Heatcraft Refrigeration Products FLEXPACK 25006801 User Manual

Multiple Compressor

Condensing Units

H-IM-FP April 2011 Part No. 25006801

Updates to March 2004 version.

Installation and Operation Manual

Table of Contents

Nomenclature ...............................................................................2

General Safety Information......................................................2

Compressor Module Specications ..................................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

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

TPC1 - One Condenser Fan Cabinet

TPC2 - Two Condenser Fan Cabinet

TPC3 - Three Condenser Fan Cabinet

General Safety Information

-

1. Installation and maintenance to be performed only by certied personnel who are familiar with this type of
equipment.

2. Make sure that all eld wiring conforms to the requirements of the equipment and all applicable national and
local codes.

3. Avoid contact with sharp edges and coil surfaces. They are a potential injury hazard.

4. Make sure all power sources are disconnected before any service work is done on units.

Inspection

Responsibility should be assigned to a dependable individual at the job site to receive material. Each shipment
should be carefully checked against the bill of lading. The shipping receipt should not be signed until all items listed
on the bill of lading have been accounted for. Check carefully for concealed damage. Any shortage or damages
should be reported to the delivering carrier. Damaged material becomes the delivering carrier’s responsibility and
should not be returned to the manufacturer unless prior approval is given to do so. When uncrating, care should be
taken to prevent damage. Heavy equipment should be left on its shipping base until it has been moved to the nal
location.

© 2011, Heatcraft Refrigeration Products LLC

2

Compressor Module Specications

Table 1. Hermetic Compressor Module Electrical Data

Hermetic Compressor Compressor Data Crankcase
Compressor Electrical Rating RLA = MCC/1.56 Heater Refrigerant Evap. Temp.

Model Volts Phase Hz RLA LRA MCC Watts Type Lbs. Min. Max

HP

ART82C1-CAV 208-230 1 60 5.9 30.0 5.9 48 22 10 0 40

1/2

CR18KQ-PFV 208-230 1 50/60 8.1 41.0 12.6 40 22 10 0 40

1 1/2

CR18KQ-TF5 208-230 3 50/60 4.9 40.0 7.7 40 22 10 0 40

1 1/2

CR24KQ-PFV 208-230 1 50/60 12.2 70.5 19.0 40 22 10 0 40

2

CR24KQ-TF5 208-230 3 50/60 5.1 55.0 8.0 40 22 10 0 40

2

CR37KQ-PFV 208-230 1 50/60 16.7 100.3 26.0 40 22 25 0 40

3

CR37KQ-TF5 208-230 3 50/60 9.9 85.0 15.5 40 22 25 0 40

3

CR53KQ-PFV 208-230 1 50/60 26.0 140.0 40.5 40 22 25 0 40

4

CR53KQ-TF5 208-230 3 50/60 16.3 107.0 25.5 40 22 25 0 40

4

CRN-0500-PFV 208-230 1 60 30.8 142.0 48.0 40 22 25 0 40

5

CRN-0500-TF5 208-230 3 60 19.2 130.0 30.0 40 22 25 0 40

5

RS64C2-CAV 208-230 1 50/60 6.9 37.0 10.8 42 22 10 0 30

3/4

RS70C1-PFV 208-230 1 60 6.3 34.2 9.8 42 22 10 0 40

1

CS10K6E-PFV 208-230 1 60 9.8 56.0 15.3 40 404a 9 -25 30

1 1/2

CS10K6E-TF5 208-230 3 60 6.7 51.0 10.5 40 404a 9 -25 30

1 1/2

CS12K6E-PFV 208-230 1 60 9.8 56.0 15.3 40 404a 9 -25 30

2

CS12K6E-TF5 208-230 3 60 6.7 51.0 10.5 40 404a 9 -25 30

2

CS14K6E-PFV 208-230 1 60 11.2 61.0 17.4 40 404a 9 -25 30

2 1/2

CS14K6E-TF5 208-230 3 60 8.2 55.0 12.8 40 404a 9 -25 30

2 1/2

CS18K6E-PFV 208-230 1 60 14.4 82.0 22.4 40 404a 22 -25 30

3

CS18K6E-TF5 208-230 3 60 9.4 65.5 14.6 40 404a 22 -25 30

3

CS20K6E-PFV 208-230 1 60 16.7 96.0 26.0 40 404a 22 -25 30

3 1/4

CS20K6E-TF5 208-230 3 60 10.3 75.0 16.0 40 404a 22 -25 30

3 1/4

CS27K6E-PFV 208-230 1 50/60 21.5 121.0 33.5 40 404a 22 -25 30

4

CS27K6E-TF5 208-230 3 50/60 13.7 105.0 21.4 40 404a 22 -25 30

4

CS33K6E-PFV 208-230 1 50/60 27.6 125.0 43.0 40 404a 22 -25 30

5

CS33K6E-TF5 208-230 3 50/60 16.8 102.0 26.2 40 404a 22 -25 30

5

RST45C1E-CAV 208-230 1 50/60 4.6 26.5 7.1 35 404a 9 -25 30

1/2

RST55C1E-CAV 208-230 1 50/60 6.1 33.7 9.5 35 404a 9 -25 30

3/4

RST64C1E-CAV 208-230 1 50/60 8.0 43.0 12.5 35 404a 9 -25 30

1

RS70C1E-PFV 208-230 1 60 6.3 34.2 9.8 45 404a 9 -25 30

1

CF04K6E-PFV 208-230 1 60 8.6 59.2 13.4 50 404a 9 -40 0

1

CF04K6E-TF5 208-230 3 60 5.7 52.0 8.9 50 404a 9 -40 0

1

CF06K6E-PFV 208-230 1 60 10.3 59.2 16.0 50 404a 9 -40 0

1 1/2

CF06K6E-TF5 208-230 3 60 6.3 52.0 9.8 50 404a 9 -40 0

1 1/2

CF09K6E-PFV 208-230 1 60 15.0 87.0 23.4 50 404a 9 -40 0

2 1/2

Low Temp. Medium Temp. High Temp.

CF09K6E-TF5 208-230 3 60 9.2 72.2 14.3 50 404a 9 -40 0

2 1/2

CF12K6E-PFV 208-230 1 60 18.4 105.0 28.7 50 404a 9 -40 0

3

CF12K6E-TF5 208-230 3 60 11.0 85.0 17.2 50 404a 9 -40 0

3

3

Compressor Module Specications

Table 2. Scroll Compressor Module Electrical Data

Scroll Compressor Compressor Data Crankcase
Compressor Electrical Rating RLA = MCC/1.56 Heater Refrigerant Evap. Temp.

Model Volts Phase Hz RLA LRA MCC Watts Type Lbs. Min. Max

HP

ZS15K4E-PFV 208-230 1 60 12.2 61.0 19.0 40 404a 22 -5 35

2

ZS15K4E-TF5 208-230 3 60 8.3 55.0 13.0 40 404a 22 -5 35

2

ZS19K4E-PFV 208-230 1 60 14.7 73.0 23.0 40 404a 22 -5 35

2 1/2

ZS19K4E-TF5 208-230 3 60 8.7 63.0 13.6 40 404a 22 -5 35

2 1/2

ZS21K4E-PFV 208-230 1 60 14.7 88.0 23.0 80 404a 22 -5 35

3

ZS21K4E-TF5 208-230 3 60 9.9 77.0 15.5 80 404a 22 -5 35

3

Medium Temp.

Low Temp.

ZS26K4E-PFV 208-230 1 60 18.6 109.0 29.0 80 404a 22 -5 35

3 1/2

ZS26K4E-TF5 208-230 3 60 12.2 88.0 19.0 80 404a 22 -5 35

3 1/2

ZS30K4E-PFV 208-230 1 60 24.0 129.0 37.5 80 404a 22 -5 35

4 1/2

ZS30K4E-TF5 208-230 3 60 13.5 99.0 21.0 80 404a 22 -5 35

4 1/2

ZS38K4E-PFV 208-230 1 60 28.8 169.0 45.0 80 404a 22 -5 35

5 1/2

ZS38K4E-TF5 208-230 3 60 19.2 123.0 30.0 80 404a 22 -5 35

5 1/2

ZS45K4E-TF5 208-230 3 60 21.5 156.0 33.5 80 404a 22 -5 35

6

ZF06K4E-PFV 208-230 1 60 12.2 61.0 19.0 40 404a 22 -40 0

2

ZF06K4E-TF5 208-230 3 60 8.3 55.0 13.0 40 404A 22 -40 0

2

ZF08K4E-PFV 208-230 1 60 14.7 73.0 23.0 40 404a 22 -40 0

2 1/2

ZF08K4E-TF5 208-230 3 60 8.7 63.0 13.6 40 404a 22 -40 0

2 1/2

ZF09K4E-PFV 208-230 1 60 12.8 88.0 20.0 80 404a 22 -40 0

3

ZF09K4E-TF5 208-230 3 60 8.7 77.0 13.5 80 404a 22 -40 0

3

ZF11K4E-PFV 208-230 1 60 16.0 109.0 25.0 80 404a 22 -40 0

3 1/2

ZF11K4E-TF5 208-230 3 60 10.9 88.0 17.0 80 404a 22 -40 0

3 1/2

ZF13K4E-PFV 208-230 1 60 22.4 129.0 35.0 80 404a 22 -40 0

4 1/2

ZF13K4E-TF5 208-230 3 60 11.9 99.0 18.5 80 404a 22 -40 0

4 1/2

ZF15K4E-PFV 208-230 1 60 25.0 169.0 39.0 80 404a 22 -40 0

5 1/2

ZF15K4E-TF5 208-230 3 60 17.0 123.0 26.5 80 404a 22 -40 0

5 1/2

ZF18K4E-TF5 208-230 3 60 19.6 156.0 30.5 80 404a 22 -40 0

6

4

Dimensional Diagrams

Figure 1.

One Fan Top View

Two Fan Top View

Optional Disconnect Switch

Please note system positions.

Liquid Lines

Suction Lines

End View

System Position

3

2

1

Electrical Knockout (4)

SYS. 1

SYS. 2

SYS. 3

Three Fan Top View

X = 100.50 (Three Fan Length)

X = 78.00 (Two Fan Length)

X = 59.00 (Single Fan Length)

Side View

5

Condensing Unit Placement

Space and Location Requirements

The most important consideration which must be taken into account when deciding upon the location of air­cooled 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

3 Feet from

Building

Wall



the Next Unit





3 Feet

(minimum)

Clearance from

unit to an Open

Block Wall or

Shrubs.



3 Feet

(minimum)
Clearance for
Contractor to

Service Unit.

6

Condensing Unit Rigging

Figure 3. Condensing Unit Rigging

Adequate rigging measures must be tak­en 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 compart­ment frame to assist.

Spreader bars may be used to protect
unit from damage.

Rigging Holes

7

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 lter-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 ow).
(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 ux 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 ux.
(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