Multiple Compressor
Condensing Units
H-IM-FP
Updates to March 2004 version.
April 2011
Part No. 25006801
Installation and Operation Manual
Table of Contents
Field Wiring................................................................................. 12
Refrigeration Charging........................................................... 13
Operational Checkout ............................................................ 14
System Balancing ..................................................................... 14
Preventive Maintenance..................................................15-17
Parts............................................................................................... 18
Wiring Diagram......................................................................... 19
Start-up Checklist...............................................................20-21
Nomenclature...............................................................................2
General Safety Information......................................................2
Compressor Module Specifications..................................3-4
Dimensional Diagrams..............................................................5
Condensing Unit Placement ...................................................6
Condensing Unit Rigging.........................................................7
Refrigeration Piping and Line sizing ..............................8-10
Leak Detection and Evacuation .......................................... 11
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Compressor Module Specifications
Table 1. Hermetic Compressor Module Electrical Data
Hermetic
Compressor
Model
Compressor
Electrical Rating
Compressor Data
RLA = MCC/1.56
Crankcase
Heater
Watts
48
Refrigerant
Evap. Temp.
Volts
Phase
1
1
3
1
3
1
3
1
3
1
3
1
1
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
1
1
1
1
3
1
3
1
3
1
3
Hz
60
50/60
50/60
RLA
LRA
30.0
41.0
40.0
70.5
55.0
100.3
85.0
140.0
107.0
142.0
130.0
37.0
34.2
56.0
51.0
56.0
51.0
61.0
55.0
82.0
65.5
96.0
75.0
121.0
105.0
125.0
102.0
26.5
33.7
43.0
34.2
59.2
52.0
59.2
52.0
87.0
72.2
105.0
85.0
MCC
Type
22
22
22
22
22
22
22
22
22
22
22
22
Lbs.
Min.
0
0
0
0
0
0
0
0
0
0
0
0
Max
40
40
40
40
40
40
40
40
40
40
40
30
40
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
0
HP
1/2
1 1/2
1 1/2
2
2
3
3
4
4
5
5
3/4
1
1 1/2
1 1/2
2
ART82C1-CAV
CR18KQ-PFV
CR18KQ-TF5
CR24KQ-PFV
CR24KQ-TF5
CR37KQ-PFV
CR37KQ-TF5
CR53KQ-PFV
CR53KQ-TF5
CRN-0500-PFV
CRN-0500-TF5
RS64C2-CAV
RS70C1-PFV
CS10K6E-PFV
CS10K6E-TF5
CS12K6E-PFV
CS12K6E-TF5
CS14K6E-PFV
CS14K6E-TF5
CS18K6E-PFV
CS18K6E-TF5
CS20K6E-PFV
CS20K6E-TF5
CS27K6E-PFV
CS27K6E-TF5
CS33K6E-PFV
CS33K6E-TF5
RST45C1E-CAV
RST55C1E-CAV
RST64C1E-CAV
RS70C1E-PFV
CF04K6E-PFV
CF04K6E-TF5
CF06K6E-PFV
CF06K6E-TF5
CF09K6E-PFV
CF09K6E-TF5
CF12K6E-PFV
CF12K6E-TF5
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
5.9
8.1
4.9
5.9
12.6
7.7
10
10
10
10
10
25
25
25
25
25
25
10
10
9
40
40
40
40
40
40
40
40
40
40
42
42
40
40
40
40
40
40
40
40
40
40
40
40
40
40
35
35
35
45
50
50
50/60 12.2
50/60 5.1
50/60 16.7
50/60 9.9
50/60 26.0
50/60 16.3
19.0
8.0
26.0
15.5
40.5
25.5
48.0
30.0
10.8
9.8
60
60
50/60
60
60
60
60
60
60
60
60
60
60
60
30.8
19.2
6.9
6.3
22
0
9.8
6.7
9.8
6.7
11.2
8.2
14.4
9.4
16.7
10.3
15.3
10.5
15.3
10.5
17.4
12.8
22.4
14.6
26.0
16.0
33.5
21.4
43.0
26.2
7.1
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
-25
-25
-25
-25
-25
-25
-25
-25
-25
-25
-25
-25
-25
-25
-25
-25
-25
-25
-40
-40
-40
-40
-40
-40
-40
-40
9
9
9
9
2
2 1/2
2 1/2
3
9
22
22
22
22
22
22
22
22
9
9
9
9
9
9
9
9
9
9
9
9
3
3 1/4
3 1/4
4
4
5
50/60 21.5
50/60 13.7
50/60 27.6
50/60 16.8
5
50/60
50/60
50/60
60
60
60
60
60
60
60
4.6
6.1
1/2
3/4
1
1
1
9.5
8.0
6.3
12.5
9.8
8.6
5.7
13.4
8.9
0
0
0
0
0
0
0
1
10.3
6.3
15.0
9.2
18.4
11.0
16.0
9.8
23.4
14.3
28.7
17.2
50
50
50
50
50
50
1 1/2
1 1/2
2 1/2
2 1/2
3
60
60
3
3
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Compressor Module Specifications
Table 2. Scroll Compressor Module Electrical Data
Scroll
Compressor
Model
ZS15K4E-PFV
ZS15K4E-TF5
Compressor
Electrical Rating
Compressor Data
RLA = MCC/1.56
Crankcase
Heater
Watts
40
Refrigerant
Lbs.
Evap. Temp.
HP
2
2
Volts
Phase
1
3
1
3
1
3
1
3
1
3
1
3
3
1
3
1
3
1
3
1
3
1
3
1
Hz
RLA
LRA
61.0
MCC
Type
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404A
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
404a
Min.
-5
-5
-5
-5
-5
-5
-5
-5
-5
-5
-5
-5
Max
35
35
35
35
35
35
35
35
35
35
35
35
35
0
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
208-230
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
12.2
8.3
14.7
8.7
19.0
13.0
23.0
13.6
23.0
15.5
29.0
19.0
37.5
21.0
45.0
30.0
33.5
19.0
13.0
23.0
13.6
20.0
13.5
25.0
17.0
35.0
18.5
39.0
26.5
30.5
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
55.0
73.0
63.0
40
40
40
80
80
80
80
80
80
80
80
80
40
40
40
40
80
80
80
80
80
80
80
80
2 1/2 ZS19K4E-PFV
2 1/2 ZS19K4E-TF5
3
3
ZS21K4E-PFV
ZS21K4E-TF5
14.7
9.9
88.0
77.0
109.0
88.0
129.0
99.0
169.0
123.0
156.0
61.0
3 1/2 ZS26K4E-PFV
3 1/2 ZS26K4E-TF5
4 1/2 ZS30K4E-PFV
4 1/2 ZS30K4E-TF5
5 1/2 ZS38K4E-PFV
5 1/2 ZS38K4E-TF5
18.6
12.2
24.0
13.5
28.8
19.2
21.5
12.2
8.3
6
2
2
ZS45K4E-TF5
ZF06K4E-PFV
ZF06K4E-TF5
-5
-40
-40
-40
-40
-40
-40
-40
-40
-40
-40
-40
-40
-40
55.0
0
0
0
0
0
0
0
0
0
0
0
0
2 1/2 ZF08K4E-PFV
2 1/2 ZF08K4E-TF5
14.7
8.7
12.8
8.7
73.0
63.0
88.0
77.0
3
3
ZF09K4E-PFV
ZF09K4E-TF5
3 1/2 ZF11K4E-PFV
3 1/2 ZF11K4E-TF5
4 1/2 ZF13K4E-PFV
4 1/2 ZF13K4E-TF5
5 1/2 ZF15K4E-PFV
5 1/2 ZF15K4E-TF5
16.0
10.9
22.4
11.9
25.0
17.0
19.6
109.0
88.0
129.0
99.0
169.0
123.0
156.0
3
3
6
ZF18K4E-TF5
80
4
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Dimensional Diagrams
End View
Figure 1.
Optional Disconnect Switch
One Fan Top View
System Position
3
2
1
Electrical Knockout (4)
Please note system positions.
Liquid Lines
Suction Lines
Two Fan Top View
SYS. 2
X = 100.50 (Three Fan Length)
X = 78.00 (Two Fan Length)
X = 59.00 (Single Fan Length)
Side View
Three Fan Top View
5
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Condensing Unit Placement
Space and Location Requirements
The most important consideration which must be taken into account when deciding upon the location of air-
cooled equipment is the provision for a supply of ambient air to the condenser, and removal of heated air from the
condensing unit or remote condenser area. Where this essential requirement is not adhered to, it will result in higher
head pressures, which cause poor operation and potential failure of equipment. Units must not be located in the
vicinity of steam, hot air or fume exhausts. Corrosive atmospheres require custom designed condensers.
Another consideration which must be taken is that the unit should be mounted away from noise sensitive spaces and
must have adequate support to avoid vibration and noise transmission into the building. Units should be mounted
over corridors, utility areas, rest rooms and other auxiliary areas where high levels of sound are not an important
factor. Sound and structural consultants should be retained for recommendations. (Refer to actual building plans for
unit locations.)
Figure 2. Condensing Unit Placement
3 Feet
(minimum)
Clearance to
the Next Unit
3 Feet
3 Feet from
Building
Wall
(minimum)
Clearance from
unit to an Open
Block Wall or
Shrubs.
3 Feet
(minimum)
Clearance for
Contractor to
Service Unit.
6
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Condensing Unit Rigging
Figure 3. Condensing Unit Rigging
Adequate rigging measures must be tak-
en to support unit weight and to protect
the unit from damage during unloading
and placement process.
Rigging holes have been provided in legs
and under the unit compressor compart-
ment frame to assist.
Rigging Holes
Spreader bars may be used to protect
unit from damage.
7
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Refrigeration Piping And Line Sizing
Refrigeration Piping And Line Sizing
The system as supplied by Heatcraft Refrigeration Products, was thoroughly cleaned and dehydrated at the factory.
Foreign matter may enter the system by way of the evaporator to condensing unit piping. Therefore, care must
be used during installation of the piping to prevent entrance of foreign matter. Install all refrigeration system
components in accordance with applicable local and national codes and in conformance with good practice required
for the proper operation of the system. The refrigerant pipe size should be selected from the tables in Refrigeration
System Installation Manual, Part Number 25001201. The interconnecting pipe size is not necessarily the same size as
the stub-out on the condensing unit or the evaporator.
The following procedures should be followed:
(a) Do not leave dehydrated compressors or filter-driers on condensing units open to the atmosphere any longer
than is absolutely necessary.
(b) Use only refrigeration grade (ACR) copper tubing, properly sealed against contamination.
(c) Suction lines should slope 1/4”per 10 feet towards the compressor (in direction of flow).
(d) Suitable P-type oil traps should be located at the base of each suction riser to enhance oil return to the
compressor.
(e) For desired method of superheat measurement, a pressure tap should be installed in each evaporator suction
line in the proximity of the expansion valve bulb.
(f) When brazing refrigerant lines, an inert gas should be passed through the line at low pressure to prevent scaling
and oxidation inside the tubing. Dry nitrogen is preferred.
(g) Use only a suitable silver solder alloy on suction and liquid lines.
(h) Limit the soldering paste of flux to the minimum required to prevent contamination of the solder joint internally.
Flux only the male portion of the connection, never the female. After brazing, remove excess flux.
(i) Wrap expansion valves with wet rags during brazing to the liquid line.
CAUTION: If the temperature gets too high, these components may be damaged. Heat absorbing compounds
or wet rags must be used to protect the expansion valve when brazing to the refrigerant
piping/line connections, and the suction line sensor must be removed per above instructions.
(j) Do not use “bull head”tees. This will cause oil return problems and can cause poor performance.
(k) If isolation valves are installed at the evaporator, full port ball valves should be used.
8
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Refrigeration Piping
Suction Lines
NOTE: If the suction line must rise to the point higher than the suction connection on
the evaporator, a suction line trap at the outlet of the evaporator must be provided.
Horizontal suction lines should slope away from the evaporator toward the compressor at the rate of 1/4’per 10 feet
for good oil return. When multiple evaporators are connected in series using a common suction line, the branch
suction lines must enter the top of the common suction line.
Suction lines that are outside of refrigerated space must be insulated. See “Line Insulation”for more information.
Suction Line Risers
NOTE: To provide proper oil return, a suction trap must be provided at the base of
all suction risers.
Prefabricated wrought copper traps are available, or a trap can be made by using two street ells and one regular ell.
The suction trap must be the same size as the suction line. For long vertical risers, additional traps may be necessary.
Generally, one trap is recommended for each length of pipe (approximately 20 feet) to insure proper oil movement.
See Figure 4 below for methods of constructing proper suction line P-traps.
Figure 4. Suction P-traps
Condensate Drain Lines
Copper drain lines should be used and properly protected from freezing. In running drain lines, provide a minimum
of 4 inches per foot pitch for proper drainage. Drain lines should be at least as large as the evaporator drain
connection. All plumbing connections should be made in accordance with local plumbing codes. All condensate
drain lines must be trapped, and run to an open drain. They must never be connected directly to the sewer
systems. Traps in the drain line must be located in a warm ambient. We recommend a trap on all evaporators. Traps
located outside, or extensive outside runs of drain line must
be wrapped with a drain line heater. The heater should be
Figure 5. Drain Line
connected so that it is continuously on. It is recommended that
the drain line be insulated to prevent heat loss. A heat input
of 20 watts per lineal foot of drain line for 0ºF (-18°C) room
applications and 30 watts per lineal foot for -20°F (-29°C) rooms
is satisfactory.
Inspect the drain pan periodically to insure free drainage of
condensate. If the drain pan contains standing water, check for
proper installation. The drain pan should be cleaned regularly
with warm soapy water.
WARNING: All power must be disconnected
before cleaning. The drain pan also serves as
cover for hazardous moving parts. Operation
of unit without drain pan constitutes a hazard.
NOTE: Always trap drain lines individually
to prevent vapor migration.
9
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Refrigeration Piping
Figure 6. Example of
Pipe Support
1. Normally, any straight run of tubing must be supported in at least two locations near each end of the run. Long
runs require additional supports. The refrigerant lines should be supported and fastened properly. As a guide,
3/8 to 7/8 should be supported every 5 feet, 1-1/8 and 1-3/8 every 7 feet; and 1-5/8 and 2-1/8 every 9 to 10 feet.
2. When changing directions in a run of tubing, no corner should be left unsupported. Supports should be placed a
maximum of 2 feet in each direction from the corner.
3. Piping attached to a vibrating object (such as a compressor or compressor base) must be supported in such
a manner that will not restrict the movement of the vibrating object. Rigid mounting will fatigue the copper
tubing.
4. Do not use short radius ells. Short radius elbows have points of excessive stress concentration and are subject to
breakage at these points.
5. Thoroughly inspect all piping after the equipment is in operation and add supports wherever line vibration is
significantly greater than most of the other piping. Extra supports are relatively inexpensive as compared to
refrigerant loss.
Figure 7.
Line Insulation
After the final leak test, refrigerant lines exposed to high
or low ambient conditions should be insulated to reduce
heat loss or gain and prevent the formation of flash gas
in the liquid lines. Suction lines should be insulated with
3/4" wall Armstrong “Armaflex”or equivalent. Liquid lines
should also be insulated with 1/2-inch wall insulation or
better. The insulation located in outdoor environments
should be protected from UV exposure to prevent
deterioration of insulating value.
10
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Leak Detection And Evacuation
Leak Testing
After all lines are connected, the entire system must be leak tested. The complete system should be pressurized to
not more than 150 PSIG with refrigerant and dry nitrogen. The use of an electronic type of leak detector is highly
recommended because of its greater sensitivity to small leaks. As a further check, it is recommended that this
pressure be held for a minimum of 12 hours and then rechecked. For a satisfactory installation, the system must be
leak tight.
Leak detection can be carried out in the conventional manner. If HCFC or CFC tracer gas is used, care must be taken
to completely remove all traces of the gas prior to introducing HFC’s. Electronic leak detectors are now available that
will sense HFC’s. This is considered preferable since it removes the possibility of chlorine remaining in the system
after leak testing with HCFC’s and/or HCFC’s. There is a view that even small quantities of chlorine may act as a
catalyst encouraging copper plating and/or corrosion and should therefore be avoided.
Within the last several years, manufacturers have developed fluorescent dye leak detection systems for use with
refrigerants. These dyes mix with the lubricant and, when exposed to an ultraviolet light, fluoresce to indicate the
location of leaks. Copeland has tested and approved the Rigid “System Safe”dye and found it to be compatible with
the compressor materials in systems.
Evacuation
CAUTION:
Do not use the refrigeration compressor
to evacuate the system. Do not start the
compressor while it is in a vacuum.
Due to the smaller molecule size of HFC’s, they will tend to leak more readily than CFC. Consequently, it is of
the utmost importance that proper system evacuation and leak detection procedures be employed. Copeland
recommends a minimum evacuation to 500 microns. In addition, a vacuum decay test is strongly recommended to
assure there is not a large pressure differential between the system and vacuum pump. Good evacuation processes
include frequent vacuum pump oil changes and large diameter, short hose connections to both high and low sides
of the system preferably using bronze braided hose.
A good, deep vacuum pump should be connected to both the low and high side evacuation valves with copper tube
or high vacuum hoses (1/4”ID minimum). If the compressor has service valves, they should remain closed. A deep
vacuum gauge capable of registering pressure in microns should be attached to the system for pressure readings.
A shut-off valve between the gauge connection and vacuum pump should be provided to allow the system pressure
to be checked after evacuation. Do not turn off vacuum pump when connected to an evacuated system before
closing shut-off valve.
The vacuum pump should be operated until a pressure of 1,500 microns absolute pressure is reached – at which time
the vacuum should be broken with the refrigerant to be used in the system through a drier until the system pressure
rises above “0”psig.
NOTE: Refrigerant used during evacuation can not be vented.
Reclaim all used refrigerant. EPA regulations are constantly
being updated. Ensure your procedures follow correct regulations.
Repeat this operation a second time.
Open the compressor’s service valves and evacuate the entire system to 500 microns absolute pressure.
Raise the pressure to 2 psig with the refrigerant and remove the vacuum pump.
11
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Field Wiring
WARNING: All wiring must be done in accordance with applicable codes and local ordinances.
The field wiring should enter the areas as provided on the unit. The wiring diagram for each unit is
located on the inside of the electrical panel door. All field wiring should be done in a professional manner
and in accordance with all governing codes. Before operating unit, double check all wiring connections,
including the factory terminals. Factory connections can vibrate loose during shipment.
1. The nameplate on the unit is marked with the electrical characteristic for wiring the unit.
2. Consult the wiring diagram in the unit cooler and in the condensing unit for proper connections.
3. Wire type should be of copper conductor only and of the proper size to handle the connected load.
4. The unit must be grounded.
5. For multiple evaporator systems, follow the wiring diagrams for multiple evaporator systems carefully.
This will assure complete defrost of all evaporators in the system.
6. If a remote defrost Timer is to be used, the Timer should be located outside the refrigerated space.
Note: Control wiring from the remote machines such as ice machines, drink machines, cases,
etc. must be connected to the relays in the Control Panel to properly energize condenser fans.
Figure 8.
System #3
System #2
System #1
12
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Refrigeration Charging
Refrigeration Charging
1. Install a liquid line drier in the refrigerant supply line between the service gauge and the liquid service port of the
receiver. This extra drier will insure that all refrigerant supplied to the system is clean and dry.
2. When initially charging a system that is in a vacuum, liquid refrigerant can be added directly into the receiver tank
to break the vacuum. Weighing in the charge is recommended with the initial charge
consisting of approximately 2 pounds per system compressor horsepower.
3. Remove the refrigerant drum and connect it to the suction side of the compressor to charge with refrigerant vapor
into the low side of the system until the pressure is above atmospheric.
4. Start the system and finish charging until the sight glass indicates a full charge and the proper amount has been
weighed in (a total of 4 to 5 pounds per system compressor horsepower).
5. If refrigerant must be added to the system through the suction side of the compressor, charge in vapor form only.
Liquid charging must be done in the high side only or with liquid metering devices to protect the compressor.
Check-Out & Start-Up
After the installation has been completed, the following points should be covered before the system is placed in
operation:
(a) Check all electrical and refrigerant connections. Be sure they are all correct and tight.
(b) Check setting of time delay relay for low pressure switch in condensing unit. It should be set at two minutes (the
third marker).
(c) Check high and low pressure controls, pressure regulating valves, oil pressure safety controls, and all other safety
controls and adjust them, if necessary.
(d) Liquid line should always be insulated.
(e) Wiring diagrams, instruction bulletins, etc. attached to the condensing units should be read and filed for future
reference.
(f) All fan motors on air cooled condensers, evaporators, etc. should be checked for proper rotation. Fan motor
mounts should be carefully checked for tightness and proper alignment.
(g) Observe system pressures during charging and initial operation. Do not add oil while the system is short of
refrigerant unless oil level is dangerously low.
(h) Continue charging until system has sufficient refrigerant for proper operation. Do not overcharge. Remember that
bubbles in a sight glass may be caused by a restriction as well as a shortage of refrigerant.
(i) Do not leave unit unattended until the system has reached normal operating conditions and the oil charge has
been properly adjusted to maintain the oil level at the center of the sight glass.
CAUTION: Extreme care must be taken in starting compressors for the first time after system charging. At
this time, all of the oil and most of the refrigerant might be in the compressor creating a condition which
could cause compressor damage due to slugging. Activating the crankcase heater for 24 hours prior to
start-up is recommended. If no crankcase heater is present, then directing a 500 watt heat lamp or other
safe heat source on the lower shell of the compressor for approximately thirty minutes will be beneficial in
eliminating this condition which might never reoccur.
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Operational Checkout
After the system has been charged and has operated for at least 2 hours at normal operating conditions without any
indication of malfunction, it should be allowed to operate overnight on automatic controls. Then a thorough re-
check of the entire system operation should be made as follows:
(a) Check compressor discharge and suction pressures. If not within system design limits, determine why and take
corrective action.
(b) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is
required, leak test all connections and system components and repair any leaks before adding refrigerant.
(c) Using suitable instruments, carefully check line voltage and amperage at the compressor terminals. Voltage
must be within 10% of that indicated on the condensing unit nameplate. If high or low voltage is indicated,
notify the power company. If amperage draw is excessive, immediately determine the cause and take
corrective action. On 3 phase motor compressors, check to see that a balanced load is drawn by each phase.
(d) The maximum approved settings for high pressure controls on Heatcraft air cooled condensing equipment is
425 psig. On air cooled systems, check as follows:
• Disconnect the fan motors or block the condenser inlet air.
• Watch high pressure gauge for cutout point.
• Re-check all safety & operating controls for proper operation and adjust if necessary.
(e) Check head pressure controls for pressure setting.
(f) Check crankcase heater operation if used.
(g) Install instruction card and control system diagram for use of building manager or owner.
System Balancing
IMPORTANT: In order to obtain the maximum capacity from a system, and to ensure
trouble-free operation, it is essential to balance each and every system.
The critical value to be checked here is suction superheat at the compressor:
1. Measure the suction pressure at the suction service valve of the compressor and determine the saturation
temperature corresponding to this pressure from a “Temperature-Pressure”chart.
2. Measure the suction temperature of the suction line about one foot back from the compressor using an accurate
thermometer.
3. Subtract the saturated temperature from the actual suction line temperature. The difference is superheat.
Too low a suction superheat can result in liquid being returned to the compressor. This will cause dilution of the
oil and eventual failure of the bearings and rings or in the extreme case, valve failure or even “slugging”of the
compressor.
Too high a suction superheat will result in excessive discharge temperatures which causes a break down of the oil
and results in piston ring wear, piston and cylinder wall damage.
It should also be remembered that the system capacity decreases as the suction superheat increases. For maximum
system capacity, suction superheat should be kept as low as is practical. Copeland mandates a minimum superheat
of 20ºF and a maximum of 45ºF at the compressor. Heatcraft recommends a superheat of 30ºF.
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Preventive Maintenance
Routine preventive maintenance of any mechanical equipment is critical to its long term reliability. During normal
operation all equipment will experience some deterioration during its lifetime caused by wear and evironmental
influences. For that reason, regularly scheduled maintenance of your refrigeration equipment is required in order
to keep it operating to its maximum efficiency while avoiding potentially costly repairs of a premature failure
due to equipment neglect. The following is our minimum recommendations for regularly scheduled preventive
maintenance of your refrigeration system. Only qualified and licensed refrigeration companies should perform all
preventive and corrective maintenance on refrigeration equipment. While we cannot guarantee that close adherence
to these recommendations will eliminate all equipment problems, it will greatly reduce the potential for mechanical
and electrical failures thus providing increased reliability.
Refer to pages 16 and 17 for preventive maintenance guidelines.
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Preventive Maintenance
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Preventive Maintenance
17
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Replacement Parts
Table 3. Replacement Parts List
Parts Description
Compressor Contactor - 24 Volt
Compressor Contactor - 230 Volt
Terminal Block 6 Pole, Control Circuit
Fan Motor
Part Number
2252440
2252340
2251266
25399101
22999901
23104401
28913201
Fan Blade
Fan Guard / Motor Mount
High Pressure Control
Low Pressure Control:
Adjustable
2891402
28913401
22536801
22510001
40922001
40927901
40922301
3800017
Fixed
Time Delay Relay, Low Pressure Switch
Fuse 15 Amp
Top Panel, Over Compressors
Top Panel, Electrical Components Cover
Front Panel, Compressor Access
Hinge, 2 Required Connects Top Panels
Fan Panel:
3 Fan
46819701
46899601
46898801
2 Fan
1 Fan
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Wiring Diagram
Diagram 1. Typical Wiring Diagram
W O Y E L L
W O Y E L L
W O Y E L L
W O Y E L L
W O Y E L L
WHITE
BLACK
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Start-up Checklist
• Is the sight glass free of bubbles?
YES NO
• Are the COOLER and FREEZER fans at proper speeds?
YES NO
Date of Start-up
Location
CONDENSING UNIT
MODEL #
• Check system for refrigerant leaks. Are there any
leaks on the COOLER, FREEZER, CONDENSING UNIT or
INTERCONNECTING PIPING?
ELECTRICAL
• Check Compressor Amps for COOLER and
FREEZER compressors. Should match
nameplate.
YES
NO
• Check system piping for unusual vibration or noise. Is
there any unusual vibration or noise on the COOLER,
FREEZER, CONDENSING UNIT or INTERCONNECTING
PIPING?
YES
NO
PIPING
• Is suction line trapped at the Cooler?
YES NO
• Is suction line trapped at the Freezer?
YES
NO
YES
NO
DRAIN LINES
• Are drain lines sloped properly?
YES
NO
• Is drain line trapped outside the Cooler?
YES NO
• Is drain line trapped outside the Freezer?
YES NO
• Is heat tape wrapped along entire length of
the drain line in the Freezer?
YES
NO
• Is heat tape plugged in and heating the drain
line?
YES
NO
INSULATION
• Are Liquid lines fully insulated?
YES
NO
• Are Suction lines fully insulated?
YES NO
SYSTEM CHECKS
• Check Compressor Superheat for the
COOLER (Should be between 20°F. & 30°F.)
YES
NO
• Check Compressor Superheat for the
FREEZER (Should be between 20°F. & 30°F.)
YES
NO
•Force unit into a Defrost Check heater amps.
Should match nameplate amps.
YES
NO
• Check LPS Time Delay Relays. Should be
set at 1 minute for both the COOLER and
FREEZER.
YES
NO
• Check Low Pressure Switch on FREEZER. Should be set
at 0 psig Cut-out/10 psig Cut-in.
YES
NO
• Did FREEZER and COOLER cycle off on LPS at Set-point
Temperature?
YES
NO
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Start-up Checklist
RECORD
OUTDOOR TEMPERATURE
______°F.
______Volts
SYSTEM VOLTAGE
______PH
______L2
______L2
______L2
______PH
______L3
______L3
______L3
System 1 Compressor Amps
System 2 Compressor Amps
System 3 Compressor Amps
System 1 Discharge Pressure
System 2 Discharge Pressure
System 3 Discharge Pressure
System 1 Suction Pressure
System 2 Suction Pressure
System 3 Suction Pressure
System 1 Suction Temp.
______L1
______L1
______L1
______PSIG
______PSIG
______PSIG
______PSIG
______PSIG
______PSIG
______°F.
______°F.
______°F.
______lbs.
______lbs.
______lbs.
______°F.
______°F.
______°F.
______°F.
______°F.
______°F.
______°F.
______°F.
______°F.
System 2 Suction Temp.
System 3 Suction Temp.
System 1 Refrigerant Charge
System 2 Refrigerant Charge
System 3 Refrigerant Charge
System 1 Compressor Superheat
System 2 Compressor Superheat
System 3 Compressor Superheat
System 1 Evaporator Superheat
System 2 Evaporator Superheat
System 3 Evaporator Superheat
System 1 Discharge Temp.
System 2 Discharge Temp.
System 3 Discharge Temp.
System #3
System #2
System #1
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Notes
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Notes
23
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FlexPack
WARNING
Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly. Failure to follow this
warning may result in personal injury or death.
Since product improvement is a continuing effort,
we reserve the right to make changes in specifications without notice.
2175 W. Park Place Blvd. • Stone Mountain, Georgia 30087
(770) 465-5600 • Fax: (770) 465-5990
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