Heatcraft Refrigeration Products H-IM-FL1A User Manual

FL AC Scroll
Refrigeration Systems

H-IM-FL1A December, 2004 Part No. 25006901

Table of Contents

Installation and

Operation Manual

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

Inspection ................................................................................. 2

Warranty Statement ..................................................................

Air Cooled Condensing Unit and Condenser Space and Location

Requirements .................................................................. 3

Condensing Unit Rigging and Mounting ................................... 4

Ambient Fan Cycle Control ...................................................... 4

Condensing Unit Accessories ..................................................

Suction Filters, Driers, Sight Glasses ....................................... 5

Refrigerant Oils ........................................................................ 6

Phase Loss Monitor .................................................................. 7

Recommended Refrigerant Piping Practices ........................... 7

Refrigeration Pipe Supports .................................................... 7

Suction Lines ............................................................................ 8

Suction Line Risers .................................................................. 8

Liquid Lines .............................................................................. 8

Evacuation and Leak Detection ...............................................11

Refrigerant Charging Instructions ........................................... 12

Field Wiring............................................................................. 12

Check Out and Start Up ......................................................... 12

Operational Check Out ........................................................... 13

System Balancing - Compressor Superheat .......................... 13

System Troubleshooting Guide ..............................................

Preventive Maintenance Guidelines ....................................... 15

Replacement Parts ................................................................. 15

Wiring Diagrams ................................................................ 16-18

Submittal .......................................................................... 19, 20

Service Record ....................................................................... 21

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5

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General Safety Information

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

2. Some units are pressurized with dry air or inert gas. All units
must be evacuated before charging the system with refrigerant.

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.

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. Check carefully for concealed damage. Any shortage
or damages should be reported to the delivering carrier. Damaged
material becomes the delivering carrierʼs 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 final location. Check the serial tag
information with invoice. Report any discrepancies to your Heatcraft
Refrigeration Products Sales Representative.

Warranty Statement

Seller warrants to its direct purchasers that products, including

Service Parts, manufactured by SELLER shall be of a merchantable
quality, free of defects in material or workmanship, under normal
use and service for a period of one (1) year from date of original
installation, or eighteen (18) months from date of shipment by
SELLER, whichever first occurs. Any product covered by this order
found to Sellerʼs satisfaction to be defective upon examination at
Sellerʼs factory will at SELLERʼs option, be repaired or replaced
and returned to Buyer via lowest common carrier, or SELLER
may at its option grant Buyer a credit for the purchase price of the
defective article. Upon return of a defective product to SELLERʼs
plant, freight prepaid, by Buyer, correction of such defect by repair
or replacement, and return freight via lowest common carrier, shall
constitute full performance by SELLER of its obligations hereunder.

SELLER shall have no liability for expenses incurred for repairs
made by Buyer except by prior, written authorization. Every claim
on account of breach of warranty shall be made to SELLER in
writing within the warranty period specified above – otherwise
such claim shall be deemed waived. Seller shall have no warranty
obligation whatsoever if its products have been subjected to
alteration, misuse, negligence, free chemicals in system, corrosive
atmosphere, accident, or if operation is contrary to SELLERʼs or
manufacturerʼs recommendations, or if the serial number has been
altered, defaced, or removed.

MOTOR COMPRESSORS:

Motor compressors furnished by SELLER are subject to the
standard warranty terms set forth above, except that motor
compressor replacements or exchanges shall be made through
the nearest authorized wholesaler of the motor compressor
manufacturer (not at SELLERʼs factory) and no freight shall be
allowed for transportation of the motor compressor to and from the
wholesaler. The replacement motor compressor shall be identical
to the model of the motor compressor being replaced. Additional
charges which may be incurred throughout the substitution of
other than identical replacements are not covered by this warranty.

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© 2004, Heatcraft Refrigeration Products LLC

3. Make sure that all field wiring conforms to the requirements
of the equipment and all applicable national and local codes.

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

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

An optional, nonassignable, four (4) year extended compressor
warranty may be purchased within the boundaries of the United
Sates of America, its territories and possessions, and Canada. With
this extended compressor warranty, replacements are administered
by an authorized compressor distributor only. Replacements within
the first year of the warranty area available through the distributor;
the second through fifth years, the purchaser must submit a proof­of-purchase of a compressor and supply it to Heatcraft Refrigeration
Products Warranty Claims for reimbursement.

Seller makes no express warranties except as noted above.
All implied warranties are limited to the duration of the Express
Warranty. Liability for incidental and consequential damages is
excluded.

The forgoing is in lieu of all other warranties, express or implied,
notwithstanding the provisions of the uniform commercial code, the
Magnuson-Moss Warranty-Federal Trade Commission Improvement
Act, or any other statutory or common law, federal or state.

SELLER makes no warranty, express or implied, of fitness for
any particular purpose, or of any nature whatsoever, with respect
to products manufactures or sold by seller hereunder, except as
specifically set forth above and on the face hereof. It is expressly
understood and agreed that SELLER shall not be liable to buyer,
or any customer of buyer, for direct or indirect, special, incidental,
consequential or penal damages, or for any expenses incurred
by reason of the use or misuse by buyer or third parties of said
products. To the extent said products may be considered "consumer
products," As defined in Sec. 101 of the Magnuson-Moss Warranty

- Federal Trade Commission Improvement Act, SELLER makes no
warranty of any kind, express or implied, to "consumers," except as
specifically set forth above and on the face hereof.

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.

(c) The power supply to the unit must meet the

following conditions:

A. Three phase voltages must be +/­ 10% of nameplate ratings. Single
phase must be within +10% or

-5% of nameplate ratings.
B. Phase imbalance cannot exceed 2%.
(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.

(f) All equipment is installed in accordance with

Heatcraft specified minimum clearances.

Space and Location Requirements for
Air Cooled Condensing Units and Remote Condensers

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.

Figure 1. Space and Location Requirements for Condensing Units and Remote 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.

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 should be a minimum of “W” away from
any wall or obstruction. It is preferred that this distance
be increased whenever possible. Care should be taken
to see that ample room is left for maintenance work
through access doors and panels. Overhead obstructions
are not permitted. When the unit is in an area where it
is enclosed by three walls the unit must be installed as
indicated for units in a pit.

Units in Pits

The top of the unit should be level with the top of the pit,
and side distance increased to “2W”.

If the top of the unit is not level with the top of pit,
discharge cones or stacks must be used to raise discharge
air to the top of the pit. This is a minimum requirement.

Multiple Units

For units placed side by side, the minimum distance
between units is the width of the largest unit. If units
are placed end to end, the minimum distance between
units is 4 feet.

Decorative Fences

Fences must have 50% free area, with 1 foot undercut,
a “W” minimum clearance, and must not exceed the
top of unit. If these requirements are not met, unit must
be installed as indicated for “Units in pits”.

* “W” = Total width of the condensing unit or condenser.

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Condensing Unit Rigging and Mounting

Rigging holes are provided on all units. Caution should be
exercised when moving these units. To prevent damage to the
unit housing during rigging, cables or chains used must be held
apart by spacer bars. The mounting platform or base should be
level and located so as to permit free access of supply air.

Ground Mounting

Concrete slab raised six inches above ground level provides a
suitable base. Raising the base above ground level provides
some protection from ground water and wind blown matter.
Before tightening mounting bolts, recheck level of unit. The unit
should in all cases be located with a clear space in all directions
that is at a minimum, equal to the height of the unit above
the mounting surface. A condensing unit mounted in a corner
formed by two walls, may result in discharge air recirculation
with resulting loss of capacity.

Roof Mounting

Due to the weight of the units, a structural analysis by a
qualified engineer may be required before mounting. Roof
mounted units should be installed level on steel channels or
an I-beam frame capable of supporting the weight of the unit.
Vibration absorbing pads or springs should be installed between
the condensing unit legs or frame and the roof mounting
assembly.

Access

Provide adequate space at the compressor end of the unit for
servicing. Provide adequate space on the connection side to
permit service of components.

Spring Mounted Compressor

Compressors are secured rigidly to make sure there is no transit
damage. Before operating the unit, it is necessary to follow
these steps:

Figure 2. Solid Mount for Mobile or Deep
Sump Application.

Ambient Fan Cycle Control

This is an automatic winter control method which will maintain
a condensing pressure within reasonable limits by cycling
fan motors in response to outside air temperature. The
thermostat(s) should be field adjusted to shut off the fan when
the condensing temperature is reduced to approximately 90˚F.
Table 2 on page 5 lists approximate settings for several system
T.D.ʼs. These settings are approximate as they do not take into
account variations in load.

CAUTION: Under no circumstance should all
condenser motors be allowed to cycle
off on one control. At least one motor
shall be wired to operate at all times.
Under most circumstances, the
condenser motor nearest the inlet
header should remain on whenever the
compressor is operating.

a. Remove the upper nuts and washers.
b. Discard the shipping spacers.
c. Install the neoprene spacers. (Spacers located

in the electrical panel or tied to compressor.)

d. Replace the upper mounting nuts and washers.
e. Allow 1/16 inch space between the mounting nut/

washer and the neoprene spacer.

Rigid Mounted Compressor

Some products use rigid mounted compressors. Check the
compressor mounting bolts to insure they have not vibrated
loose during shipment.

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Condensing Unit Accessories

Suction Filters, Driers, Sight Glasses

There are two types of suction and liquid filter/driers used
on Heatcraft Refrigeration Products units. Replaceable core
and/or sealed units are used, dependent upon the option
package ordered.

Suction filters, regardless of type, are always installed
upstream of the compressor suction service valve, and
any accumulators or other options that may be installed.
Suction filters are equipped with “Schrader” type access
valves to allow field measurement of pressure drop across
the device. This allows plugged filters and elements to be
identified very quickly and easily so they can be replaced
when the pressure drop is excessive. Refer to the specific
manufacturersʼ recommendation on servicing these units by
make and model.

Liquid filter/driers, regardless of type, are always installed
downstream of the receiver outlet service valve, and up-

stream of the liquid line solenoid valve (if supplied). Liquid line
driers may or may not have an access valve, dependent on the
size and application. The basic servicing of these units is similar
to suction filters. Liquid line driers should be replaced whenever
there is evidence of excessive pressure drop across the filter,
or the system becomes contaminated due to system leaks,
compressor burnouts, acid formation, or moisture accumulation
as indicated by the liquid line sight glass.

The sight glass is installed in the main liquid line assembly,
downstream from the receiver outlet service valve, and
immediately after the liquid line drier. The sight glass is
designed to give a visual indication of moisture content in the
system. Generally, it requires no field service. However, in
cases of extreme acid formation in a system after a compressor
burnout, the acid may damage the sensing element or etch the
glass. This would require that the sight glass be replaced, along
with the liquid line drier after any compressor motor burnout.

Table 1. Recommended Low Pressure Control Settings for Outdoor Air Cooled Condensing Units

R-22 R-404A/R-507 R-134a
*Minimum Cut-In Cut-Out Cut-In Cut-Out Cut-In Cut-Out
Temp. ˚F PSI PSI PSI PSI PSI PSI

50 70 20 90 35 45 15
40 55 20 70 35 35 10
30 40 20 55 35 25 10
10 30 10 45 25 13 0
0 15 0 25 7 8 0

-10 15 0 20 1 --- ---

-20 10 0 12 1 --- ---

-30 6 0 8 1"Hg. --- ---

* Minimum ambient or box temperature anticipated, Hi pressure control setting: R-22, 360 PSI; R-404A, R-507, 400 PSI; R-134a, 225 PSI.

Table 2. Thermostat Settings

Design Thermostat Settings
Models T.D. T1 T2 T3

30 60
2-fan units: 25 65
20 70
4-fan units: 15 75
30 60 40
3-fan units: 25 65 55
20 70 60
6-fan units: 15 75 65
30 60 50 30
8-fan units: 25 65 55 40
20 70 65 50
15 75 70 60

NOTE: Cycle pairs of fans on double wide units.

CAUTION: Fans closest to the headers should not be
cycled on standard temperature or pressure
controls. Dramatic temperature and pressure
changes at the headers as a result of fan action
can result in possible tube failure. Fan motors are
designed for continuous duty operation.

Fan cycling controls should be adjusted to maintain a minimum
of (5) minutes on and (5) minutes off. Short cycling of fans may
result in a premature failure of motor and/or fan blade.

Compressors operating below +10°F SST must have air flowing
over the compressor at all times when the compressor is
running.

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Refrigeration Oils*

With the changes that have taken place in our industry due to
the CFC issue, we have reevaluated our lubricants to ensure
compatibility with the new HFC refrigerants and HCFC interim
blends offered by several chemical producers. As a secondary
criteria, it is also desirable that any new lubricant be compatible
with the traditional refrigerants such as CFC-12, HCFC-22 or
R502. This “backward compatibility” has been achieved with the
introduction of the Polyol ester lubricants.

Table 3 below summarizes which oils/lubricants are approved
for use in Copeland compressors:

Polyol Ester Lubricants

Color

As received, the POE lubricant will be clear or straw colored.
After use, it may acquire a darker color. This does not indicate
a problem as the darker color merely reflects the activity of the
lubricantʼ s protective additive.

Oil Level

During Copelandʼ s testing of Polyol ester oil, it was found that
this lubricant exhibits a greater tendency to introduce oil into the
cylinder during flooded start conditions. If allowed to continue,
this condition will cause mechanical failure of the compressor.

A crankcase heater is required with condensing units and it
must be turned on several hours before start-up.

Hygroscopicity

Ester lubricants (POE) have the characteristic of quickly
absorbing moisture from the ambient surroundings. This is
shown graphically in Figure 3 where it can be seen that such
lubricants absorb moisture faster and in greater quantity than
conventional mineral oils. Since moisture levels greater than
100 ppm will results in system corrosion and ultimate failure, it
is imperative that compressors, components, containers and the
entire system be kept sealed as much as possible. Lubricants
will be packaged in specially designed, sealed containers.
After opening, all the lubricant in a container should be used at
once since it will readily absorb moisture if left exposed to the
ambient. Any unused lubricant should be properly disposed of.
Similarly, work on systems and compressors must be carried
out with the open time as short as possible. Leaving the system
or compressor open during breaks or overnight MUST BE

AVOIDED!

Oil level must not exceed 1/4 sight glass.

Figure 3.

Mineral Oil

Table 3. Refrigeration Oils

Interims HFCʼs
Traditional Refrigerants R401A, R401B, R402A HFC-134a,
Refrigeration Oils HCFC-22 (MP-39, MP-66, HP-80) R404A, R507
POEʼs Mobil EAL ARCTIC 22 CC A A P

ICI (Virginia KMP) EMKARATE RL 32CF A A P
Suniso 3GS P PM
Mineral Texaco WF32 P PM NOT
Oils Calumet RO15 (Witco) P PM ACCEPTABLE
Sontex 200-LT (White Oil) (BR & Scroll Only)
Witco LP-200 P

A/B Zerol 200TD AM PM NOT
Soltex Type AB-200 PM ACCEPTABLE

P = Preferred Lubricant Choice A = Acceptable Alternative M = Mixture of Mineral Oil and Alkyl Benzene (AB) with minimum 50% AB.
* (Reprinted with permission from Copeland)

Mineral Oils

The BR and Scroll compressors use Sontex 200, a “white oil”.
This oil is not suitable for low temperature applications nor is
it available through the normal refrigeration wholesalers. For
field “top-off” the use of 3GS or equivalent, or Zerol 200TD
is permissible, as long as at least 50% of the total oil charge
remains Sontex 200.

Suniso 3GS, Texaco WF32 and Calumet R015 (yellow oils) are
available through normal refrigeration wholesalers. These oils
are compatible if mixed and can be used on both high and low
temperature systems.

Polyol Ester Lubricants

The Mobil EAL ARCTIC 22 CC is the preferred Polyol ester due to
unique additives included in this lubricant. ICI Emkarate RL 32S is
an acceptable Polyol ester lubricant approved for use when Mobil
is not available. These POEʼs
used in the system. They are also acceptable for use with any

must be used if HFC refrigerants are

6

of the traditional refrigerants or interim blends and are
compatible with mineral oils. They can therefore be mixed
with mineral oils when used in systems with CFC or HCFC
refrigerants. These lubricants are compatible with one another
and can be mixed.

Alkyl Benzenes

Zerol 200TD is an alkyl benzene (AB) lubricant. Copeland
recommends this lubricant for use as a mixture with mineral oil
(MO) when using the interim blends such as R-401A, R-401B
and R-402A (MP39, MP66 and HP80). A minimum of 50% AB is
required in these mixtures to assure proper oil return.

Shell MS 2212 is a 70/30 mixture of AB/MO. If this lubricant is
used in a retrofit situation virtually all of the existing MO must be
drained prior to refilling with the MS 2212 to assure a minimum
50% AB content.

Phase Loss Monitor

The combination phase sequence and loss monitor relay
protects the system against phase loss (single phasing), phase
reversal (improper sequence) and low voltage (brownout).
When phase sequence is correct and full line voltage is present
on all three phases, the relay is energized as the normal
condition indicator light glows.

NOTE: If compressor fails to operate and the normal condition
indicator light on the phase monitor does not glow, then the
supplied electrical current is not in phase with the monitor. This
problem is easily corrected by the following steps:

1. Turn power off at disconnect switch.

2. Swap any two of the three power input wires.

3. Turn power on. Indicator light should glow and
compressor should start.

4. Observe motors for correct rotation.

Recommended Refrigerant Piping Practices

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.

Refrigerant 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.

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 copper tubing, properly
sealed against contamination.

(c) Suction lines should slope 1/4" per 10 feet towards the
compressor.

(d) Suitable P-type oil traps should be located at the base of
each suction riser of four (4) feet or more to enhance oil
return to the compressor.

(e) For desired method of superheat measurement,
a pressure tap should be installed in each evaporator
suction line in the proximity of the expansion valve bulb.

(f) When brazing refrigerant lines, an inert gas should

be passed through the line at low pressure to
prevent scaling and oxidation inside the tubing.
Dry nitrogen is preferred.

(g) Use only a suitable silver solder alloy on suction and
liquid lines.

Figure 4. Example of Pipe Support

Figure 5. Condensing Unit / Compressor to Wall Support.

(h) Limit the soldering paste or flux to the minimum
required to prevent contamination of the solder
joint internally. Flux only the male portion of the
connection, never the female. After brazing, remove
excess flux.

(i) If isolation valves are installed at the evaporator, full port
ball valves should be used.

7

Suction Lines

Suction Line Risers

NOTE: If the suction line must rise to a point

higher than the suction connection on the
evaporator, a suction line trap at the outlet
of the evaporator must be provided.

Horizontal suction lines should slope away from the evaporator
toward the compressor at the rate of 1/4 inch per 10 feet for
good oil return. When multiple evaporators are connected in
series using a common suction line, the branch suction lines
must enter the top of the common suction line.

For dual or multiple evaporator systems, the branch lines to
each evaporator should be sized for the evaporator capacity.
The main common line should be sized for the total system
capacity.

Suction lines that are outside of refrigerated space must be
insulated. See the Line Insulation section on page 11 for more
information.

Figure 6. Suction P-Traps.

Prefabricated wrought copper traps are available, or a trap can
be made by using two street ells and one regular ell. The suction
trap must be the same size as the suction line. For long vertical
risers, additional traps may be necessary. Generally, one trap is
recommended for each length of pipe (approximately 20 feet) to
insure proper oil movement. See Figure 6 below for methods of
constructing proper suction line P-traps.

Slope 1/4"
per 10 ft.
toward
compressor

Liquid Lines

Liquid lines should be sized for a minimum pressure drop to
prevent “flashing”. Flashing in the liquid lines would create
additional pressure drop and poor expansion valve operation.
If a system requires long liquid lines from the receiver to the
evaporator or if the liquid has to rise vertically upward any
distance, the losses should be calculated to determine whether
or not a heat exchanger is required. The use of a suction
to liquid heat exchanger may be used to subcool the liquid
to prevent flashing. This method of subcooling will normally
provide no more than 20˚F subcooling on high pressure

systems. The amount of subcooling will depend on the design
and size of the heat exchanger and on the operating suction
and discharge pressures. An additional benefit from the use
of the suction to liquid type heat exchanger is that it can
help raise the superheat in the suction line to prevent liquid
return to the compressor via the suction line. Generally, heat
exchangers are not recommended on R-22 low temperature
systems. However, they have proved necessary on short,
well insulated suction line runs to provide superheat at the
compressor.

8