Kool Star R-404A, Remote Refrigeration Installation Manual

Condensing Unit and Refrigeration System

Installation & Operations Manual

21720 South Wilmington Ave.

Bldg. 450, Suite 308

Long Beach, CA 90810

888-478-8600 or 310-952-8000 ext. 2225

Fax 310-513-8156

www.koolstar.com

TABLE OF CONTENTS

INTRODUCTION .........................................................................................................................3

WARNING LABELS AND SAFETY INSTRUCTIONS ................................................................4

B-SERIES CONDENSING UNIT FEATURES .............................................................................5

M-SERIES CONDENSING UNIT FEATURES ............................................................................6

REFRIGERATION NOMENCLATURE ........................................................................................7

PRE-INSTALLATION INSTRUCTIONS ......................................................................................8

General Information ............................................................................................................................................8

Delivery Inspection .............................................................................................................................................8

INSTALLATION INSTRUCTIONS ...............................................................................................8

Handling and Placement of Condensing Unit .....................................................................................................8

Handling and Placement of Evaporator Coil in Walk-In ......................................................................................9

Electrical .............................................................................................................................................................9

Refrigerant Piping ...............................................................................................................................................9

Leak Check .......................................................................................................................................................10

Evacuation, Dehydration and Start-Up .............................................................................................................10

Evacuation Procedure ................................................................................................................................ 10

Finish Charging Procedures .......................................................................................................................10

Preliminary ........................................................................................................................................... 10

Remote "M-Series" .............................................................................................................................11

Built-Up Remote "B-Series" Condensing Units ....................................................................................11

Pre-Charged Remote Refrigeration Systems.......................................................................................12

Final Check List for All Models ..........................................................................................................................13

R-404A SUCTION AND LIQUID LINE SIZES ..........................................................................14

R-22 SUCTION AND LIQUID LINE SIZES ...............................................................................16

EQUIVALENT LENGTH ALLOWANCE FOR FITTINGS ..........................................................18

LOW AMBIENT OPERATION CHARGE ..................................................................................19

CONDENSING UNIT SPECIFICATIONS ..................................................................................21

UNIT BASE SPECIFICATIONS ................................................................................................37

SALE AND DISPOSAL .............................................................................................................40

INSTALLATION DATA ...............................................................................................................41

INTRODUCTION

Thank you for purchasing our refrigeration equipment. This manual contains important instructions for installation, use and service. Read all of this manual carefully before installing or servicing your refrigeration equipment.

NOTICE

Installation and service of the refrigeration and electrical components must be performed by a refrigeration mechanic or licensed electrician.

The portions of this manual covering refrigeration and electrical components contain technical instructions intended only for persons qualiﬁed to perform refrigeration and electrical work.

DANGER

Equipment MUST be properly grounded. Improper or faulty hook-up of electrical components of the refrigeration units can result in severe injury or death. All electrical wiring hook-ups must be done in accordance with all applicable local, regional or national standards.

NOTICE

Read this manual before installing your refrigeration. Keep the manual and refer to it before doing any service. Failure to do so could result in personal injury or equipment damage.

This manual cannot cover every installation, use or service situation. If you need additional information, contact us at:

888-478-8600 or 310-952-8000 ext. 2225

Fax 310-513-8156

WARNING LABELS AND SAFETY INSTRUCTIONS

HIGH VOLTAGE. TURN POWER OFF BEFORE SERVICING. MAY HAVE MORE THAN ONE DISCONNECT SWITCH.

DANGER

HAUTE TENSION. COUPEZ LE COURANT AVANT DE REPARER. IL PEUT Y AVOIR PLUSIEURS INTERRUPTEURS.

DANGER

VOLTAJE DE GRAN POTENCIA. CORTAR LA ELECTICIDAD ANTES DE REPARAR. ES POSIBLE QUE TENGA MAS DE UN INTERRUPTOR.

PELIGRO

This is the safety-alert symbol. When you see this symbol, be alert to the potential for personal injury or damage to your equipment.

Be sure you understand all safety messages and always follow recommended precautions and safe operating practices.

NOTICE TO EMPLOYERS

You must make sure that everyone who installs, uses or services your refrigeration is thoroughly familiar with all safety information and procedures.

Important safety information is presented in this section and throughout the manual. The following signal words are used in the warnings and safety messages.

DANGER: Severe injury or death WILL occur if you ignore the message.

WARNING: Severe injury or death CAN occur if you ignore the message.

CAUTION: Minor injury or damage to your refrigeration can occur if you ignore the message.

NOTICE: This is important installation, operation or service information. If you ignore the message,

you may damage your refrigeration.

The warning and safety labels shown throughout this manual are placed on your equipment at the factory. Follow all warning label instructions. If any warning or safety labels become lost or damaged, call our service department at 888-478-8600 for replacements.

This label is located on the condensing unit.

B-SERIES CONDENSING UNIT FEATURES

STANDARD COMPONENTS

The B-Series units offer the most complete set of standard features (pre-wired and mounted except as

noted)*

These include:

• Liquid line and suction line vibration absorbers(eliminators) for semi-hermetic units only

• Adjustable dual pressure control

• Head pressure control (ooding valve)

• Corrosion-resistant hinged weather hood with lockable snap-down hood latch for easy installation and

service access

• Suction line lter

• Heavy-duty 12 gauge galvanized steel legs

• Pre-wired electrical control panel with timer and circuit breaker or fuse block

• Crankcase heater

• Liquid line lter/drier

• Sight glass

• Liquid and suction line kit with service valve

• Liquid line solenoid valve (shipped loose)

• Timer

• Generously-sized condenser (for 105° to 110° ambient)

• Large liquid receiver (good for maximum 250 ft. line run)

• Defrost heater contactor when required

• Compressor contactor used in 1

• PSC fan motors

• One year limited compressor warranty

/2 HP units and up

*Components may vary depending on horsepower and application. Consult our factory for veriﬁcation of

standard and optional components.

OPTIONALLY AVAILABLE

• Water-cooled units

• Special voltages

• Condensing units above 40 H.P.

• Insulated and heated receiver (thermostatically controlled)

• Suction accumulator (shipped loose)

• R-22 demand cooling on Discus compressors

• Coated condenser coils

• Phase loss/low voltage monitor

• Factory pre-assembled evaporator coil (includes factory pre-mounting of thermostatic air control and

expansion valve)

• Pre-mounted solenoid at evaporator

• Extended four year limited compressor warranty

M-SERIES CONDENSING UNIT FEATURES

STANDARD COMPONENTS

The M-Series set of standard features (pre-wired and mounted except as noted)* include:

• Liquid line and suction line vibration absorbers (eliminators) for semi-hermetic units only

• Preset non-adjustable high pressure control and preset non-adjustable low pressure control**

• Crankcase heater

• Head pressure control (ooding valve)

• Heavy gauge, galvanized steel mechanically-fastened weather hood

• Suction service valve

• Heavy-duty angle leg base

• Liquid line lter/drier

• Pre-wired electrical control panel

• Sight glass

• Liquid and suction line kit with service valve

• Timer (standard on low temp units only)

• Compressor contactor

• Defrost heater contactor (when required)

• Generously-sized condenser (rated up to 120° ambient)

• Ried tubes in condenser for greater efciency

• PSC condenser fan motors

• Large liquid receiver (good for maximum 100 ft. line run)

• One year limited compressor warranty

*Components may vary depending on horsepower and application. Consult our factory for veriﬁcation of standard and optional components. **Preset high pressure control and preset low pressure control are non-adjustable in medium temp MSeries units. The low pressure control is adjustable in low temp units.

OPTIONALLY AVAILABLE

• Special voltages

• Insulated and heated receiver (thermostatically controlled)

• Suction accumulator

• Coated condenser coils

• Oil separator

• Phase loss/low voltage monitor

• Factory pre-assembled evaporator coil (includes factory pre-mounting of thermostatic air control and

expansion valve)

• Factory pre-charged system with quick connect liquid and suction line sets up to 40 ft. (specify length

when ordering)

• Adjustable low pressure control for medium and high temp units

• Dual pressure control

• Circuit breaker

• Suction lter

• Fan cycling switch

• Pre-mounted solenoid at evaporator

• Liquid line solenoid valve (shipped loose)

• Timer for medium temp units

• Extended four year limited compressor warranty

REFRIGERATION NOMENCLATURE

MODEL NUMBER EXPLANATION (CONVENTIONAL = ACCESSIBLE HERMETIC )

BC = Built-up Remote Conventional Condensing Unit MH = Hermetic Condensing Unit BH = Built-up Remote Hermetic Condensing Unit MS = Scroll Condensing Unit BS = Built-up Remote Scroll Condensing Unit MD = Discus Condensing Unit MC = Conventional Condensing Unit

ROOM TEMPERATURE EXPLANATION

H = +35° Thru +70° F. Room Temperature L = 0° F. Thru -20° F. Room Temperature M = +25° Thru +34° F. Room Temperature

HORSEPOWER RATING EXPLANATION (NOTE: APPLIES TO B-SERIES ONLY)

005 = ½ H.P. 017 = 1¾ H.P. 030 = 3 H.P. 075 = 7½ H.P. 150 = 15 H.P. 270 = 27 H.P. 007 = ¾ H.P. 020 = 2 H.P. 040 = 4 H.P. 090 = 9 H.P. 200 = 20 H.P. 300 = 30 H.P. 010 = 1 H.P. 025 = 2½ H.P. 050 = 5 H.P. 100 = 10 H.P. 220 = 22 H.P. 350 = 35 H.P. 015 = 1½ H.P. 028 = 3 H.P. 060 = 6 H.P. 120 = 12 H.P. 250 = 25 H.P. 400 = 40 H.P.

BTU/HR RATING EXPLANATION (NOTE: APPLIES TO M-SERIES ONLY)

Room temp H = Nominal BTUH capacity @ +30° suction, 90° ambient (1000 multiplier) Room temp M = Nominal BTUH capacity @ +20° suction, 90° ambient (1000 multiplier) Room temp L = Nominal BTUH capacity @-20° suction, 90° ambient (1000 multiplier)

EQUIPMENT VARIATION EXPLANATION

0 = Standard W = Water Cooled A = Plasma Units X = Special Applications D = Demand Cooling Y = Special Applications

L = Large Condenser

VOLTAGE EXPLANATION

A = 115/60/1 F = 200-220/50/3 B = 230/60/1 or 208-230/60/1 (As Applicable) G = 380-420/50/3 C = 208-230/60/3 H = 208/60/1 D = 460/60/1 J = 380/50/1

E = 460/60/3 K = 200-220/50/1 or 220/50/1

OPTIONS EXPLANATION (NOTE: APPLIES TO B-SERIES ONLY)

C = Coated Condenser Coil D = Coated Condenser Coil, Heated And Insulated Receiver L = Large Condenser

PRE-INSTALLATION INSTRUCTIONS

I. General Information

Please read this manual prior to installing your refrigeration equipment. This information is based on good refrigeration practice and should be used as a guide for installation and operation.

To complete the installation, please record the data requested on the Installation Data form on page 41 of the manual and return this manual to the owner.

II. Delivery Inspection

You are responsible for ﬁling all freight claims with the delivering truck line. Inspect all cartons and crates for damage as soon as they arrive. If damage is noted to shipping crates or cartons or if a shortage is found, note this on the bill of lading (all copies) prior to signing.

If damage is discovered when the cabinet is uncrated, immediately call the delivering truck line and follow up the call with a written report indicating concealed damage to your shipment. Ask for an immediate inspection of your concealed damage item. Crating material MUST be retained to show the inspector from the truck line.

INSTALLATION INSTRUCTIONS

I. Handling and Placement of Condensing Unit

To minimize damage to the unit housing, it is recommended that the crate not be removed until the

unit is moved to its ﬁnal location.

The following should be considered when placing the unit:

A. The condenser coil (air inlet) should not be located so as to restrict air ow into the coil. A

minimum of 12" is required (18" is preferred) between the face of the coil and a wall or other vertical obstruction.

B. A minimum of 6" is required on the sides to allow access to the housing clamps.

C. A minimum of 24" is required on the louvered end ( air outlet) for clearance when opening housing and for ease of maintenance.

D. Do not position multiple units so that the air discharge of one is into the condenser air intake of another.

Holes are provided in the base supports for mounting bolts and for bridle lift rods.

For indoor mounting, motor rooms should be provided with fans designed to move 1000 cfm of air per ton of refrigeration.

II. Handling and Placement of Evaporator Coil in Walk-In

To minimize damage to the evaporator coil, it is recommended that the carton (or crate) not be removed until the evaporator coil is moved close to its ﬁnal location. When the container is removed from the evaporator coil, extreme care must be used when lifting and mounting to the ceiling, to

prevent sheet metal damage. Consult evaporator “Operating and Installation Instructions” for proper

installation details.

DANGER

Installation of the refrigeration and electrical components must be performed only by a refrigeration mechanic or licensed electrician. Improper or faulty hook-up of electrical components can result in death.

III. Electrical

Electric power supply must match the condensing unit power requirements indicated on the unit data plate. A WIRING DIAGRAM IS LOCATED ON THE INSIDE OF THE ELECTRICAL BOX COVER. All ﬁeld wiring may enter the holes provided in left side, back and bottom of the electrical box. All ﬁeld wiring should be done in a professional manner, in accordance with all governing codes. Double check all wiring connections, including factory terminals, before start-up of condensing unit.

IV. Refrigerant Piping

The condensing unit must remain sealed and pressurized from the manufacturer until piping is complete and ﬁnal connections are ready to be made.

Use only refrigeration grade copper tubing, (ACR), type "L", bright annealed, dehydrated, and properly sealed against contamination. Soft temper tubing may not be used for ﬁeld interconnection of refrigeration components (condensing unit to evaporator assembly). Take extreme care to keep

refrigeration tubing clean and dry prior to installation. Use an appropriate size tube cutter (DO NOT

CUT TUBING WITH A SAW).

Refrigerant lines must be sized as dictated by the charts on pages 14-17.

Suction lines should slope down 1/2 inch for each 10 feet of horizontal run towards the compressor.

If any portion of the suction line rises above the exit elevation of the evaporator, P-type oil traps should be located at the base of each suction riser for proper oil return to the compressor.

When brazing, dry nitrogen MUST be passed through the lines at low pressure to prevent scaling and oxidation inside the tubing and ttings. All ux must be removed from the joints after brazing.

MINIMIZE the amount of ux used to prevent internal contamination of the refrigeration system.

Silver brazing wire is to be utilized (high temperature alloy of 15% silver content on all copper to copper connections, and high temperature alloy of 45% silver content on all dissimilar metal con-

nections).

NOTICE

Be sure solenoid valves are open before beginning evacuation and leak check.

V. Leak Check

When all refrigeration line connections have been made, the complete system, including factory connections, should be leak checked.

Add the proper refrigerant to 60 psig, then boost to 175 psig with dry nitrogen. Leak check all joints with an electronic leak detector or a halide torch. If leaks are found, relieve the pressure and make repairs as necessary and recheck.

VI. Evacuation, Dehydration and Start-Up

A vacuum of 500 microns or less must be pulled to properly dehydrate the system. This requires a two-stage vacuum pump with an electronic vacuum indicator.

DO NOT USE THE SYSTEM COMPRESSOR AS A VACUUM PUMP.

DO NOT OPERATE COMPRESSOR WHILE SYSTEM IS IN A VACUUM.

Evacuation Procedure

A. Open all condensing unit service valves and relieve system pressure. Also, open any line valves installed in the system and energize all solenoid valves to facilitate evacuation.

B. Connect the vacuum pump to the high and low sides of the system using 1/4" or larger cop per lines or 1/4" ID hoses with high vacuum designation.

Leaks or moisture will be indicated if the system pressure rises when the vacuum line is closed off.

D. Pull a vacuum of 1500 microns, close vacuum line and “break” vacuum to 5 psig, maximum,

with refrigerant to be used in the system.

E. Repeat step D.

F. A ﬁnal vacuum of 250 microns should be pulled before charging. When 250 microns is reached, close vacuum line and charge through high side, with proper refrigerant to the level

of 2-1/2 lbs. per ton of refrigeration.

Finish Charging Procedures

A. Preliminary

1. Be sure all service valves are “open”.

2. Loosen the compressor hold-down bolts and remove shipping clips to allow compressor to

oat freely on the springs.

3. Check evaporator fan motors after start-up. Medium temperature, air defrost fans run continuously. Low temperature fans and coolers provided with electric defrost will be delayed by the fan control.

4. Start the system by “ipping on” the circuit breaker in the unit electric box.

5. Start charging per (B), (C), (D) or (E) on the following pages.

CAUTION: Never add liquid refrigerant to the suction side of the compressor.

6. Check operating pressures while charging and on initial pulldown to prevent damage if a

problem occurs. If system “oods” back to the compressor, adjust the thermostatic expan- sion valve as required for proper operation. There should be at least +30°F superheat

entering the compressor.

7. Observe compressor amperage draw and compare to compressor nameplate to prevent damage due to high amperage. The oil sight glass should be between 1/2 and 3/4 full

during normal operation.

B. Remote "M-Series" Condensing Units

1. For models without head pressure control valve: With the system operating, add refrigerant until the sight glass indicates a full charge, then add one pound for each 2 rated

horsepower of the condensing unit when charging above +75°F. If ambient is below +75°F, add 1/2 to the above. See A.6 above.

2. For models with head pressure control valve: Add additional charge per the procedure on page 19.

C. Built-Up Remote "B-Series" Condensing Units

These units are equipped with a head pressure control valve for low ambient operation. This

valve will ood the condenser when ambient temperatures are low, requiring additional refrig-

erant to provide correct operation under various ambient conditions. See attached Charts B and C (pages 19 and 20) for the additional charge data, and ﬁnish charging as follows.

1. Add the proper refrigerant for a full sight glass.

2. Add additional charge per the procedure on page 19.

DANGER

Charging of the refrigeration system must be performed only by a certiﬁed refrigeration mechanic. Improper or faulty hook-up of refrigeration electrical components can result in injury or death.

Technical installation instructions for Pre-Charged Remote Refrigeration are given on the following pages. Installation requirements for other remote refrigeration systems may vary. If additional information is needed, your certiﬁed refrigeration mechanic or electrician can call 888-478-8600.

Quick-Couples are pre-charged with the proper refrigerant at the factory.

D. Pre-Charged Remote Refrigeration Systems

• Place a steel or treated-wood spreader on the top of the walk-in

to distribute the load of the coil. The spreader must be at least twice the width of the coil. The coil must be mounted away from the edge of the roof a distance equal to the height of the coil (See Figure #1)

4" x 4"

Treated

Wood

Spreader

See Figure #2

Drain Line

Evap. Coil

• Uncrate the coil and through-bolt it to the ceiling of the walk-in

with suitable fasteners.

Figure #1 Quick-Couple Remote Refrigeration

Condensing Unit

• Uncrate the condensing unit and locate near coil. Be sure air movement around the unit is

not restricted so the condensing unit will have a sufﬁcient supply of air to function properly.

NOTE: Install evaporator coil in accordance with the manufacturer's recommenda-

tions from inside wall or obstructions to rear of evaporator.

• Drill holes through the walk-in wall large enough to pass refrigeration lines, electrical line and

drain line.

• Connect liquid and suction lines to the coil and the condensing unit.

• Lubricate rubber seal in male half of coupling with refrigeration oil.

• Thread coupling halves together by hand to ensure proper

Male Coupling Half

Female Coupling Half

mating of threads. Tighten with wrenches until coupling bodies

“bottom” or a denite resistance is felt. (See Figure #2.)

Figure #2 Quick-Couple Coupling Detail

• Using a scribe or ink pen, mark a line lengthwise from the coupling hex to the bulkhead. Then tighten an additional 1/6 to 1/4 turn. The misalignment of the mark will show the degree of

tightening for future reference. This ﬁnal turn is necessary to ensure that the knife edge metal seal bites into the brass seat of the coupling halves, forming a leak-proof joint.

• When routing refrigeration lines, special care should be taken not to “kink” the lines and restrict the ow of refrigerant.

NOTE: Wiring diagrams are located inside the pre-wired electrical panel on the condensing unit.

CAUTION

Be sure the electrical supply is sufﬁcient for all electrical loads of the Quick-Couple Remote Refrigeration system.

• Connect correctly rated overcurrent protection device in the service line to the service line

J-box on the condensing unit.

• After routing condensate line from drain pan of evaporator coil, seal around all refrigeration,

electrical and drain lines with silicone or butyl caulking.

• Start compressor and allow to run at least 24 hours before placing product into the walk-in.

During the testing period you should:

• Check the temperature holding range against the control setting.

• On low temperature units, check the defrost control system to see that all ice is removed from

the coil during each defrost cycle.

• Perform checks of door operation and all other component operations.

These particular systems are pre-charged at the factory with proper refrigerant, but should be operationally checked as per page 11, A.6 and A.7.

VII. Final Check List for All Models

A. Check high-low pressure control settings.

B. Check setting of defrost timer:

1. Medium temperature 2 to 4 defrost/24 hours, with 35 minutes fail safe.

2. Low temperature 3 to 4 defrost/24 hours, with 44 minutes fail safe.

C. Check operating pressure.

D. Check electrical requirements of unit to power supply voltage.

E. Set temperature control for desired temperature range.

F. Check setting of thermostatic expansion valve for proper operation.

G. Check sight glass for proper refrigerant charge.

H. Check compressor oil level.

I. Check system for proper defrost settings and operation.

J. Check condensing unit for vibrating or rubbing tubing. Dampen or clamp as required.

K. Open all valves completely counter clockwise.

L. Check packing nuts on all service valves.

M. Replace all service valve caps and latch unit covers.

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