12th digit - Refrigerant Type

2 - R22

4 - R134a

6 - R404a, R507

8 - Multiple

UNIT DESIGNATION

Units are identified by letter, brand, compressor type,

quantity of compressors, horsepower, condenser type,

control voltage, defrost type, refrigerant / range, unit voltage

and application. Unless otherwise requested by the

customer all refrigeration circuits are numbered from one to

the highest and from left to right while facing the electrical

panel.

13th digit - Unit Voltage

C - 208 - 230/3/60

D - 460/3/60

E - 575/3/60

J - 208/3/60

K - 230/3/60

M - 380/3/60

14th digit - Application

1 - Indoor

2 - Outdoor

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SYSTEM WARRANTY

Floor & Foundation Requirements

This equipment is designed to operate properly and produce

the rated capacity when installed in accordance with good

refrigeration practice.

The total weight of a single unit will vary between 1200

pounds and 10,000 pounds. Allowances must be made for

the parallel rack and all other equipment installed in the

same area as the parallel units. The location and installation

of all equipment should be in accordance with all local and

national code requirements.

The following conditions should be adhered to when

installing this unit to maintain the manufacturers warranty.

(a) System piping must be in accordance with good

refrigeration practices.

(b) Inert gas must be charged into the piping during

brazing.

following conditions:

While each unit is constructed with a welded steel base

frame adequately designed to withstand vibration, the

natural pulsating action of the interconnected motor-

compressors may cause considerable noise and vibration if

the unit is not mounted on a firm level surface and isolated

from the structure of the building.

• All voltages must be +/- 10% of the

nameplate ratings.

• Phase (voltage) imbalance cannot

exceed 2%.

Vibration Mounts

In ordinary ground level or basement installations, all that is

necessary to assure a vibration-free installation is to place

the unit on the concrete floor with the waffle-surfaced

resilient pads supplied. See Figure 2 for suggested pad

locations. Mezzanine and other installations require some

special considerations. The equivalent of 6 inch thick

properly reinforced concrete floor must be provided for

mounting parallel units above grade. It is recommended that

the suggestions previously given for rigid floor construction

on above-grade installations be closely adhered to. If this is

not possible, special vibration absorbing spring mounts

(optional equipment) must be placed under the base frame

of each unit. See Figure 1 for view of Spring Isolator. The

spring mounts are placed under the unit and the unit

carefully lowered on to the mounts. Note that no other

mounting hardware is required and any unevenness in the

floor or uneven weight distribution may be compensated for

by turning the spring mount leveling nuts with an open-end

wrench. This adjustment should be made after all piping is

installed and the system is charged with refrigerant.

(d) All control and safety switch circuits must be

properly connected according to the wiring

diagram.

(e) The factory installed wiring must not be changed

without written factory approval.

RIGGING

Warning: Careful considerations for lifting should be made

before the unit is lifted by any means. The only part of the

unit designed to carry any of the lifting load is the welded

channel base. The unit may be lifted at the base with a

forklift or by means of cables at the four corners of the base.

If cables are used, the lifting cables should be prevented

from contacting any of the unit piping or electrical

components.

LOCATION OF EQUIPMENT - INDOOR

Clearances

The parallel systems should be located so they are level and

easily serviced. The minimum suggested clearance around

the units should be 24 inches at the rear and 42 inches in

the front of panel (or as required by National or Local

Codes). For parallel system units placed end to end, 24

inches between units is suggested.

NOTE: Turn each leveling nut until the tip

casting rises 1/4" to 3/8" above the bottom

casting. MOUNT ADJUSTMENT SHOULD

NEVER EXCEED 3/4".

Figure 1. Vibration Pad and Spring Isolator

Figure 2. Vibration Pad Locations

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LOCATION OF EQUIPMENT - OUTDOOR

• The mounting platform or base should be level and located

so as to permit free access of supply air.

COMPRESSOR SPRING VIBRATION

ISOLATORS

On units with this option, the compressors are secured rigidly

to make sure there is no transit damage. Before operating

the unit, it is necessary to follow these steps:

• Units must not be located in the vicinity of steam, hot air or

fume exhausts.

• The unit should be mounted away from noise sensitive

spaces such as offices.

1. Remove the upper nuts and washers.

2. Discard the shipping spacers.

• The unit must have adequate support to avoid vibration and

noise transmission into the building. Sound and structural

consultants should be retained for recommendations.

3. Install the neoprene spacers. (Spacers located in

the electrical panel or tied to compressor.)

4. Replace the upper mounting nuts and washers.

Ground Mounting

5. Allow 1/16 inch space between the mounting

nut/washer and the neoprene spacer.

The unit must be set on a flat and level foundation. A single

piece concrete slab with footings extending below the frost

line and raised approximately 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. The concrete slab should be isolated from the

building structure. Finally, before tightening mounting bolts,

recheck the level of the unit.

Figure 3. Spring Mount

Roof Mounting

Rooftop installations require adequate structural beams to

support the weight of the unit and service personnel. The

design of the beams/supports must minimize deflection and

attendant vibration transmission.

Due to the weights involved, a structural analysis by a

qualified engineer may be required before mounting. Also,

for sound sensitive applications, unit vibration isolators

should be used.

UNIT VIBRATION ISOLATION

Under certain critical conditions, it is recommended that

vibration isolators, of a suitable type, be installed under the

base. The isolators must be designed for the operating

weight of the unit. Rubber-in-shear or spring type isolators

(by others) are available for this purpose.

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UNIT ACCESS

Always provide sufficient clearance for unit maintenance and

service. Minimum clearances for most situations are

described below (except 60 Inches of free space is required

in front of the control panel). Please note that these are

minimums and more clearance may be required by local

codes.

Vertical Clearance

Overhead obstructions are not permitted. Vertical air

discharge from the condenser must have no obstructions that

can cause the discharge air to be recirculated back to the

inlet side of the unit.

Lateral Clearance

(Walls or Obstructions)

The unit should be located so that air may circulate freely and

not be recirculated. For proper air flow and access, all sides

of the unit (except control panel end ) should be a minimum

of four feet (1.2 m) 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. When

the unit is in an area where it is enclosed by three walls the

unit must be installed under the guidelines for unit

installations in pits.

Decorative Fences

Fences may be installed closer than the four foot (1.2 m)

lateral minimum (except on the control panel end)

requirement whenever fences permit sufficient free area to

allow adequate air flow to the unit. Once again, care should

be taken to leave ample room for unit service. Recommended

service clearances are listed above.

Units in Pits

The top of the unit should be level with the top of the pit. If the

top of the unit is not level with the top of the pit, a wider pit or

discharge stacks must be used to raise discharge air to the

top of the pit. This is a minimum requirement.

Multiple Units

(Unit-to-Unit Clearance)

For units placed side by side, the minimum distance between

units is eight feet (2.4 M) to prevent air recirculation.

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Ventilation Requirements

Proper size refrigeration lines are essential to good

refrigeration performance. Suction lines are more critical

than liquid or discharge lines. Oversized suction lines may

prevent proper oil return to the compressor. Undersized lines

can rob refrigeration capacity and increase operating cost.

Consult the line sizing charts in this manual for proper pipe

sizes.

INDOOR UNITS

If compressors or condensing units are located in a machine

room, adequate ventilation air must be provided to avoid an

excessive temperature rise in the room. To allow for peak

summer temperatures a 10°F temperature rise is

recommended, although a 15°F rise might be acceptable.

The following procedures should be followed:

With compressors with remote condensers, approximately

10% of the heat rejected is given off by the compressor

casting and the discharge tubing. The correct formula for

calculating the ventilation requirement of the Indoor Parallel

unit is:

1. Do not leave dehydrated compressors or

filter-driers open to the atmosphere.

2. Use only refrigeration grade copper tubing,

properly sealed against contamination.

CFM = 10% of THR/hr

3. Suction lines should slope 1/4" per 10 feet

towards the compressor.

10° TD

The air intake should be positioned so that air passes over

the units. All State, Local, and National codes should be

followed.

4. Discharge lines should slope 1/4" per 20 feet

toward the condenser.

SUCTION P-TRAPS

ELECTRICAL

* Provide P-traps at the base of each suction

riser of four (4) feet or more to enhance oil

return to the compressor. Use a P-trap for

each 20 feet section of riser. See Figure 4

below.

To insure the proper operation of equipment and reduce the

possibility of interruption of refrigeration due to electrical

power failure, the following precautions must be observed:

• All electrical work must be done in accordance

with the National Electrical Code and existing

local codes.

Figure 4. P-trap Requirements

• The power supply must be the same as

specified on the unit data plate.

• An adequate power supply must be provided.

• Voltage fluctuations in excess of 10 percent

must be corrected.

• Overload relays (Carrier compressors only)

are selected in accordance with specified

limits as determined by the motor-compressor

manufacturer. They must not be changed in

size or shorted-out.

• Control panels must be provided with a single

phase, 60 Hertz supply. See the unit wiring

diagram for the voltage requirement.

• Before starting up a parallel unit, insure that all

fuses and motor-protective devices are in

place and that all wiring is secure. A

complete wiring diagram for troubleshooting

the unit will be found inside the control panel

cover.

* The P-trap should be the same size as the

horizontal line. See Figure 5 below.

REFRIGERANT PIPING

Figure 5. P-Trap Construction

The system as supplied by Heatcraft, was thoroughly cleaned

and dehydrated at the factory. Foreign matter may enter the

system by way of the field piping required. Therefore, care

must be used during installation of the piping to prevent

introduction of foreign matter.

Install all refrigeration system components in accordance with

all applicable local and national codes and in conformance

with good practice required for the proper operation of the

system.

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• In systems equipped with capacity control

compressors, or where multiple compressors

are used with one or more compressors

cycled off for capacity control, double suction

risers should be installed. See Figure 6

below. The two lines should be sized so that

the total cross-section area is equivalent to

the cross section area of a single riser that

would have both satisfactory gas velocity and

acceptable pressure drop at maximum load

conditions. The two lines normally are

different in size, with the larger line trapped

as shown. The smaller line must be sized to

provide adequate velocities and acceptable

pressure drop when the entire minimum load

is carried in the smaller riser.

• 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.

• Use long radius ell’s for lower pressure drop.

• Provide expansion loops in long straight

refrigerant lines that are subject to expansion

and contraction. See Expansion Loops in

this manual for more information.

Refrigerant Line Insulation

• Insulate suction lines from the evaporators to

the parallel unit with minimum 3/4" thickness

closed-cell type insulation on low temperature

circuits. Insulate suction lines on medium

temperature circuits with minimum 1/2" thick

insulation to prevent condensation.

Figure 6. Double Suction Risers

• Long liquid lines run in areas exposed to high

temperatures should be fully insulated with

minimum 1/2" insulation.

• Suction and liquid lines should never be taped

or soldered together.

Refrigerant Line Support

• Strap and support tubing to prevent excessive

line vibration and noise. All tubing clamps

should have an insulating material (i.e. Hydra

Sorb bushing) to prevent metal to metal

contact.

• In operation, at maximum load conditions gas

and entrained oil will be flowing through both

risers. At minimum load conditions, the gas

velocity will not be high enough to carry oil up

both risers. The entrained oil will drop out of

the refrigerant gas flow and accumulate in the

"P" trap forming a liquid seal. This will force

all of the flow up the smaller riser, thereby

raising the velocity and assuring oil circulation

through the system.

Figure 8. Pipe Support

• Straight runs should be supported near each

end.

• When connecting more than one suction line

to a main trunk line, connect each branch line

with an inverted trap. See Figure 7 below.

• Long runs require additional supports. A

general guide is

* 3/8" to 7/8" every 5 feet.

Figure 7. Inverted Trap

* 1 1/8" to 1 3/8" every 7 feet.

* 1 5/8" to 2 1/8" every 10 feet.

• When changing directions, supports should be

placed a maximum of 2 feet in each direction.

• 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.

• Use only a suitable silver solder alloy on

suction and liquid lines.

• 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.

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Expansion Loops

Suction, liquid and remote condenser lines are subject to

In order to compensate for the expansion of the tubing, it is

necessary to estimate the amount of expansion and then

expansion and contraction and proper piping techniques must provide offsets or loops in the refrigerant piping. Normally the

be employed (especially on hot gas lines) to prevent line

breakage. This is critical on long straight runs of generally

70’ or more where expansion loops must be provided and

hangers should allow for longitudinal movement of the piping.

area to be most concerned with is the straight line distance

from the fixture to the parallel compressor unit.

A simple form of expansion loop can be made of soft

tempered copper tube by bending it to the correct size and

shape. A neater type is made by assembling hard tube with

solder elbows as in Figure 9. The correct proportions of such

expansion loops to meet various conditions are shown in

Table 1.

On a refrigeration system with gas defrost, the refrigerant

lines expand and contract with temperature changes. The

suction line normally has the greatest movement since it has

the largest temperature change during defrost. If the

expansion and contraction is not planned for during the

installation of refrigeration lines, kinking and breaking of the

lines could occur.

In compensating for expansion and contraction, two items are

very important.

Figure 9. Offsets

• Liquid and suction lines can not be joined

together and should not touch at any point.

• Pipe hangers must be located and installed in

such a manner as not to restrict the

expansion and contraction of the tubing. All

tubing clamps should have an insulating

material (i.e. Hydra Sorb bushing) to prevent

metal to metal contact.

Table 1. Expansion Chart

Table of Values for "L"

Ref. Line

O.D. "

⁷/8

Amount of Expansion (Inches)

¹/2

1¹/2

2¹/2

1¹/8

1³/8

1⁵/8

2¹/8

2⁵/8

NOTE: Calculations for expansion and contraction should be based on the average coefficient of expansion of copper

which is .0000094 per degree Fahrenheit between 77°F and 212°F. Example, the expansion for each 100 feet of

length of any size of tube heated from room temperature of 70°F to 170°F, a rise of 100°F, is:

100°F (rise °F) X 100 (linear feet) X 12 (inches) X.0000094 (coefficient) = 1.128 inches

(Reprinted from Copper & Brass Research Association)

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Table 2.Pressure Loss of Liquid Refrigerants

(In Liquid Line Risers - Expressed in Pressure Drop, PSIG, and Subcooling Loss, °F)

Liquid Line Rise in Feet

10’

15’

20’

25’

30’

40’

50’

75’

100’

Refrigerant PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F

R12

R22

5.4 2.8 8.1 4.2 10.7 5.4 13.4 6.9 16.1 8.3 21.5 11.3 26.9 14.3 40.3 22.4 53.7 31.0

4.8 1.6 7.3 2.3 9.7 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

4.9 1.5 7.3 2.2 9.7 3.0 12.1 3.7 14.6 4.5 19.5 6.0 24.3 7.6 36.4 11.5 48.6 14.8

4.9 2.0 7.4 2.9 9.8 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

R502

R134A

R507, R404A 4.1 1.1 6.1 1.6 8.2 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

Based on 110°F liquid temperature at bottom of riser.

Table 3. Equivalent Feet of Pipe

(Due to Valve and Fitting Friction)

Copper Tube,

O.D., Type "L"

Globe Valve (Open)

Angle Valve (Open)

90° Turn Through Tee

Tee - Straight Through

or Sweep Below

¹/2

⁵/8

⁷/8

1¹/8

1³/8

1⁵/8

2¹/8

2⁵/8

3¹/8

3⁵/8

4¹/8

118

5¹/8

138

6¹/8

168

.75

1.5

2.5

3.5

90° Elbow or Reducing

Tee (Straight Through)

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Table 4. Weight of Refrigerants in Copper Lines During Operation

(Pounds per 100 Lineal feet of type "L" tubing.)

Line Size

Suction Line at Suction Temperature

O.D.

Liquid

Line

4.0

Hot Gas

Line

.15

in Inches

Refrigerant

12, 134a

-40°F

.01

-20°F

.01

0°F

.02

+20°F

.04

+40°F

.06

3/8

1/2

3.9

.22

.02

.03

.04

.06

.08

R507, 502, 404A

12, 134a

3.4

.31

.03

.04

.06

.09

.13

7.4

.30

.01

.03

.04

.07

.11

7.4

.41

.03

.05

.07

.11

.15

R507, 502, 404A

12, 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

.65

.05

.08

.12

.17

.25

R507, 502, 404A

12, 134a

.93

.07

.11

.17

.25

.35

.99

.05

.10

.15

.24

.36

7/8

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, 502, 404A

12, 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

.17

.28

.42

.61

.87

R507, 502, 404A

12, 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

.27

.42

.64

.93

R507, 502, 404A

12, 134a

.40

.58

.95

1.32

.87

.20

.37

.57

.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, 502, 404A

12, 134a

.56

.82

1.35

.98

.34

.64

.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, 502, 404A

12, 134a

.98

.52

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, 502, 404A

12, 134a

1.44

2.16

.99

R507, 502, 404A

12, 134a

1.94

2.92

1.29

2.53

3.80

R507, 502, 404A

12, 134a

R507, 502, 404A

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Table 5A. Recommended Line Sizes for R-404A and R507 *

SUCTION LINE SIZE

SUCTION TEMPERATURE

SYSTEM

CAPACITY

BTU/H

+20˚F

+10˚F

-10˚F

-20˚F

Equivalent Lengths

Equivalent

25'

3/8

1/2

5/8

7/8

50'

75' 100' 150' 200' 25'

50' 75'

3/8 3/8

1/2 1/2

1/2 5/8

5/8 7/8

7/8 7/8

100' 150' 200' 25'

50'

75' 100' 150' 200' 25' 50' 75'

1,000

3,000

3/8

1/2

5/8

7/8

3/8

1/2

5/8

7/8

3/8

1/2

5/8

7/8

3/8

1/2

5/8

7/8

3/8

5/8

7/8

3/8

1/2

5/8

3/8

1/2

5/8

7/8

3/8

5/8

7/8

1/2

5/8

7/8

3/8

1/2

5/8

3/8

1/2

5/8

7/8

3/8

5/8

7/8

1/2

5/8

7/8

1/2

5/8

7/8

1/2

7/8

3/8

1/2

5/8

3/8 1/2

1/2 5/8

5/8 5/8

5/8 7/8

7/8 7/8

7/8 1 1/8

4,000

6,000

9,000

7/8 1 1/8 5/8

12,000

15,000

18,000

24,000

30,000

36,000

42,000

48,000

54,000

60,000

66,000

72,000

78,000

84,000

90,000

120,000

150,000

180,000

210,000

240,000

300,000

360,000

480,000

600,000

720,000

900,000

1 1/8 7/8

1 1/8 1 1/8 7/8

1 1/8 7/8

1 1/8 1 1/8 7/8

7/8 1 1/8 1 1/8 1 1/8 7/8

7/8 1 1/8 1 1/8 7/8

1 1/8 1 1/8 1 1/8 7/8

7/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8

7/8 1 1/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8

7/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8

7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 1/8 1 3/8

1 1 /8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8

1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8

1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8

1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8

1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8

1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8

1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 1 5/8

1 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8

1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 5/8 1 5/8 1 5/8 2 1/8

1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1 3/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 1 5/8 2 1/8 2 1/8

1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8

1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 1/8 2 1/8 2 5/8

1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8

1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8

2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 2 5/8 2 5/8 2 5/8

2 1/8 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 2 5/8 2 5/8 3 1/8

2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 2 5/8 2 5/8 2 5/8 2 5/8 3 5/8 3 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 4 1/8 2 5/8 3 1/8 3 1/8

2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 3 1/8 3 1/8 3 1/8 3 5/8 4 1/8 4 1/8 3 1/8 3 1/8 3 1/8

2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 4 1/8 3 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 3 5/8 3 5/8 4 1/8 5 1/8 5 1/8 5 1/8 3 5/8 4 1/8 5 1/8

3 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 3 1/8 3 5/8 3 5/8 4 1/8 5 1/8 5 1/8 3 5/8 4 1/8 5 1/8 5 1/8 5 1/8 5 1/8 4 1/8 5 1/8 5 1/8

* NOTES:

1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not

exceed horizontal size. Properly placed suction traps must also be used for adequate oil return.

All sizes shown are for O.D. Type L copper tubing.

2. Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly.

3. Recommended liquid line size may increase with reverse cycle hot gas systems.

4. If system load drops below 40% of design, consideration to installing double suction risers should be made.

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Table 5B. Recommended Line Sizes for R-404A and R507 (continued) *

SUCTION LINE SIZE

LIQUID LINE SIZE

Receiver to

SUCTION TEMPERATURE

-20˚F

-30˚F

-40˚F

Expansion Valve

Equivalent Lengths

SYSTEM

CAPACITY

BTU/H

Lengths

Equivalent Lengths

100' 150' 200' 25'

50'

3/8

1/2

5/8

7/8

75'

1/2

5/8

7/8

100' 150'

200' 25'

50'

1/2

5/8

7/8

75'

1/2

5/8

7/8

100' 150' 200' 25' 50' 75' 100' 150' 200'

1/2

5/8

7/8

1/2

7/8

1/2

7/8

3/8

1/2

5/8

1/2

5/8

7/8

1/2

7/8

5/8

7/8

3/8

1/2

5/8

1/2

5/8

7/8

5/8

7/8

5/8

7/8

3/8 3/8 3/8 3/8 3/8

3/8

1/2

5/8

7/8

1,000

3,000

7/8

4,000

7/8

7/8 1 1/8 3/8 3/8 3/8 3/8 3/8

1 1/8 1 1/8 3/8 3/8 3/8 3/8 3/8

6,000

1 1/8 1 1/8 5/8

1 1/8

1 1/8 5/8

1 1/8 7/8

1 3/8 7/8

9,000

1 1/8 1 1/8 1 1/8 7/8

1 1/8 1 1/8 1 3/8 7/8

1 1/8 1 1/8

1 1/8 1 3/8

1 3/8 1 3/8

1 3/8 1 5/8

1 5/8 1 5/8

1 5/8 2 1/8

2 1/8 2 1/8

2 1/8 2 5/8

2 5/8 2 5/8

2 5/8 3 1/8

3 1/8 3 1/8

3 1/8 3 5/8

3 5/8 3 5/8

4 1/8 4 1/8

5 1/8 5 1/8

5 1/8 6 1/8

1 1/8 1 1/8 1 1/8 3/8 3/8 3/8 3/8 3/8

12,000

15,000

18,000

24,000

30,000

36,000

42,000

48,000

54,000

60,000

66,000

72,000

78,000

84,000

90,000

120,000

7/8 1 1/8

1 1/8 1 1/8 1 1/8 1 3/8 3/8 3/8 3/8 3/8 1/2

1 1/8 1 3/8 1 3/8 7/8 1 1/8 1 1/8

1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 3/8 3/8 3/8 1/2 1/2

1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8

1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 3/8 3/8 1/2 1/2 1/2

1 5/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 3/8 1/2 1/2 1/2 1/2

1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1/2 1/2 1/2 1/2 1/2

1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1/2 1/2 1/2 1/2 5/8

1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1/2 1/2 1/2 5/8 5/8

2 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1/2 1/2 1/2 5/8 5/8

2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1/2 1/2 5/8 5/8 5/8

2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1/2 1/2 5/8 5/8 5/8

2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1/2 5/8 5/8 5/8 5/8

2 1/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 5/8 5/8 5/8 5/8 5/8

2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 5/8 5/8 5/8 5/8 7/8

2 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 5/8 5/8 5/8 7/8 7/8

2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 5/8 5/8 7/8 7/8 7/8

1 3/8

1 3/8 1 5/8 1 1/8 1 1/8 1 3/8

1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8

1 5/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8

1 5/8

1 5/8 1 5/8 1 1/8 1 3/8 1 3/8

1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 3/8

1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8

1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8

1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8

2 1/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8

2 1/8 2 1/8 2 5/8 1 5/8 2 1/8 2 1/8

2 1/8 2 5/8 2 5/8 1 5/8 2 1/8 2 1/8

2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8

2 5/8 2 5/8 3 1/8 2 1/8 2 1/8 2 5/8

2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8

2 5/8 3 1/8 3 1/8 2 5/8 2 5/8 2 5/8

3 1/8 3 5/8 3 5/8 2 5/8 2 5/8 3 1/8

3 5/8 3 5/8 4 1/8 2 5/8 3 1/8 3 1/8

3 5/8 3 5/8 4 1/8 3 1/8 3 5/8 3 5/8

5 1/8 5 1/8 5 1/8 4 1/8 5 1/8 5 1/8

2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 5/8 7/8 7/8 7/8 7/8 1 1/8 150,000

3 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 7/8 7/8 7/8 7/8 1 1/8 1 1/8 180,000

3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 210,000

3 5/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 240,000

4 1/8 2 5/8 2 5/8 3 1/8 3 5/8 3 5/8 4 1/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 300,000

4 1/8 2 5/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 360,000

4 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 4 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 480,000

5 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 5 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 600,000

6 1/8 4 1/8 5 1/8 5 1/8 5 1/8 5 1/8 6 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 720,000

6 1/8 5 1/8 5 1/8 5 1/8 5 1/8 6 1/8 6 1/8 1 3/8 1 3/8 1 5/8 2 1/8 2 1/8 2 1/8 900,000

* NOTES:

1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed

horizontal size. Properly placed suction traps must also be used for adequate oil return.

All sizes shown are for O.D. Type L copper tubing.

2. Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly.

3. Recommended liquid line size may increase with reverse cycle hot gas systems.

4. If system load drops below 40% of design, consideration to installing double suction risers should be made.

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Table 6A. Recommended Line Sizes for R-22 *

SUCTION LINE SIZE

SUCTION TEMPERATURE

+20˚F

SYSTEM

CAPACITY

BTU/H

+40˚F

+10˚F

0˚F

Equivalent Lengths

100' 150' 200' 25'

Equivalent Lengths

Equivalent

25'

3/8

1/2

5/8

7/8

50'

75' 100' 150' 200' 25'

50' 75'

3/8 3/8

1/2 1/2

1/2 5/8

5/8 5/8

5/8 7/8

7/8 7/8

50'

75' 100' 150' 200' 25' 50' 75'

1,000

3,000

3/8

1/2

5/8

7/8

3/8

1/2

5/8

7/8

3/8

1/2

5/8

7/8

3/8

1/2

5/8

7/8

3/8

1/2

5/8

7/8

3/8

1/2

5/8

3/8

1/2

5/8

7/8

3/8

5/8

7/8

3/8

5/8

7/8

3/8

1/2

5/8

7/8

3/8

1/2

5/8

7/8

3/8

1/2

5/8

7/8

3/8

1/2

5/8

7/8

3/8

5/8

7/8

1/2

5/8

7/8

3/8

1/2

5/8

3/8 3/8

1/2 1/2

1/2 5/8

5/8 5/8

7/8 7/8

7/8 1 1/8

4,000

6,000

9,000

12,000

15,000

18,000

24,000

30,000

36,000

42,000

48,000

54,000

60,000

66,000

72,000

78,000

84,000

90,000

120,000

150,000

180,000

210,000

240,000

300,000

360,000

480,000

600,000

720,000

900,000

1 1/8 1 1/8 7/8

1 1/8 5/8

1 1/8 7/8

1 1/8 1 1/8 7/8

7/8 1 1/8 1 1/8 7/8

1 1/8 1 1/8 7/8

7/8 1 1/8 1 1/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8

7/8 1 1/8 1 1/8 1 1/8 7/8

1 1/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8

7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8

7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8

7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8

7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8

7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8

7/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 5/8

1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8

1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8

1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8

1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8

1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 1 5/8 2 1/8

1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8 2 5/8 1 5/8 2 1/8 2 1/8

1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1 3/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 1 5/8 2 1/8 2 1/8

1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8

1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8

1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 1/8 2 5/8 2 5/8

2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8

2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 2 5/8 2 5/8 3 1/8

2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 3 1/8 3 1/8 3 1/8 3 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 2 5/8 3 1/8 3 1/8

2 1/8 2 5/8 3 1/8 3 1/8 3 1/8 3 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 4 1/8 2 5/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 3 1/8 3 5/8 3 5/8

2 5/8 3 1/8 3 1/8 3 1/8 3 5/8 3 5/8 3 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 4 1/8 3 1/8 3 5/8 4 1/8

* NOTES:

1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not

exceed horizontal size. Properly placed suction traps must also be used for adequate oil return.

All sizes shown are for O.D. Type L copper tubing.

2. Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly.

3. Recommended liquid line size may increase with reverse cycle hot gas systems.

4. If system load drops below 40% of design, consideration to installing double suction risers should be made.

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Table 6B. Recommended Line Sizes for R-22 (continued) *

SUCTION LINE SIZE

LIQUID LINE SIZE

Receiver to

SUCTION TEMPERATURE

0˚F

-10˚F

-20˚F

Expansion Valve

Equivalent Lengths

SYSTEM

CAPACITY

BTU/H

Lengths

Equivalent Lengths

100' 150' 200' 25'

50'

3/8

1/2

5/8

7/8

75'

3/8

1/2

5/8

7/8

100' 150'

200' 25'

50'

3/8

1/2

5/8

7/8

75'

3/8

5/8

7/8

100' 150' 200' 25' 50' 75' 100' 150' 200'

3/8

5/8

7/8

1/2

5/8

7/8

1/2

5/8

7/8

3/8

1/2

5/8

3/8

5/8

7/8

1/2

5/8

1/2

5/8

7/8

3/8

1/2

5/8

1/2

5/8

7/8

1/2

5/8

7/8

1/2

7/8

3/8 3/8 3/8 3/8 3/8

3/8

1/2

5/8

7/8

1,000

3,000

5/8

4,000

7/8

6,000

7/8

1 1/8 1 1/8 3/8 3/8 3/8 3/8 3/8

9,000

7/8 1 1/8 7/8

1 1/8 1 1/8 7/8

1 18

1 1/8 7/8

1 3/8 7/8

1 1/8 1 1/8 1 1/8 3/8 3/8 3/8 3/8 3/8

12,000

15,000

18,000

24,000

30,000

36,000

42,000

48,000

54,000

60,000

66,000

72,000

78,000

84,000

90,000

120,000

150,000

1 1/8 1 1/8

1 1/8 1 1/8 1 1/8 1 1/8 3/8 3/8 3/8 3/8 3/8

1 1/8 1 1/8 1 1/8 7/8

1 1/8 1 1/8 1 1/8

1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 3/8 3/8 3/8 3/8 1/2

1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 3/8 3/8 1/2 1/2 1/2

1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8

1 1/8 1 3/8 1 3/8 7/8 1 1/8 1 1/8 1 3/8 1 3/8

1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8

1 3/8 1 3/8 1 5/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8

1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8

1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8

1 5/8 1 5/8 2 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8

1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8

1 5/8 2 1/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8

1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8

1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8

2 1/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8

2 1/8 2 1/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8

2 1/8 2 5/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8

2 1/8 2 5/8 2 5/8 1 5/8 2 1/8 2 1/8 2 5/8 2 5/8

2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8

2 5/8 2 5/8 3 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8

2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8

3 1/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8

3 1/8 3 5/8 3 5/8 2 5/8 3 1/8 3 1/8 3 1/8 3 5/8

3 5/8 3 5/8 4 1/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8

4 1/8 4 1/8 5 1/8 3 1/8 3 5/8 4 1/8 4 1/8 5 1/8

1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 3/8 3/8 1/2 1/2 1/2

1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 3/8 1/2 1/2 1/2 1/2

1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 3/8 1/2 1/2 1/2 1/2

1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1/2 1/2 1/2 1/2 1/2

1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1/2 1/2 1/2 1/2 5/8

2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1/2 1/2 1/2 5/8 5/8

2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1/2 1/2 5/8 5/8 5/8

2 1/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1/2 1/2 5/8 5/8 5/8

2 1/8 1 3/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1/2 5/8 5/8 5/8 5/8

2 1/8 1 3/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1/2 5/8 5/8 5/8 7/8

2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 5/8 5/8 5/8 7/8 7/8

2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 5/8 7/8 7/8 7/8 7/8

2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 5/8 7/8 7/8 7/8 7/8 1 1/8 180,000

2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 7/8 7/8 7/8 7/8 7/8 1 1/8 210,000

3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 7/8 7/8 7/8 7/8 1 1/8 1 1/8 240,000

3 1/8 2 1/8 2 5/8 3 1/8 3 1/8 3 1/8 3 5/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 300,000

3 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 7/8 7/8 1 18 1 1/8 1 1/8 1 1/8 360,000

3 5/8 2 5/8 3 1/8 3 5/8 3 5/8 3 5/8 4 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 480,000

4 1/8 3 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 600,000

5 1/8 3 5/8 4 1/8 4 1/8 5 1/8 5 1/8 5 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 720,000

4 1/8 5 1/8 5 1/8 3 5/8 4 1/8 4 1/8 5 1/8 5 1/8 5 1/8 3 5/8 4 1/8 5 1/8 5 1/8 5 1/8 6 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 900,000

* NOTES:

1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not

exceed horizontal size. Properly placed suction traps must also be used for adequate oil return.

All sizes shown are for O.D. Type L copper tubing.

2. Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly.

3. Recommended liquid line size may increase with reverse cycle hot gas systems.

4. If system load drops below 40% of design, consideration to installing double suction risers should be made.

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Table 7. Recommended Remote Condenser Line Sizes

R-12 & R-134a

Liquid Line

R-22

R-502

Liquid Line

R507 & R-404A

Liquid Line

Cond. to

Receiver

(O.D.)

3/8

Net

Evaporator

Capacity

Total

Equiv.

Length

100

Discharge

Line

(O.D.)

3/8

Cond. to

Receiver

(O.D.)

3/8

Discharge

Line

(O.D.)

3/8

Discharge

Line

(O.D.)

3/8

Cond. to

Receiver

(O.D.)

3/8

Discharge

Line

(O.D.)

3/8

Cond. to

Receiver

(O.D.)

3/8

3,000

1/2

3/8

1/2

3/8

1/2

3/8

6,000

9,000

1/2

3/8

1/2

3/8

1/2

3/8

1/2

3/8

5/8

3/8

1/2

3/8

1/2

3/8

1/2

3/8

5/8

3/8

1/2

3/8

1/2

3/8

5/8

3/8

5/8

1/2

3/8

1/2

3/8

1/2

3/8

12,000

18,000

100

7/8

1/2

5/8

3/8

5/8

3/8

5/8

3/8

7/8

1/2

3/8

5/8

1/2

5/8

1/2

7/8

1/2

5/8

3/8

5/8

1/2

5/8

1/2

7/8

5/8

7/8

1 1/8

1 3/8

1 5/8

2 1/8

2 5/8

3 1/8

3 5/8

4 1/8

5/8

7/8

1/2

5/8

7/8

1 1/8

1 3/8

1 5/8

2 1/8

2 5/8

3 1/8

3 5/8

5/8

7/8

5/8

7/8

1 1/8

7/8

5/8

7/8

24,000

36,000

48,000

60,000

72,000

90,000

120,000

100

1 1/8

1 3/8

1 1/8

1 3/8

1 5/8

2 1/8

1 5/8

2 1/8

2 5/8

2 1/8

2 5/8

3 1/8

2 5/8

3 1/8

2 5/8

3 1/8

3 5/8

3 1/8

3 5/8

3 1/8

3 5/8

4 1/8

1 1/8

1 3/8

1 5/8

2 1/8

1 5/8

2 1/8

2 5/8

2 1/8

2 5/8

3 1/8

2 5/8

3 1/8

3 5/8

1 1/8

1 3/8

1 1/8

1 3/8

1 5/8

2 1/8

2 5/8

2 1/8

2 5/8

3 1/8

2 5/8

3 1/8

2 5/8

3 1/8

3 5/8

3 1/8

3 5/8

7/8

1 1/8

7/8

1 1/8

1 3/8

1 5/8

2 1/8

2 5/8

3 1/8

3 5/8

4 1/8

1 1/8

1 3/8

1 5/8

2 1/8

2 5/8

3 1/8

3 5/8

4 1/8

1 1/8

1 3/8

1 5/8

2 1/8

2 5/8

2 1/8

2 5/8

3 1/8

2 5/8

3 1/8

2 5/8

3 1/8

180,000

240,000

300,000

360,000

480,000

600,000

720,000

840,000

960,000

1,080,000

100

1,200,000

1,440,000

1,680,000

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Leak Checking, Evacuation,

and Start-up

4. With all compressor and control breakers and toggle

switches turned off, apply power to the unit. If the unit is

using a phase monitor, the green light must come on

before going any further. (See instructions for phase

protector elsewhere in this manual.) A red light indicates

incorrect phasing or voltage. Check with a volt meter to

see if correct voltage is connected to the unit. Correct the

Power Supply before proceeding.

Warning: It is illegal to knowingly vent or discharge

any CFC’s and HCFC’s to the atmosphere. ALL

CFC’s and HCFC’s must be reclaimed or recycled.

5. Turn on the circuit breaker for the control power. If an

electronic control system is installed on the unit, it will

initiate at this time. The Heatcraft preferred controller is

manufactured by Computer Process Control (CPC).

Review the manual for the controller supplied with the

system.

Leak Check

1. To check the systems for leaks, leave all valves closed on

suction, liquid and hot gas manifolds. The unit is shipped

with a holding charge of dry nitrogen and should be leak

free. Build up the pressure in each circuit to a maximum

of 150 psig dry nitrogen and check each individual circuit.

6. Turn on circuit breakers to all compressors. The

compressors can be started by turning on the compressor

toggle switches. Likewise, each circuit control can be

started by turning on the circuit toggle switch. It is

recommended that one compressor at a time be started

and checked before allowing them all to operate. It is also

advisable to check one circuit at a time to be certain all

components work when called upon and that the circuit

wiring is correct.

2. After each circuit has been checked, open all valves to

allow the pressure into the unit assembly. Check to be

sure pressure is throughout the assembly. Check all

connections and accessories for leaks.

Evacuation

1. After the system is leak checked, connect a good high

vacuum pump with fresh oil to both the low and high side

evacuation valves. Connections between the pump and

evacuation valves should be made with copper tubing or

high vacuum hose having a diameter of at least 3/8”.

Evacuate the system to 1500 microns for the first

evacuation.

7. When each circuit and compressor has been tested and

the appropriate amount of refrigerant has been added for

proper operation, allow the system to operate and pull-

down the room/fixture temperatures.

8. Once the system is operating, set all regulating valves.

2. After each evacuation, the vacuum should be broken by

the introduction of refrigerant into the system. The

refrigerant should be passed through a drier when

breaking the vacuum until the pressure is brought up to 0

psig.

9. When the room and/or the fixture temperatures are at

design, the expansion valves should be set. (See

instructions elsewhere in this manual.)

10.Adjust the electronic or manual pressure controls as

necessary to maintain proper pressures and

temperatures.

3. Between the first and second evacuation, the liquid filter

driers and suction filters should be installed in each

replaceable core shell.

11. Check the refrigerant level in the receiver. The minimum

level that should be maintained is 20%.

4. A triple evacuation is recommended. The third and final

evacuation should achieve a value of 500 microns or less.

After this vacuum is reached, add as much refrigerant as

possible into the receiver. Now the system is ready to be

started.

12.All circuit defrost controls must be set and checked.

Again, one circuit at a time should be tested.

13.Set condenser fan controls to maintain the proper

discharge pressure.

Start-up

14.All safety controls should be checked and verified. Check

that the alarm circuitry is operating at this time.

1. Set all pressure controls as recommended elsewhere in

this manual. Recheck all service valves and shut-off

valves to be sure they are open.

15.Check the oil reservoir during the start-up and add oil as

necessary. The oil level should be between the upper and

lower reservoir sight glass. Do not add more than two

gallons of oil to a system. If more oil is needed, recheck

the piping as oil is not returning to the unit properly.

2. Check and be sure the condenser fan motors are running

in the correct rotation.

3. All evaporator fan motors should be checked for proper

rotation. The fans in low temperature boxes generally

have a fan delay for defrost purposes that keep the fans

from operating until the evaporator coil has reached a

certain temperature. It will be necessary to jump-out the

fan controls on freezer units to make them run through

final charging and room temperature pull-down. The

wiring diagram for the unit will have to be consulted to

determine how to best force the fans to operate for this

step.

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Refrigerant Distribution

Hot discharge gas is injected into the suction line at the

parallel rack and flows to the evaporator being defrosted. The

discharge gas will condense into liquid as it flows through the

cold evaporator.

The distribution system is selected based upon the type of

defrost for that particular system. For each set of liquid /

suction lines a distribution system must be selected.

The liquid exits the coil at the distributor side-port, then flows

through the liquid line by pass check valve into the drain

manifold and then returned to the condenser inlet.

Liquid solenoids are recommended to be installed at the

evaporator on all systems, particularly systems with long line

runs. The solenoid will prevent continued feed to the

evaporator through the expansion valve when it is not in

operation. A solenoid is mentioned in each of the refrigerant

distribution analysis, and are shipped loose to be installed at

the evaporators.

The pressure in the condenser is controlled to be below the

returning liquid pressure by a discharge gas regulator valve.

The returning liquid pressure helps in driving refrigerate from

the condenser to the receiver to maintain liquid refrigerant

flows to the refrigerating evaporators. The Priority I system

requires that no more than 20% of the evaporators defrost at

one time.

Heatcraft offers three types of defrost : Off cycle defrost,

Electric defrost and the Priority I hot gas defrost system for

Racks. The type of defrost is generally a matter of either

contractor or owner preference. Typical operation is as

follows:

The discharge gas regulator valve (DDGR) is normally set to

maintain approximately 25 psig differential pressure. The

next part of the Priority I system consists of a small capacity

control system located at the compressor rack. The

discharge gas bypass regulator valve should be set to

maintain the normal suction pressure during normal

refrigeration. There is a desuperheating TXV mounted to

prevent overheating the suction line. The expansion valve

should not require an adjustment as it is preset to maintain

20°F superheat. See page 31 of this manual for more

information on the adjustment of the discharge gas bypass

regulator valve.

Off cycle

The off cycle system consists of liquid and suction line ball

valves for circuit isolation, liquid solenoid and defrost

controller. Defrost is initiated by the controller. The liquid

solenoid closes pumping down the circuit, the evaporator fans

remain in operation and room air melts the ice on the coil.

The controller terminates the defrost period after a

predetermined time period and opens the liquid solenoid

putting the system back into refrigeration.

Electric defrost

Head pressure control system

The electric defrost system consists of liquid and suction line

ball valves for circuit isolation, liquid solenoid, evaporator

heater contactor, heater fusing, evaporator fan motor

contactor and fuses if three phase fans are used, and defrost

controller.

Almost all refrigeration systems require some form of year

round head pressure control. This is due to the fixed amount

of condenser surface which has been selected for summer

conditions. During the winter, the condenser is oversized for

the system and low head pressure will result. This will cause

erratic operation of the system.

Defrost is initiated by the controller. The liquid solenoid

closes, the evaporator fan contactor opens stopping the fans,

and the defrost heater contactor is energized.

The following method of head pressure control is considered

the most effective means and has the advantage of

When the defrost heaters warm the coil to a predetermined

level an adjustable defrost termination device within the

evaporator signals the defrost controller to end the defrost

period. A fan delay is provided at the end of each defrost

cycle to allow the evaporator to cool before the fans start.

This also prevents warm air and condensation from being

discharged from the unit. The liquid solenoid opens putting

the system back into refrigeration.

performing well at low outside ambient temperatures. The

disadvantage is the fact that a relatively large quantity

refrigerant must be used to flood the condenser and sufficient

receiver storage must be provided during summer operation.

Head pressure control system consists of a condenser

drain line valve and a discharge bypass valve. In order to

maintain moderate head pressure the condenser drain valve

senses condensing pressure. As condensing pressure falls in

response to lower ambient temperatures, the drain valve will

begin to restrict flow of liquid from the condenser filling

condenser tubes with liquid refrigerant. This results in

decreased surface area causing the discharge pressure to

rise.

Priority I hot gas defrost

For Racks Only

The Priority I hot gas defrost system consists of liquid and

suction line ball valves for circuit isolation, liquid line solenoid

with by pass check valve, suction solenoid valve, hot gas

solenoid valve, liquid drain solenoid valve, liquid drain

manifold, and defrost controller.

When pressure reaches the midpoint setting the valve begins

to open allowing liquid to flow to the receiver. Simultaneously

the discharge bypass valve installed in a line between the

discharge manifold and the receiver maintains minimum

receiver pressure to insure liquid flow.

Defrost is initiated by the defrost controller closing the liquid

solenoid and suction solenoid. The hot gas and liquid drain

solenoids open (Unlike typical systems wherein the

condensed liquid from the defrosting evaporator is returned

into the liquid manifold, the Priority I design returns the liquid

to the condenser through a liquid drain manifold).

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Electronic control system

High suction superheat will result in excessive discharge

temperatures that can cause a breakdown of the oil. This

action results in piston ring wear, piston and cylinder wall

damage.

The electronic controller has become the standard on parallel

compressor systems. The increased capabilities of the

controllers magnify the efficiency of the parallel compressor

system making it a very attractive accessory item.

Also, as the superheat increases, the suction pressure

decreases resulting in reduced capacity. For maximum

system capacity, suction superheat should be kept as low as

is practical. HEATCRAFT recommends that the superheat at

the compressor be no lower than 20°F.

The electronic control system preferred by Heatcraft is the

Computer Process Control (RMCC) controller. The RMCC

offers a complete control and monitoring package through

one or more input boards (16AI). The controller continuously

monitors the parameters for refrigerant pressures, defrost

operation, temperature control, and system alarms.

If adjustments to the suction superheat need to be made, the

expansion valve at the evaporator should be adjusted. See

instructions in next section.

As the RMCC monitors the system in operation, it compares

the reported values against programmed set points it is to

maintain, thus cycling compressors, unloaders, condenser

fans, defrost periods and sounding alarms as required.

Evaporator Superheat

Check Your Superheat after the box temperature has reached

or is close to reaching the desired temperature, the

evaporator superheat should be checked and adjustments

made if necessary. Generally, systems with a design TD of

10°F should have a superheat value of 6° to 10° F for

maximum efficiency.

Interface with the actual devices being controlled is through

one or more pressure transducers, watt transducer,

temperature sensors, refrigerant sensors, humidity sensors,

refrigerant level sensor, phase loss, and output boards (8R0).

The 8RO boards can be mounted remotely for lower

installation cost, when controlling devices such as air cooled

condensers. These boards are connected to the RMCC via a

three wire network and are purchased as needed for the

application. Remote communications capabilities is standard

with the RMCC through a modem that is supplied.

To properly determine the superheat of the evaporator, the

following procedure is the method Heatcraft recommends.

1. Measure the temperature of the suction line at

the point the bulb is clamped.

2. Obtain the suction pressure that exists in the

suction line at the bulb location by either of the

following methods:

System Balancing

a) A gauge in the external equalized line

will indicate the pressure directly and

accurately.

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.

b) A gauge directly in the suction line near

the evaporator or directly in the suction

header of the evaporator will yield the

same reading as above.

System Superheat

3. Convert the pressure obtained in 2a or 2b

above to saturated evaporator temperature by

using a temperature-pressure chart.

This is extremely important with any refrigeration system.

The critical value that must be checked is suction

superheat.

4. Subtract the Saturated temperature from the

actual suction line temperature. The difference

is Superheat.

Superheat is not preset at the factory.

Suction superheat should be checked at the compressor as

follows:

Alternative Superheat Method

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.

The most accurate method of measuring superheat is found

by following the previous procedure, Temperature / Pressure

method. However, that method may not always be practical.

An alternative method which will yield fairly accurate results is

the temperature / temperature method.

2. Measure the suction temperature of the

suction line about one foot back from the

compressor using an accurate thermometer.

1. Measure the temperature of the suction line at

the point the bulb is clamped (outlet).

2. Measure the temperature of one of the

distributor tubes close to the evaporator coil

(inlet).

3. Subtract the Saturated temperature from the

actual suction line temperature. The difference

is Superheat.

3. Subtract the outlet temperature from the inlet

temperature. The difference is approximate

Superheat.

If suction superheat is too low, it can result in liquid refrigerant

being returned to the compressor. This will cause dilution of

the oil and eventual failure of the bearings and piston rings.

In extreme cases, the compressor will fail as a result of the

diluted oil.

This method will yield fairly accurate results as long as the

pressure drop through the evaporator coil is low.

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Compressors

reciprocating systems or as directed by the specific

compressor manufacturer. A high pressure cutout and oil

failure control are installed and wired for each compressor.

The majority of the Heatcraft Parallel systems incorporate the

Copeland compressor. Other brand compressors are

available upon customer request. The compressors are solid

mounted to a base frame or mounted on the refrigerant

receiver. All reciprocating compressors incorporate oil floats.

Crankcase heaters will be installed and wired. Cylinder head

cooling fans will be installed on all low temperature

Many compressors are available with unloading for capacity

control. The unloading of a compressor adds many capacity

steps to those normally available to an electronic controller.

Usually, the more steps available the better the load can be

matched.

Copeland Compressors

Table 8. 3D / 4D / 6D Solid State Modules

Control Voltage

Model

Number

Copeland

Kit

Copeland

Number

T.I.

Number

115 - 230 Volts

3D-FSM

4D / 6D

998-0524-00

071-0524-00

31AA-1600E

Table 9. Typical Voltage Ranges

Voltage

60 Hertz Rating

50 Hertz Rating

Code

Rating

230-1

208/230-3

460-3

575-3

208/230/460-3

Min.

207

187

414

518

187

Max.

Rating

200/220-3

380/420-3

500-3

200/380/400-3

380/420-3

200/400-3

Min.

Max.

253

506

633

506

180

342

450

180

342

180

240

462

550

440

462

440

230/460-3

200-3

207

180

506

220

Refer to voltage rating of specific models.

Table 10. Unloader Factors

Model

Factors

See Copeland Application Bulletin Number AE 21-1278

Moduload - Capacity Control for 3D Compressors

Full Load

One Bank

Two Bank

Unloading

Performance

CAPACITY

POWER

AMPS

CAPACITY

POWER

.50

.56

.60

.70

.75

.50

.56

.74

.70

.72

.84

1.00

1.01

1.00

1.01

1.03

1.00

1.03

1.00

1.03

1.04

1.00

1.02

1.00

1.02

.50

.56

.60

.70

.71

.77

.36

.40

.55

.36

.42

.60

.36

.43

.72

AMPS

Multiply compressor rating data by above factors when used with blocked suction unloading.

Refer to Copeland AE 17-1287 for Demand Cooling Restrictions on unloading.

Table 11. Oil Safety Switch

Pressure

Alarm

Copeland

Part No.

MFGRS.

Model No.

Diff. Psi (bar)

Circuit

Cut-In

Cut-Out

Sentronic

P45NCA-12

P30-5826

PD21-2502

PD21-1006

P45NCB-3

LG21-2501

7 – 9

12 - 14

Yes

085-0062-00

Penn

Ranco

Robertshaw

Penn

9 (± 2)

085-0088-00

085-0101-00

Robertshaw

All controls are Manual Reset type with a 120 second nominal time delay at the rated voltage.

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Table 12. Oil Charges

Model

Standard

Deep Sump

Family

Initial (oz)

Recharge (oz)

Initial (oz)

Recharge (oz)

110

190

170

115

140

135

130

140

255

105

130

120

125

130

245

4DA3-100E

4DL3-150E

4DA3-200E

4DT3-220E

4DH3-250E

4DJ3-300E

250

245

255

235

240

245

6DT3-300*

6DJ3-400*

Approved Copeland Lubricants

Mineral Oil - Suniso 3GS or Equivalent

POE - Copeland Ultra 22CC / Mobil EAL™ Arctic 22 CC / ICI

Emkarate™ RL32CF / Thermal Zone 22CC

Alkyl Benzene - Copeland Ultra 200 / Shrieve Zerol 200 TD /

Soltex AB 200A / Thermal Zone 200

Bitzer Screw / Copeland Contour Screw compressor

lubricant: Solest 170

Carlyle Compressors

Oil Pressure

Approved Carlyle Lubricants

The O6D and O6E oil pump is a positive displacement vane

type. It produces high volume oil flow at a low oil pressure.

The compressor utilizes an internal pressure regulator valve

to maintain oil pressure at a constant 12 to 36 psi above

suction pressure.

For CFC and HCFC refrigerants use:

Totaline 150 / Suniso 3GS / Shrieve Zerol 150 / Texaco WFI-

32-150 / IGI Petroleum Cryol-150

For HFC refrigerants use:

CPI Solest 120 / ICI Emkarate™ RL68H / ⁺Lubrizol Lubrikuhl

2916S / *Mobil Arctic EAL™ 68 / *Castrol SW68

+ Lubrizol ISO68 also sold under Texaco Capella HFC 68NA brand

* Medium temperature applications only

Table 13. O6D/E Oil Pressure History

O6D MODELS

O6E MODELS

PSI (BAR)

Before May 1984

12 to 18

(.83 to 1.24)

16 to 22

12 to 18

(.83 to 1.24)

16 to 22

(Prior S/N 2084J...)

May 1984 to March 1994

(Between S/N 2084J... & 1094J)

Starting March 1994

(1.1 to 1.52)

18 to 26

(1.1 to 1.52)

18 to 34

(Starting S/N 1094J....)

(1.24 to 1.8)

(1.24 to 2.3)

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Table 14. Oil Safety Switch

Pressure

Carlyle

Part No.

634-2008

P529-2130

634-2050

Danfoss

Part No.

Time

Delay

Diff. Psi (bar)

Cut-In

Cut-Out

Reset

60B2101

60B2151

45 sec.

8 – 11

4 - 8

Manual

(.55 - .76)

(.28 - .55)

P529-2100

Pressure

Diff. Psi (bar)

Carlyle

Part No.

O6DA660115

Johnson

Part No.

P345

Time

Delay

45 sec.

Cut-In

Cut-Out

4 - 8

Reset

Manual

8 – 11

(.55 - .76)

(.28 - .55)

Table 15. Part Load Performance Multipliers

Multiplication Factor

For 1 Bank Unloaded

Multiplication Factor

For 2 Bank Unloaded

Compressor Model

Capacity

.49

Power

.57

.73

EER

.86

.92

Capacity

Power

EER

.70

All 4 Cylinder Models

All 6 Cylinder Models

.67

.32

.46

Table 16. Required Differential Pressure

for Unloader Operation

Suction Pressure

Range PSI (Bar)

∆P Required-Discharge Minus

Application

Suction Pressure PSI (Bar)

O6D

O6E

L.T. R-502, 404A, 507

M.T. R-502, 404A, 507

L.T. R-12, 134a

10-25

(1.7-2.7)

(2.1)

(2.8)

(2.1)

(3.5)

(2.1)

(3.1)

(2.4)

(3.8)

30-60

10-30

30-90

(3.1-5.2)

(1.7-3.1)

(3.1-7.2)

M.T. R-22 or H.T. R-22

Multiply compressor rating data by above factors when used with blocked suction unloading.

3-Phase Voltage Monitor

The microprocessor-based voltage and phase sensing circuit

constantly monitors the three phase voltages to detect

harmful power line conditions. When a harmful condition is

detected, the phase monitor output relay is deactivated after

a specified trip delay. The output relay reactivates after

power line conditions return to an acceptable level for a

specified amount of time (Restart Delay). The trip delay

prevents nuisance tripping due to rapidly fluctuating power

line conditions.

reversed. Each main power line should be checked for

proper voltage and imbalance prior to reversing a phase.

Also check the settings of the Voltage Monitor for proper field

conditions.

For semi-hermetic compressor units, two of the three power

monitor leads on the Voltage Monitor to L1, L2, and L3 may

need to be switched. For units with Scroll or Screw

compressors, which are rotation sensitive, two of the main

power lines to the compressor unit will have to be switched to

match the correct rotation of the compressors. The rotation

of Screw and Scroll compressors has been properly phased

in the manufacturing plant prior to shipping.

The Bicolor LED indicator light is green in normal conditions

and red during trip conditions. On initial start-up, if the light is

continuously red, the unit electrical phase may need to be

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Sight Glass & Moisture

Indicator

With a suitable Relief Device installed on the Vessel, the

refrigerant is released at a controlled rate and a safe

pressure is maintained in the Vessel.

Figure 11. Direct Type Relief Valves

The sight glass/moisture indicator helps determine that a unit

has sufficient refrigerant charge and/or when the liquid line

filter drier cores need to be replaced.

Bubbles in the glass may indicate a shortage of refrigerant or

a restriction in the liquid line (i.e. plugged liquid line filter

drier). Moisture typically results from a leak in the refrigerant

system or service operations which open the refrigerant

system to the atmosphere.

Moisture is detrimental because it leads to the formation of

acids which attack components in the system. A change of

color in the indicating dial from green to either chartreuse or

yellow indicates unacceptable moisture in the system in

which case the liquid line filter drier cores need to be

changed.

Upon changing the cores, the indicating dial should return to

green within 12 hours of returning system to operation.

Figure 10. Sight Glass

After a “Direct Type” Relief Device has discharged once, it

should be replaced. The “Direct Type” Relief Device is

designed to re-close automatically at a predetermined

pressure, but reliability of the Device to reseal tightly and to

operate at the designed pressure can not be guaranteed after

discharging. Be safe and replace the Device after such an

occurrence.

Figure 12. 3-way Relief Valve

Safety Relief Devices

A refrigerant Safety Relief Device is designed to prevent

pressure in a Vessel from rising above a safe limit when

operating controls fail or when the Vessel is exposed to

excessive heat.

When a Vessel, containing liquid refrigerant, is shut off from

other parts of the system a rise in temperature will cause a

rise in pressure. If the Vessel is completely filled with liquid a

small rise in temperature will cause a rapid and excessive

rise in pressure due to the expansion of the liquid. If the

Vessel contains both liquid and vapor, which is normal for

Refrigerant Receivers, the pressure will rise according to the

temperature-pressure saturation characteristic of the

refrigerant.

If pressure builds up high enough to cause the Vessel to

rupture, large quantities of liquid refrigerant are released.

This causes a sudden reduction of pressure so that the liquid

released is vaporized almost instantly with explosive results.

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Table 17. Henry Relief Valve Capacity Ratings

Pounds of Air per Minute for all Refrigerants Except Ammonia R717

SIZE CONNECTION STANDARD PRESSURE SETTINGS PSIG

TYPE

CATALOG

NUMBER

526E

INLET

OUTLET

3/8 FLARE

5/8 FLARE

3/8 FLARE

1/2 FLARE

5/8 FLARE

3/4 F.P.T.

350

10.2

28.5

11.2

18.6

28.1

41.2

74.0

129.7

400

11.6

32.4

12.7

21.1

32.0

46.8

84.2

147.5

425

12.3

34.4

13.5

22.4

33.9

49.1

89.3

156.4

450

13.0

36.3

14.3

23.7

35.8

52.5

94.4

165.4

ANGLE

3/8 M.P.T.

1/2 M.P.T.

3/8 M.P.T.

1/2 M.P.T.

3/4 M.P.T.

1 M.P.T.

527E

5231

5231-A

5231

5232

STRAIGHT

THROUGH

5240-1/2

5242-3/4

5244-1

5246-1-1/4

3/4 F.P.T.

1 F.P.T.

1-1/4 F.P.T.

1-1/4 M.P.T.

Table 18. Discharge Piping Table

RELIEF DEVICE

MAXIMUM LENGTH OF DISCHARGE PIPE IN FEET

* FOR 400 PSIG PRESSURE SETTING

CAPACITY

LBS. AIR/MIN.

SOFT COPPER TUBE O.D.

SCHEDULE 40 PIPE

1”

3/8”

3 ¹/2

2 ¹/2

1/2”

19 ¹/4

12 ¹/4

9 ¹/2

5 ¹/4

4 ¹/4

2 ¹/2

5/8”

19 ¹/4

9 ¹/2

1/2”

108

3/4”

445

308

228

137

110

1 ¹/4”

1 ¹/2”

2”

125

150

371

238

165

121

5 ¹/4

3 ¹/2

2 ¹/2

366

233

119

257

198

156

282

196

For Relief Devices set at 400 psig

• Obtain the capacity at 400 psig setting.

• Locate this capacity or the nearest larger capacity in the left-hand column of the discharge piping table above and read across to obtain the

maximum lengths for each tube and pipe size.

For relief devices set at 350 psig, use the above table and multiply by .75 to determine maximum lengths.

For relief devices set at 425 psig, use the above table and multiply by 1.15 to determine maximum lengths.

For relief devices set at 450 psig, use the above table and multiply by 1.25 to determine maximum lengths.

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Liquid Level Switch

Series P100 Pressure

Control

The P100 series, manufactured by Johnson Control, Inc., are

encapsulated, non adjustable, single-pole single throw, direct

mount pressure controls typically used for low or high

pressure cutouts. On the Heatcraft manufactured parallel

systems, the control is used for High Pressure cutout.

S-9400 Level Switch Series

OPTION – Not available on all systems or receivers.

Table19. Level Switch Table

CAT

NO.

VOLTAGE

RESISTIVE

RATING

CONTACTS

LIQ. PRESENT

There are two types available. Auto Reset Models and

Manual Reset Models.

S-9420

208/240

50/60 Hz

.5 Amp

N.C.

Figure 13.

CAT

NO.

REPLACEMENT REPLACEMENT

WIRE COLOR MODULE NO. SIGHT GLASS

CODE

S-9420 RED & WHITE

NO.

2-044-015

3-020-063

Figure 14.

Operation

Auto Reset Models

The S-9400 Series Level Switches manufactured by A C & R

COMPONENTS uses light reflecting from a conical glass prism as

a means of detecting the absence of a fluid at the level of the

glass cone. When no fluid covers the lower half of the cone,

infra-red light from the module reflects from the mirror-like

inner surface of the cone back to a light detector signaling the

electronic module to switch. When fluid covers the lower half

of the glass cone, the light from the module passes into the

fluid. This absence of light is detected by the module which

switches into the opposite direction. The module provides a

.06/.10 differential distance from the cone point down.

When pressurized to the selected actuation pressure setting,

the internal snap-acting disc reverses its shape and drives a

set of electrical contacts either open or closed. When the

pressure drops below the de-actuation pressure setting, the

disc snaps back to its preset position thus resetting the

electrical contacts.

Manual Reset Models

The snap-acting disc in the manual reset model opens the

electrical contacts when actuated by the pressure sensor.

Once the disc snaps, the contacts are held open until an

external force on the push button closes them. Because of

the disc’s link with the pressure sensor, the contacts cannot

be reset until the pressure drops to a predetermined level.

The latching mechanism inside the manual reset model is trip

free. The electrical contacts will cutout even if the reset

button is held fully depressed. The control can only be reset

when the pressure returns to a predetermined level.

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Low Pressure Oil System

Module Replacement

This type system is normally used for parallel compressors

and uses three basic components: Oil Separator, Oil

Reservoir, and Oil Level Regulators. The common discharge

is piped to the inlet of the oil separator and the outlet of the oil

separator is piped to the condenser. An oil return line is

brought from the oil separator to the top valve of the oil

reservoir. A vent line is installed to the suction line with a

pressure valve in line to lower the pressure in the reservoir,

making a low pressure oil system. This valve will keep the

reservoir pressure a set pressure above suction depending

on the value of the valve, either 5 or 20 psig to the oil level

regulator. Mechanical oil level regulators are rated for

pressures ranging from 5 to 90 psig differential. The bottom

valve of the oil reservoir is piped to oil level regulators

mounted on the compressor crankcases. These regulators

open to feed oil as the oil level drops and closes as the oil

level raises to the set level. In this manner, the oil level in the

compressor is kept at a constant level. Either one oil strainer

per regulator or one oil filter per separator must be used to

remove debris from the oil.

1. Disconnect power at the fuse box.

2. Remove wiring box from the retainer.

3. Remove the IRR 4000-93 Ring with an IRR P-101

or equivalent retaining ring pliers.

4. Remove the Retainer.

5. Pull out the module by the leads.

6. Install new Module.

7. Verify the voltage rating.

8. Reassemble the Retainer, Ring, and wiring.

Figure 15.

Figure 16. Low Pressure Oil System

Oil Control

A proper oil control system is essential to insure compressor

lubrication. An oil control system can be very cost effective

alternative to replacing expensive compressors due to loss of

oil. Oil traveling through the system tends to build up in the

evaporator, condenser, and vessels of a refrigeration system.

This causes a lack of oil return to the compressor until finally,

a large amount returns as a “slug” of oil.

A slug of oil down the suction line can be just as damaging to

the compressor as a slug of liquid refrigerant. This delay in

oil return requires an additional amount of oil to be added to

the system, depending on the size of the system, the piping,

the temperatures, the miscibility of the refrigerant/oil mix, and

the refrigerant velocity.

Oil Separators

There are two types of oil separator that may be used in the

Heatcraft parallel racks. One type utilizes the standard

impingement screen. This type separator works by having

the compressed mass flow enter into a large separator

chamber which lowers the velocity and then the atomized oil

droplets collect on the impingement screen surface. As the

oil droplets collect into larger particles they fall to the bottom

of the separator.

By removing oil from the discharge gas of compressors, not

only is the oil level for each compressor more accurately

controlled, the efficiency of the system is increased. Oil does

not change phase from liquid to gas in a refrigeration system

and therefore makes a very poor refrigerant. Oil also takes

up volume through the system that otherwise could be filled

with refrigerant. Additionally, oil tends to film the condenser

tubing wall lowering heat transfer and as oil and refrigerant

exits the expansion valve, the oil will foam insulating the

evaporator walls and again lowering heat transfer.

The second separator more commonly used is the coalescent

type. This type separator contains a matrix type borosilicate

coalescent filter to do the work impingement screens formerly

did. The exceptionally pure, extremely fine glass fibers

matrices excite the oil molecules to collide into one another

thus agglomerating them into bigger droplets until they are

forced to the outer drain layer of the filter. These droplets fall

to the bottom of the separator reservoir and the oil is then

returned to the compressor.

IMPORTANT: An oil control system does not

replace the need for proper system design. An oil

control system will drastically reduce the amount

of oil going through the system. Correct piping,

suction traps, and proper sizing of valves, con-

trols, and components must still be implemented

to insure the system will work properly.

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Table 21. Temprite Models

TEMPRITE MODEL

NO.

Before the oil separator is installed, an initial charge of oil

must be added to it. This initial charge of oil is the amount

that is needed to just float the needle valve float. This

amount of oil will stay in the oil separator when in operation

and will seal the needle and prevent damage to the float

mechanism. Oil Precharge is very important. Failure to

Precharge the separator sump may result in damage to the

oil return float mechanism by the turbulent hot gas bouncing

the float and causing the needle valve to leak.

OIL PRECHARGE

77 oz. / 2.2 L

922R, 923R

924R , 925R

926R, 927R

928R

109 oz. / 3.22 L

1.8 gal./ 6.7 L

3.5 gal. / 13.25 L

5.7 gal . / 21.25 L

930R

New systems from the factory have been Precharged.

Use the same type of oil that is in the compressor crankcase.

See the table below for the proper amount of oil to be

Precharged.

Figure 17. Temprite Oil System

Table 20. AC & R Models

HELICAL MODEL

NO.

OIL PRECHARGE

4 oz. / 11 cl

S-5180, S-5181

S-5182, 85, 87, 88

S-5190, 92, 94

14 oz. / 40 cl

40 oz. / 114 cl

25 oz. / 71 cl

S-5200 / S-5410 series

CONVENTIONAL

MODEL NO.

OIL PRECHARGE

12 oz. / 34 cl

30 oz. / 86 cl

S-5500 series

S-5600 series

S-1900, S-5700 series

S-5800 series

25 oz. / 71 cl

12 oz. / 34 cl

Temprite Models

Oil Level Regulators

The Temprite brand used is the coalescent filter type

separator. Because this filter is finer than a filter/drier, it will

pick up any and all effluent and dirt circulating in the system

down to 0.3 microns. These filters should be changed after

24 to 48 hours of initial run time. A second filter is supplied

with the system for this purpose. If the filter becomes dirty, it

will not function at its optimum performance level. In the

event of a compressor burnout, all the effluent will be

contained in the oil separator.

The A C & R adjustable oil regulators are designed to feed oil

between 1/4 and 5/8 sight glass levels. The regulator may

adjust beyond this range due to the actual oil pressure.

Adjustable regulators include an adjustment mechanism to

raise or lower the oil set point. The A C & R design

eliminates the need to shut the system down in order to

adjust the oil level. The oil level may be adjusted while the

system is under pressure and running. Adjust the oil level by

removing the seal cap, the locking disk (S-9130 & S-9190

series only), and rotating the adjustment clockwise to lower,

counter clockwise to raise the oil level. Replace the cap and

locking disk when done. Each full turn of the adjustment

mechanism moves the oil level approximately 1/16”. Oil

levels on these regulators are typically factory set just below

1/2 sight glass.

When the Temprite coalescent separator is used, the

separate oil reservoir is not required. The oil separator

serves the additional function as the reservoir. There is a

constant pressure valve used between the oil return outlet

and the oil level regulators to maintain a low pressure oil flow

to the regulators. This valve should be adjusted to maintain

oil pressure to the level regulators at 20 psig higher than the

highest suction pressure group. This valve can be adjusted

by removing the external cap and rotating the adjusting spring

in or out as required.

All level regulators have a operating pressure differential

range that should not be confused with its working pressure.

The operating differential is the difference of pressure

between the oil feeding into the regulator and the component

where the regulator is controlling oil level. Specifically, the

reservoir pressure minus the crankcase pressure. If the

differential pressure is too low for that regulator, insufficient

oil flow to the compressor may result. If the differential

pressure is too high, the regulator will overfill.

The valve currently used is manufactured by Parker and is a

model A7 constant pressure expansion valve with a range of

0 to 90 psig. Temprite Part No. is 67070000. An alternative

valve manufactured by Sporlan is Model ADRI - 1¹/4 - 0/90.

Temprite Valve Adjustment

Turn in (clockwise) to increase pressure. Turn out

(counterclockwise) to decrease pressure. Approximately 7

psi per turn. Factory set at 40 psi ±2.

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Note that there is no way to clean or repair welded oil

separators. If it is determined that the float is clogged or

otherwise malfunctioning, the entire oil separator must be

replaced.

Table 22. A C & R Model Regulators

A C & R CONNECTION OPERATION OIL LEVEL,

MODEL

NO.

SIZE

PRESSURE

DIFF, psig

5 - 30

SIGHT

GLASS

1/2

When the refrigerant and/or oil types are changed in a

system, there is the potential for leaks around o-ring seals.

Most elastomers absorb oil and refrigerant and may swell or

shrink when exposed to a new oil or refrigerant. In these

cases replace the o-rings and seals in the system as needed.

S-9010

S-9010A

S-9015

S-9090

S-9090A

S-9110

S-9120

S-9130

S-9190

3 BOLT

4 BOLT

5 - 30

1/2

3/4” NPTF F.

3 BOLT

5 - 30

1/2

5 - 90

Adjustable

1/2

4 BOLT

5 - 90

3 BOLT

5 - 30

Liquid Filter-Driers &

Suction Filters

3 BOLT

5 - 30

1/4 +

3 BOLT

5 - 90

Adjustable

3 BOLT

30 - 90

A replaceable core liquid filter/drier is supplied as standard

on all Rack units and is an option in all other parallel

systems. A Schrader type access valve is installed in the

flange plate of some models. The liquid cores are always

shipped loose for field installation. (See No. 5 of Leak

Checking, Evacuation, and Start-up section in this manual).

Troubleshooting Oil System

The oil return line should always be checked. Feeling the oil

return line and seeing how often it gets hot is the main way to

tell if the separator is working properly. It is easier if an oil

line sight glass is installed, mainly because if the oil line is hot

you don’t know if it is oil or hot gas causing it to be hot. If the

oil line cycles between hot and cold at least a few times per

hour, the separator is most likely working properly. The float

tends to open and feed a few ounces of oil at a time and shut

until the oil builds back up. If the oil return is cycling there is

no need to drain the separator to look at the float

components.

Always check the oil reservoir level during a service call. Oil

levels in the reservoir will normally vary during periods of

varying loads: compressors shutdown, hot-gas defrost, etc.

This is normal, however if the level is consistently low or high,

the oil system should be checked thoroughly.

Compressor oil levels can be deceiving. It is sometimes hard

to tell if the regulator is feeding oil or if oil is coming down the

suction line. If the reservoir has too much pressure, often

times this pressure will force oil out of the regulator and show

a low level, even though there may be excessive oil in the

compressor. Many times the best way to check the oil in the

compressor is to shut off the oil feeding to the regulator while

the compressor is operating and wait a few minutes. If oil is

pushed out of the regulator or trapped in the motor cavity on

semi-hermetic models, the compressor will overfill.

Table 23. Sporlan Valve Co.

SPORLAN

MODEL

NO. OF

CORES

DESICCANT

VOLUME

(CU IN)

CORE

PART NO.

C-489-(G)

C-969-(G)

C14411-(G)

C-19211-(G)

C-4021-(G)

C-4025-(G)

144

192

RC-4864

RC-4864-HH

RCW-48

192

“G” indicates flange plate supplied with _” FPT

#“RC__” Standard Core, “RC__HH” Burnout Core

“RCW_” High Water Capacity

The oil line sight glass is a good way to see how the

separator is working. Look for movement in the glass. If the

separator is not feeding on single or low pressure systems,

the sight glass will have little or no movement and normally

will appear empty. If the separator is feeding, the sight glass

will show a rush of oil and foam past the glass. Most of the

time, viewing this sight glass can prevent having to open the

system.

Table 24. Alco Controls

ALCO

MODEL

NO. OF

CORES

DESICCANT

VOLUME

(CU IN)

CORE

PART NO.

To check the oil level in the separator if the separator has a

drain, shut off the oil return line to prevent further feeding,

pump down the system, shut off the system, evacuate the

separator, and drain the oil from the bottom. The separator

should hold the pre-charge amount plus or minus a few

ounces during operation. By looking at the amount above or

below the pre-charge, any problem with the separator or float

can be determined.

STAS-489-T*

STAS-969-T

STAS-14411-T

STAS-19211-T

STAS-19213-T

STAS-19217-T

144

192

D-48

H-48

UK-48

W-48

192

* “T” indicates Liquid Line Service

#“D” Standard Capacity, “H” High Capacity

”UK” High Capacity, “W” Burnout Block

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Suction Filter

11. Check the

system again

after

Replaceable core suction filters are supplied as standard on

all units. The flanged shell holds replaceable pleated filter

elements suitable for installation in the suction line of

refrigeration systems. In this way any contaminants left in the

system at start-up can be removed before they circulate back

to the compressor. The suction filters are shipped loose for

field installation. (See No. 3 of Leak Checking, Evacuation,

and Start-up section in this manual).

approximately 2

weeks of

operation. If the

oil is still

discolored, or

checks acid,

replace the

liquid and

suction line

filter-driers.

Compressor Motor Burnout Cleanup

Procedure

Another benefit of the suction filter is its use in cleanup of a

system after a burnout. Standard liquid cores can be

installed in the shell to aid in the cleanup of acids and other

contaminants from a motor burnout.

12. Cleanup is

complete when

the oil is clean,

odor free, and is

determined to

be acceptable

by testing for

The following procedure can be used in case of a motor

burnout.

acids or other contaminants.

1. Determine the extent of the burnout. For mild

burnout’s where contamination has not spread through

the system, it may be economical to save the

refrigerant. Normally it is economical to save the

refrigeration charge if the system has service valves.

A severe burnout exists if the oil is discolored, an acid

odor is present and contamination products are found

in the high and low side. With this condition, extreme

caution should be exercised to avoid breathing the

acid vapors and to prevent contaminated liquid from

making contact with the skin.

13. Replace the suction line filter-drier with suction line

filters cores to minimize suction line pressure drop and

to provide maximum compressor protection.

For more detailed information on burnout cleanup procedures

and recommendations, consult the RSES Service Manual,

section 91.

Sporlan Valve Company

2. Thoroughly clean and replace all system controls, such

as expansion valves, solenoids, check valves,

reversing valves, oil separators, suction accumulators,

etc. Remove all strainers and filter-driers.

Replaceable Suction Filter

The correct replacement suction filter element in Sporlan

Valve replaceable shells is Sporlan part number RFE-48-BD.

However any suitable filter that is sized to fit a 48 cu. inch

vessel will substitute.

3. Install a replacement compressor and make a

complete electrical check.

4. Make sure the suction line adjacent to the compressor

is clean. Install a liquid line filter-drier or a replaceable

cartridge designed for “cleanup” into the suction line

shell.

5. Install a burnout core in the liquid line shell.

6. If the refrigerant is removed from the system, follow

the evacuation procedure found on page 17 of this

manual.

7. Start the compressor and put the system in operation.

Record the pressure drop across the suction line filter

and keep for reference.

8. Replace the suction line filter-drier blocks if the

pressure drop becomes excessive.

9. Observe the system during the first 4 hours. Repeat

step 8 as often as required, until no further change in

pressure drop is observed.

10. After the system has been in operation for 48 hours,

check the condition of the oil for Acids. If the oil test

indicates an acid condition, replace the liquid and

suction line filter-driers.

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Superior Valve Company

Replaceable Suction Filter

Table 28. Type AFD (for cleanup)

Replaceable Cartridges -

• On many parallel systems, the Superior Valve Co.

suction filter is installed.

Shell

No.

Filter

Core

Cartridge

OD (in)

1 - 29/32

2 - 3/4

Filter Area

Area (in²)

BTAS-2

BTAS-3

BTAS-4

BTAS-5

A2F-D

Table 25. Type F Filter

Replaceable Cartridges

115

3 - 3/4

189

4 - 5/16

270

Shell

No.

Catalog

No.

IBCA

No.

Cartridge

OD (in)

1 - 23/32

2 - 5/8

Filter

Area (in²)

2CFA

3CFA

4CFA

5CFA

F25A

F35A

F45A

F55A

51071

51072

51073

51074

115

Head Pressure Control

3 - 17/32

4 - 1/16

189

In a system with variable pressure control the receiver

pressure is maintained at the desired pressure by supplying

discharge gas to it through an adjustable outlet regulator.

Further power savings may be realized by directing only the

hot gas to the top of the receiver to minimize the mixing of

cold liquid and hot gas. As a result subcooled liquid is fed to

the evaporators resulting in increased refrigeration effect and

efficiency. Also, the amount of hot gas, that would otherwise

condense to wary liquid, is reduced and a lower cost, smaller

regulator can be used. In general, only one third of bypass is

needed compared to mixing the gas and liquid entering the

receiver.

270

Table 26. Type DF (for cleanup)

Replaceable Cartridges

Shell No. Catalog

IBCA

No.

Cartridge

OD (in)

1 - 23/32

2 - 5/8

Filter

Area (in²)

No.

2CFA

3CFA

4CFA

5CFA

DF25A

DF35A

DF45A

DF55A

51053

51059

51060

51061

115

3 - 17/32

4 - 1/16

189

270

Valve Functions

Alco Controls

Referring to the Figure above, Valve A is an Inlet Pressure

Regulator in the liquid drain line from the condenser, and

senses the condenser pressure. The regulator closes as the

condenser pressure drops below the set point, thus back-

flooding the condenser and reducing the inside surface area

available for condensing.

Alco Suction Filter

Comparable to the Superior suction filters and

interchangeable cores.

Table 27. Type AF Filter

Valve B is and Outlet Pressure Regulator in the bypass line

from compressor discharge to the condenser liquid drain line.

This valve senses the receiver pressure and opens when this

pressure drops below the set point, thus maintaining the

receiver pressure.

Replaceable Cartridges -

Shell

No.

Filter

Core

A2F

A3F

A4F

A5F

Cartridge

OD (in)

1 - 29/32

2 - 3/4

Filter Area

Area (in²)

BTAS-2

BTAS-3

BTAS-4

BTAS-5

Valve C is an In-line Check Valve in the liquid drain line to

prevent higher pressure from backing up into the condenser

during low ambient conditions when the compressor is idle.

115

3 - 3/4

189

4 - 5/16

270

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Liquid Drain Control Method

This method is ideal for large capacity systems since a

smaller regulator is required for liquid line than for discharge

line.

5. Final adjustments should be made when the outdoor

ambient is below 65°F. Ideally the ambient should be

near minimum system outdoor temperature to allow the

system pressures to drop below the regulator pressure

settings. Before adjusting make sure that all manual

opening stems on the regulators are set for automatic

operation. It may be necessary to temporarily deactivate

the low pressure cut out controls to keep the compressors

running during adjustment.

During warm ambient temperature conditions valves A and C

will be open and Valve B will be closed. When the ambient

temperature at the condenser drops, the condenser pressure

will tend to become lower. As this pressure is reduced, when

the pressure becomes as low as its setting, Valve A will begin

to close, thus causing the refrigerant to back up inside the

condenser tubes, reducing the condensing surface and

allowing the pressure to be maintained. As Valve A closes,

the receiver pressure may be reduced by the cold entering

liquid to a level below the setting of Valve B, which will begin

to open to bypass sufficient gas to maintain the receiver

pressure at the set point of Valve B. Check valve C will

prevent the high pressure from backing up to the condenser

when the receiver pressure is higher than the condenser

pressure, as would be the case during shutdown in a system

with a warm receiver.

6. The regulators should be preset using information in

Table 29.

7. When the valves are adjusted with the system operating,

enough time must be allowed for the system to stabilize.

Check the sight glass to make sure sufficient liquid is

supplied to the evaporators.

8. Turn the condenser fans off to allow the discharge

pressure to build up. The regulator A should be adjusted

to open when the pressure reaches the desired control

point. Listen for flow through regulator A while watching

the pressure gauge.

When the condenser pressure builds up to the setting of

Valve A, it will open allowing liquid to flow to the receiver.

To determine the final setting of regulator B, allow the

condenser fans to run long enough to subcool the liquid

supplied to the receiver. Adjust the regulator until the desired

receiver pressure is obtained. Flow through the valve can be

determined by listening at the valve for gas flow or by feeling

the outlet for change in temperature. The setting of regulator

B should be at least 10 psi lower than the setting of regulator

To describe it again, during cold ambient temperature

conditions this liquid will be considerably subcooled and will

tend to lower the receiver pressure. Valve B will sense the

drop in pressure and open to admit hot gas into the drain line,

thus pressurizing and warming the liquid and maintaining the

receiver pressure.

Recommended Valve Settings

Regulators ordered for a Condenser Pressure Control system

for use with common refrigerants will be furnished with the

ranges and factory settings shown in Table 29 below. Turning

the adjusting stem in (clockwise) will raise the set point;

turning the stem out (counterclockwise) will lower the set

point. See Table 29 below for ranges and amount of

pressure change per turn.

Hot Gas Bypass Regulator

Adjustment

Discharge Bypass Valves (DVB) respond to changes in

downstream or suction pressure. When the evaporating

pressure is above the valve setting, the valve remains closed.

As the suction pressure drops below the valve setting, the

valve responds and begins to open. as with all modulating

type valves, the amount of opening is proportional to the

change in the variable being controlled - in this case the

suction pressure. As the suction pressure continues to drop,

the valve continues to open farther until the limit of the valve

stoke is reached.

Table 29. Pressure Range, Set point & Change per Turn

Factory

Valve

Type

A4A

ARA0

A7A

Range

Set Point

psig

Change Per Turn

psig

psig kg/cm²

75 to 5.2 to

kg/cm²

140

120

9.8

3.7

280

75 to 5.3 to

280 19.7

19.7

On refrigeration systems discharge bypass valves are used to

prevent the suction pressure from going below the minimum

value determined by the job requirements.

A7A1

A72

8.4

5.3

1.8

80 to 5.6 to

220 15.5

Sporlan Valve Company

Valve Setting and Adjustment

A complete discussion on valve settings is given in Sporlan

Application Bulletin 90-40. The fully adjustable models

ADRS(E)-2, ADRP(E)-3, and ADRH(E)-6 are available with

two adjustment ranges - 0/30 and 0/80 psig. The standard

factory settings for these are 20 and 60 psig, respectively.

The ADRI(E)-1-1/4 is available with a 0/55 psig range and the

standard factory setting is 28 psig.

Field Adjustment

Before final field adjustment of regulators for Condenser

Pressure Control, the following should be done:

1. Install gauges to read compressor discharge, condenser

and receiver pressures.

To adjust these valves, remove the cap an turn the

2. Fully charge the system.

adjustment nut with a 5/16” hex wrench for fully adjustable

models ADRS(E)-2, ADRP(E)-3, and ADRH(E)-6. The

ADRI(E)-1-1/4 model has a 3/8” adjustment screw on top of

the adjustment housing. A clockwise rotation increases the

setting and a counterclockwise rotation decreases the setting.

3. Have other controls and components functioning

properly.

4. Have the system as fully loaded as possible.

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Adjusting these valves can be complicated because the load

must be varied during the setting procedure and it is difficult

to determine exactly when the bypass valve opens unless a

pressure gauge can be located at the valve outlet.

Table 30. Control settings for R404A (507)

Air Temp

°F

EPR

psig

LP C/I

psig

LP C/O

psig

38-42

34-38

34-36

33-35

28-32

24-28

-10-/0

-10-/-5

-15/-10

-20/-15

Therefore, sufficient load must be available in some form to

raise the suction pressure above the desired valve setting.

Once this is accomplished, the load can be slowly decreased

until the DBV opens (a hissing sound and/or an

accompanying pressure rise at the outlet connection will

indicate that the bypass valve has opened).

Alco Controls

Valve Setting and Adjustment

CPHE and DGRE regulators are commonly used to prevent

the suction pressure from falling below a predetermined set

point. Complete information about these valves can be found

in ALCO CONTROLS Catalog 24-D.

Table 31. Control settings for R22

The first step after installation is to determine the set point for

the minimum suction pressure allowable for the application.

The following procedure should be followed.

Air Temp

°F

EPR

psig

LP C/I

psig

LP C/O

psig

38-42

34-38

34-36

33-35

28-32

24-28

-10-/0

-10-/-5

-15/-10

-20/-15

1. Start the system and determine if it is operating properly:

Install a gauge on the compressor suction line and

measure the suction pressure after the system has

stabilized. To make certain that hot gas is not being

bypassed, listen to the main regulator flow or feel the

outlet piping. If the piping is warm, this would indicate

hot gas is flowing.

2. Stop the flow of hot gas by de-energizing the hot gas

solenoid valve or by turning the power assembly

adjusting stem full C^{OUNTERCLOCKWISE}.

3. Reduce the evaporator load until the suction pressure

lowers to the point at which bypass is desired.

4. If the hot gas solenoid was de-energized to stop hot gas

flow, make sure it is now energized.

Low Pressure Switch Setting for RMCC

Some systems use a form of electronic control such as CPC’s

RMCC solid state controller for Rack operation. On these

systems, there is one mechanical low pressure control for

each suction group that may be on the rack. This control is

for backup emergency control in the event of a board or other

electronic component failure. This low pressure control must

be set for the minimum suction pressure that the rack would

be expected to operate at to keep from interfering with the

RMCC control.

5. Turn the power assembly adjusting stem in a C^LOCKWISE

direction until bypass occurs and suction pressure does

not fall below the predetermined set point. A C^LOCKWISE

turn of the adjusting stem will increase the pressure

setting; a C^{OUNTERCLOCKWISE}turn will decrease it.

Standard pressure pilot is adjustable from 0 to 80 psig,

with one complete turn equal to approximately 4 psi

change. Adjustments should be made in small

increments, allowing for the system to stabilize after each

turn.

Example, for a low temperature suction group, this control

should be set for 0 - 2 psig cutout and approximately 10 psig

cutin. A medium temperature suction group can be set

higher. In the event that this control is needed to actually

control the compressors, set the cutin and cutout for the

suction pressure that you want the compressors to operate to

maintain case or box temperatures.

6. Vary the evaporator load to test at various conditions that

the suction pressure does not fall below the

predetermined set point.

7. Replace the seal cap on the adjusting stem.

NOTE: This low pressure control will gener-

ally be mounted on a compressor with

the braided stainless steel tubing

connecting to the appropriate suction

group header.

Control Settings

The following tables are for use when mechanical low

pressure switches are incorporated for rack pressure control.

All control settings are approximate and should be adjusted

for actual field conditions and equipment. All settings are

based on 10°F T.D. evaporator.

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General Maintenance Schedule

(Service/Maintenance should be performed only by a

qualified / certified refrigeration service technician.)

Weekly

Quarterly

• Check refrigerant charge using the liquid line sight glass.

With unit in stable operation, record all operating conditions:

• Check compressor oil level.

• Suction / discharge / liquid refrigerant pressure(s) and

temperature(s)

• Check compressor crankcase heater operation.

• Check main power and control voltage

• Check appearance of area around the unit.

• Check system pressures

• System superheat, liquid subcooling, ambient

temperature

• Compressor amperage

• Test all operating and safety controls.

Monthly

• Check the refrigerant system for leaks.

Annually

• Check suction filters and liquid line filter driers.

• Obtain oil sample for analysis. Change oil if required.

• Check all flanged connection bolts, fittings and line

clamps for tightness.

• Clean condenser coil.

• Straighten condenser fins as required.

• Change liquid line filter drier and suction filter cores.

• Inspect condenser fan blades and motor mounts for

cracks, loose set screws or mounting bolts.

• Tighten all electrical connections.

Note: The above information is provided only

as a general guideline to aid servicing

personnel and equipment owners in

maintaining equipment. Due to vari-

ables in the actual equipment

• Check operation and condition of contacts on

compressor / fan motor contactors. Check appearance of

control panel interior.

• Check appearance of exterior conduit / junction boxes.

• Check appearance of insulation.

application, operating conditions, and

environment recommended service

intervals may vary.

• Check operation of auxiliary equipment.

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SERVICE DIAGNOSIS CHART

Symptom

Cause

Remedy

Compressor

does not run

Motor Line open.

1. Close starter or disconnect switch

2. Replace fuse

Fuse blown

Tripped overload

Control contacts dirty or jammed in

open position

3. See electrical section

4. Repair or replace

Piston seized

5. Remove motor-compressor head, look for

broken valve and jammed parts.

6. Repair or replace.

Frozen compressor or motor bearings

Unit short

cycles

Control differential set too close

Discharge valve leaking

Motor compressor ???

1. Widen differential

2. Replace valve plate

3. Check for high head pressure, tight bearings,

seized pistons, clogged air-cooled condenser.

4. Repair leak and recharge.

Refrigerant shortage

Refrigerant over charge

Cycling on high pres. cutout

5. Remove some refrigerant.

6. Check condenser / or non condensable in system

Compressor

will not start -

Hums

Improperly wired

Low voltage

1. Check wiring against diagram

2. Check main line voltage - determine location

of voltage drop

intermittently

Relay contacts not closing

Open circuit in start-winding

3. Check my operating manually. Replace relay

if defective

4. Check stator leads. If leads are all right,

replace stator.

Stator winding grounded

High discharge pressure

Tight compressor

5. Check stator. If leads are all right, replace stator.

6. Eliminate cause of excessive pressure

7. Check oil level. Correct binding.

Unit operates

long or

Control contacts sticking in closed position.

Insufficient refrigerant in system

Dirty condenser.

1. Clean points or replace control.

2. Check for leaks. Repair and add charge

3. Clean condenser

continuously

Air or non-condensables in system

Compressor inefficient

4. Purge high point in system

5. Check valves and pistons

Improper wiring

6. Check wiring and correct if necessary

Fixture

Insufficient refrigerant in system

Control set too high

1. Check for leaks. Repair and add charge

2. Reset control

temperature

too high

Control wiring loose

3. Check wiring to control

4. Clean or replace

Expansion valve or strainer plugged

Compressor inefficient

Expansion valve set too high

Iced or dirty coil

5. Check valves and pistons

6. Lower setting

7. Defrost or clean coil

Unit too small

8. Add unit or replace

Clogged or small refrigerant lines

9. Clear line or increase line size

10. Remove excessive oil, check refrigerant charge

10. Oil logged in system

High

Refrigerant overcharge

Non-condensables in system

Dirty condenser coil

1. Remove the excess

2. Remove the non-condensables

3. Clean

discharge

pressure

High side restriction

4. Check all valves or remove restriction

5. Adjust controls

Head pressure control setting

Fan not running

6. Check electrical circuit

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Symptom

Cause

Remedy

Low

Insufficient refrigerant in system

Faulty condenser temp. regulation

Compressor suction or discharge valve

inefficiencies.

1. Check for leaks. Repair and add charge

2. Check condenser control operation

3. Clean or replace leaky valve plates

discharge

pressure

Low suction pressure

4. See corrective steps for low suction pressure

5. Adjust valve or install a head pressure

control valve.

Head pressure control valve set wrong

or no head pressure control valve

High suction

pressure

Excessive load

1. Reduce load or add additional equipment

2. Check remote bulb. Regulate superheat.

Expansion valve overfeeding

Low suction

pressure

Lack of refrigerant

1. Check for leaks. Repair and add charge

2. Defrost or clean coil

Evaporator dirty or iced.

Clogged liquid line filter drier

Clogged suction line or compressor

suction strainer

3. Replace cartridge(s)

4. Clean strainer or replace filters

Expansion valve malfunctioning

Condensing temperature too low

5. Check and reset for proper superheat

6. Check means for regulating

condensing temperature

Improper TXV

7. Check for proper sizing

Little or No

oil pressure

Clogged suction oil strainer

Excessive liquid in crankcase

1. Clean

2. Check crankcase heater. Reset TXV for

higher superheat. Check liquid line solenoid

valve for proper operation.

3. Replace

Low oil pressure safety switch defective

Worn oil pump

4. Replace

Oil pump reversing gear stuck in

the wrong position.

5. Reverse direction of compressor rotation

Low oil level

6. Determine where the oil is or add oil.

7. Replace compressor

Worn bearings

Loose fitting on oil lines

Pump house gasket leaks.

8. Check and tighten fittings

9. Replace gasket

Compressor

loses oil

Lack of refrigerant

1. Check for leaks. Repair and add charge

2. Replace compressor

Excessive compression ring blowby

Refrigerant floods back

Improper piping or traps

3. Maintain proper superheat at compressor

4. correct piping

Compressor

thermal

Operating beyond design limits

1. Add facilities so that conditions are within

allowable limits.

protector

Discharge valve partially shut

Blown valve plate gasket

Dirty condenser coil

2. Open valve

switch open

3. Replace gasket

4. Clean coil

Overcharged system

5. Reduce charge

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SERVICE RECORD

A permanent data sheet should be prepared on each installation, with a copy for the owner and the original for the installing

contractor’s files. If another firm is to handle service and maintenance, additional copies should be prepared as necessary.

System Reference Data

The following information should be filled out and signed by the Refrigeration Installation Contractor.

Date System Installed:

Installer and Address:

_______________________

Date Started:

_______________________

__________________________________________________________________

Job Name / Location:

Compressor Unit Model: __________________________________________________________________

Compressor Unit Serial No.: ___________________________________________________________

_______________________ Phase: _______________________

_______________________ Serial No.: ________________________

Group __________________ Group _________________

__________________ / __________________ Group: __________________

Electrical :

Condenser Model:

Design SST: Group __________________

Compressor Model / Serial No.

__________________ / __________________

Group: __________________

Evacuation: # Times __________________

Final Micron: __________________

System Suction P (Group ____): ________________________

Ambient: ________________________

System Discharge P: ________________________

Superheat at Compressors: __________________________________________________________________________

Since product improvement is a continuing effort at Heatcraft, we reserve the right to make changes in specifications without notice.

HEATCRAFT INC. REFRIGERATION PRODUCTS DIVISION

2175 WEST PARK PLACE BLVD., STONE MOUNTAIN, GA 30087 • 770-465-5600 • FAX 770-465-6016

WWW.HEATCRAFTRPD.COM • E-MAIL: HRPD.FEEDBACK@HEATCRAFT.COM

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