Master-Bilt MRS-1B Installation Manual

MRS / MRSW SERIES

CONDENSING UNIT

INSTALLATION & OPERATIONS MANUAL

st

Revision (May 2009)

1

TABLE OF CONTENTS

INTRODUCTION……………………………………………………………………………………………..3
WARNING LABES AND SAFETY INSTRUCTIONS…………………………………………………….4
MRS SERIES CONDENSING UNIT FEATURES………………………………………………………...5
MRS POD SYSTEM NOMENCLATURE…………………………………………………………………..6
MRSW POD SYSTEM NOMENCLATURE………………………………………………….…………….7
PRE-INSTALLATION INSTRUCTIONS…………………………………………………………….……..8

General Information…………………………………………………………………………………….…………8
Delivery Inspection………………………………………………………………………………………….….…8

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

Handling and Placement of Multiple Rack System…………………………………………………………....8

Handling and Placement of Walk-In Evap(s)………………………………………………………………...…8
Electrical Specifications………………………………………………………………………………………. …9
Refrigerant Piping……………………………………………………………………………………………..…10
Suction and Liquid Line Sizes………………………………………………………………………..……..11-12
Leak Check…………………………………………………………………………………………………….…13

Evacuation, Dehydration, and Start-Up………………………………………………………………….....…13

Evacuation Procedure……………………………………………………………………………..…..14

Finishing Charging Procedure…………………………………………………………………......…14

Low Ambient Charging (Example)……………………………………………………………...…....17

MRS/MRSW POD CONDENSING UNIT SPECIFICATIONS………………………………..…...18-22

REFRIGERANT REQUIRED PER LENGTH OF REF. LINE………………………………..….........22

SALE AND DISPOSAL……………………………………………………………………………..….…23
LABOR WARRANTY……………………………………………………………………………………..23

ENGINEERING DETAILS (MRS/MRSW)………………………………………………………......24-30

GENERAL ELECTRICAL WIRING DIAGRAMS……………………………………………. .......31-34

MASTER-CONTROLLER WIRING DIAGRAMS…………………….........................................35-39

MRS/MRSW START-UP DATA TABLE………………………………………………………..…...…40

2

INTRODUCTION

Thank you for purchasing Master-Bilt refrigeration equipment. This manual contains important instructions for
installation, use and service. Read this entire manual carefully before installing or servicing your Master-Bilt equipment.

NOTICE

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

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

The portions of this manual covering refrigeration and electrical components contain technical instructions intended only
for persons qualified to perform refrigeration and electrical work.
This manual cannot cover every installation, use, or service situation. If you need additional information, call or write us:

Parts and Technical Service Department

Master-Bilt Products

908 Highway 15 North

New Albany, MS 38652

Phone [phone]

Email: [e-mail]

3

WARNING LABELS AND SAFETY INSTRUCTIONS

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 equipment 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 Master-Bilt Products
refrigeration at the factory. Follow all warning label instructions. If any warning or safety labels become lost or
damaged, call your customer service department at [phone] for replacements.

This Label is located on the condensing unit

4

MRS SERIES CONDENSING UNIT FEATURES

• Generously sized individual copper aluminum condenser for each compre ssor sized for high efficiency. Sized to
operate efficiently in high Ambient

• Hermetic, semi-hermetic, and Scroll compressors in any combination the customer chooses

• Reliable Ball Bearing Fan Motors

• Spring Mounted Semi-Hermetic Compressors, Hermetic and Scroll Compre ssors use Vibration Absorbing

Grommet Mounts

• Generously sized receivers with isolation valves

• Compressor Suction Service Valves with Access Ports, and Discharge Line Service Valves with Access Ports

on Semi- Hermetic Compressors only

• Pre-wired and mounted Dual Pressure Controls with each Compressor

• Units leak and electrical tested

• U.L. listed

• Easy accessibility for service

• Pre-wired for easy installation with Single Point Electrical Connection with individual Circuit Breakers for each

Compressor and Through Door Main Disconnect Switch and Circuit Breaker Installed

• Suction and discharge line vibration eliminators pre-piped and mounted (semi-hermetic only)

• Crankcase Heater Installed for each Compressor

• Refrigeration line pre-piped to edge of unit

• Pre-piped and mounted refrigerant sight glass and filter drier

• Pre-installed inverted traps on all roof top MRS series Condensing units

• Flooded Head Pressure Controls on each System

• Stainless Steel Housing

• Engineered Refrigeration Drawing Available for Specified Projects, or with Purchase Order (Contact Factory for

Additional Details

• Master-Controller Electronic Refrigeration Controls for Maximum Energy Efficiency are Optional for most
Systems. Patented Reverse Cycle Defrost Technology that saves up to 27% on Operational Energy Cost of the
System it Controls Depending on Ambient Temperatures.

5

A

MRS POD SYSTEM NOMENCLATURE

C C H X OO5 B

C = Master-Bilt Rack System

Compressor Type Voltage Code

C = Semi-Hermetic
D = Discuss B = 208-230/60/1 V
H = Hermetic C = 208-230/60/3
S = Scroll D = 460/60/1

Temperature Range

H = High/Medium
M = Medium
L = Low (-40 - -25 )ºF

Refrigerant Type OO5 = 1/2 HP
X = R-22 OO7 = 3/4 HP
Z = R404a O1O = 1 HP

System Capacity (Horsepower)

OO3 = 1/3 HP

O15 = 1 1/2 HP
O2O = 2 HP
O3O = 3 HP
O4O = 4 HP
O5O = 5 HP
O6O = 6 HP
O75 = 7 1/2 HP
O9O = 9 HP
1OO = 10 HP

= 115/60/1 V

E = 460/60/3

Options:

CAAA005A = 6" COIL (REMOTE CIRCUIT)
CAAA010A = 12" COIL (REMOTE CIRCUIT)
CAAA025A = 24" COIL (REMOTE CIRCUIT)
CAAA035A = 36" COIL (REMOTE CIRCUIT)
CAAA060A = 48" COIL (REMOTE CIRCUIT)

6

MRSW POD SYSTEM NOMENCLATURE

A

C C H X OO5 W B

W

= Water Cooled

C

= Master-Bilt Rack System

Compressor Type

C = Semi-Hermetic B = 208-230/60/1
D = Discuss C = 208-230/60/3
H = Hermetic D = 460/60/1
S = Scroll E = 460/60/3

Temperature Range

H = High/Medium
M = Medium OO3 1/3 HP
L = Low (-40 - 25 )ºF OO5 = 1/2 HP

Refrigerant Type

X = R-22 O15 = 1 1/2 HP
Z = R404a O2O = 2 HP

Voltage Code

= 115/60/1

System Capacity (Horsepower)

OO7 = 3/4 HP
O1O = 1 HP

O3O = 3 HP
O4O = 4 HP
O5O = 5 HP
O6O = 6 HP
O75 = 7 1/2 HP
O9O = 9 HP
1OO = 10 HP

7

PRE-INSTALLATION INSTRUCTIONS

I. GENERAL INFORMATION

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

II.

DELIVERY INSPECTION

You are responsible for filling 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 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 damaged to your shipment. Ask for an immediate inspection of your
concealed item. Crating material MUST be retained to show the inspector representing the truck line.

INSTALLATION INSTRUCTIONS

I.

HANDLING AND PLACEMENT OF MULTIPLE RACK SYSTEM

To minimize damage to the unit housing, it is recommended that the crate not be removed until the rack system is
moved to its final location.

There should be a minimum of 3 feet around the perimeter of the Rack System that should be unobstructed.
This allows for proper air flow through the condenser. Likewise, this will also make servicing the equipment
much easier.

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 100 CFM of air per one ton of

refrigeration capacity.

II. HANDLING AND PLACEMENT OF WALK-IN EVAP(S)

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

Evaporator coils will be mounted the appropriate distance from the cooler wall to allow proper air return to evaporato r
coils. Minimum distance shall be greater than or equal to the vertical height of the evaporator coil or as specified in
applicable Installation and Operation Manuals.

8

III. ELECTRICALSPECIFICATIONS

Electrical power supply must match the condensing unit
power requirements indicated on the unit data plate. A

WIRING DIAGRAM IS LOCATED ON THE INSIDE ON
THE ELECTRICAL BOX COVER. For best results, it is

suggested that power supply for MRS Rack systems be
applied as illustrated below in Figure 1. All field wiring
should be done in a professional manner, in accordance
with all governing codes. All wiring (including factory
terminals) should be double checked before start-up

The refrigeration installer will be responsible for the inter­connect wiring between Medium temperature timers and
solenoids and Low temperature evaporators and timers.

MASTER-BILT WILL GLADLY SHIP ANY TIMER LOOSE
WITH PROPER ENCLOSURE SO THAT THEY MAY BE
PLACED
IN A MORE SUITABLE LOCATION IF REQUESTED
AND APPROVED BY FEC OR CONSULTANT.

Figure 1: Suggested Field Wiring Location for MRS Units.

Evaporator drain line heaters will be installed on any application with a room temperature less than 34ºF. A 6 ft. drain
line heater (208-230V) will be provided with each low temperature coil.

NOTICE!

Systems with scroll compressors must be checked for proper power phasing. Improper power phasing will result in
improper compressor rotation causing compressor to pump incorrectly. An optional phase monitor may be purchased
for this purpose.

Three phase scroll compressors are directional dependent, i.e., they will only compress in one rotational direction and
will rotate in either direction depending on power phasing. Verification of proper rotational direction is made by
observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse
rotation also results in an elevated
compared to data tag values.

NOTICE!

Check phase alignment on all incoming power.

sound level over correct rotation, as well as substantially reduced current draw

9

IV. REFRIGERANT PIPING

Use only refrigeration grade copper tubing, (ACR), type “L”, bright annealed, dehydrated, and properly se aled 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. Remove any burring that may occur when cutting the tubing. Use dry nitrogen to purge the
system of any foreign objects that may have come about during any pipe cutting.

All suction lines will be insulated with not less than ¾” Armaflex or acceptable substitute as determined by Master-Bilt
personnel. Armaflex insulation must be properly glued or taped as approved by insulation manufacturer to prevent
refrigeration lines from “sweating”.

Appropriate oil must be added to systems with refrigeration line exceeding 50 ft horizontal or 10 ft vertical as per
Compressor manufacturer specifications.

Suction lines should be sloped down ½” for each 10 feet of horizontal run towards the compressor. This will facilitate
good oil return to the compressor.

Refrigeration lines will be sized appropriately to facilitate
proper oil return to the compressor and reduce refrigerant
line pressure drop. Table 1 and Table 2 depict proper line
sizing options. Use this as a guideline for your selection.
Any fittings used may be accounted for in the Table to the
right.

Fitting

Size 90º Ell

1/2" 0.9
5/8" 1

7/8" 1.5
1-1/8" 1.8
1-3/8" 2.4
1-5/8" 2.8
2-1/8" 3.9

Tee Tee

45º Ell (Line) (Branch)

0.4 0.8 2

0.5 1 2.5

0.7 1.5 3.5

0.9 1.5 4.5

1.2 1.8 6

1.4 2 7

1.8 3.8 10

Equivalent Length Allowances for Pipe Fittings
(length in feet)

10

R- 2 2 S u ctio n a n d L iq u id lin e siz e s

20F suction temperature 10F suction temperature -15F suction temperature -25F suction temperature All

System 50' 100' 200' 50' 100' 200' 50' 100' 200' 50' 100' 200'

Capacity suction line suction line suction line suction line suction line suction line suction line suction line suction line suction line suction line suction line liquid

BTU/Hr. horiz. v ert. horiz. vert. horiz. vert. horiz. vert. horiz. vert. horiz. vert. horiz. vert. horiz. vert. horiz. vert. horiz. vert. horiz. vert. horiz. vert. line

1500
2000
3000
4000
5000
6000
7000
8000

9000
10000 5/8 5/8 3/4 5/8 3/4 5/8 3/4 5/8 3/4 5/8 7/8 5/8 3/4 3/4 7/8 7/8 1 1/8 7/8 7/8 7/8 1 1/8 7/8 1 1/8 7/8 5/16
12000 5/8 5/8 3/4 5/8 3/4 5/8 3/4 3/4 3/4 3/4 7/8 3/4 7/8 7/8 1 1/8 7/8 1 1/8 7/8 7/8 7/8 1 1/8 7/8 1 1/8 7/8 3/8
14000 3/4 5/8 3/4 5/8 7/8 5/8 7/8 3/4 7/8 3/4 1 1/8 3/4 7/8 7/8 1 1/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 3/8
16000 3/4 3/4 7/8 3/4 7/8 3/4 7/8 3/4 7/8 3/4 1 1/8 3/4 7/8 7/8 1 1/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 3/8
18000 3/4 3/4 7/8 3/4 1 1/8 3/4 7/8 7/8 7/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1/2
20000 3/4 3/4 7/8 7/8 1 1/8 7/8 7/8 7/8 7/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1/2
25000 7/8 7/8 1 1/8 7/8 1 1/8 7/8 7/8 7/8 1 1/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 3/8 1 1/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1/2
30000 7/8 7/8 1 1/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1/2
35000 7/8 7/8 1 1/8 7/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 5/8
40000
45000
50000
60000
70000
80000
90000

100000
110000
120000
130000
140000
150000 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 7/8

160000

5/16 5/16 5/16 5/16 3/8 5/16 3/8 5/16 3/8 5/16 3/8 5/16 3/8 3/8 1/2 3/8 1/2 3/8 1/2 3/8 1/2 3/8 5/8 3/8 1/4
3/8 5/16 3/8 5/16 1/2 5/16 3/8 3/8 1/2 3/8 1/2 3/8 1/2 3/8 1/2 3/8 5/8 3/8 1/2 3/8 5/8 3/8 5/8 3/8 1/4
3/8 3/8 3/8 3/8 1/2 3/8 1/2 3/8 1/2 3/8 5/8 3/8 1/2 1/2 5/8 1/2 5/8 1/2 5/8 1/2 5/8 1/2 3/4 1/2 1/4
1/2 3/8 1/2 3/8 5/8 3/8 1/2 3/8 1/2 3/8 5/8 3/8 5/8 1/2 5/8 1/2 3/4 1/2 5/8 5/8 3/4 5/8 3/4 5/8 1/4
1/2 3/8 1/2 3/8 5/8 3/8 1/2 3/8 5/8 3/8 5/8 3/8 5/8 5/8 3/4 5/8 3/4 5/8 3/4 5/8 3/4 5/8 7/8 5/8 1/4
1/2 3/8 5/8 3/8 5/8 3/8 5/8 1/2 5/8 1/2 3/4 1/2 5/8 5/8 3/4 5/8 7/8 5/8 3/4 3/4 7/8 3/4 7/8 3/4 5/16
1/2 1/2 5/8 1/2 5/8 1/2 5/8 1/2 5/8 1/2 3/4 1/2 3/4 5/8 3/4 5/8 7/8 5/8 3/4 3/4 7/8 3/4 1 1/8 3/4 5/16
5/8 1/2 5/8 1/2 5/8 1/2 5/8 1/2 3/4 1/2 3/4 1/2 3/4 3/4 7/8 3/4 7/8 3/4 3/4 3/4 7/8 7/8 1 1/8 7/8 5/16
5/8 1/2 5/8 1/2 5/8 1/2 3/4 5/8 3/4 5/8 7/8 5/8 3/4 3/4 7/8 3/4 1 1/8 3/4 7/8 7/8 1 1/8 7/8 1 1/8 7/8 5/16

1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 5/8
1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 5/8
1 1/8 1 1/8 1 3/8 1 1/8 1 3/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 5/8
1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 3/4
1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 3/4
1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 3/4
1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 3/4
1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 3/4
1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 7/8
1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 7/8
1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 7/8
1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 7/8

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

Table 1

11

R-404a Suction and Liquid line sizes

20F suction temperature 10F suction temperature -15F suction temperature -25F suction temperature -35F suction temperature

50' 100' 200' 50' 100' 200' 50' 100' 200' 50' 100' 200' 50' 100' 200'

System

Capacit line liquid

y suction line suction line suction line suction line suction line suction line suction line suction line suction line suction line suction line suction line suction line suction line suction

BTU/Hr vert. line

. horiz. vert. horiz. vert. horiz. vert. horiz. vert. horiz. vert. h oriz. vert. horiz. vert. horiz. vert. horiz. v ert. horiz. vert. horiz. vert. horiz. vert. horiz. vert. horiz. vert. horiz.

All

1500

3/8 5/16 3/8 5/16 1/2 5/1 6 3/8 5/16 1/2 5/16 1/2 5/16 1/2 3/8 1 /2 3/8 5/8 3/8 1/2 3/8 5/8 3/8 5/8 3/8 1/2 1/2 5/8 1/2 3/4

2000

3/8 5/16 1/2 5/16 1/2 5/16 3/8 3/8 1/2 3/8 1/2 3/8 1/2 3/8 5/8 3/8 5/8 3/8 1/2 1/2 5/8 1/2 3/4 1/2 5/8 1/2 5/8 1/2 3/4

3000

1/2 3/8 1/2 3/8 5/8 3/8 1/2 3/8 1/2 3/8 5/8 3/8 5/8 1/2 5/8 1/2 3/4 1/2 5/8 1/2 3/4 1/2 3/4 1/2 5/8 5/8 3/4 5/8 7/8
1/2 3/8 1/2 3/8 5/8 3/8 1/2 3/8 5/8 3/8 5/8 3/8 5/8 1/2 3/4 1/2 3/4 1/2 5/8 5/8 3/4 5/8 7/8 5/8 3/4 3/4 7/8 3/4 7/8

4000 3/4 5/16

1/2 3/8 5/8 3/8 5/8 3/8 5/8 1/2 5/8 1/2 3/4 1/2 5/8 5/8 3/4 5/8 7/8 5/8 3/4 3/4 7/8 3/4 7/8 3/4 3/4 7/8 7/8 7/8 1 1/8

5000 7/8 3/8

6000

5/8 1/2 5/8 1/2 5/8 1/2 5/8 1/2 5/8 1/2 3/4 1/2 3/4 5/8 3/4 5/8 7/8 5/8 3/4 3/4 7/8 3/4 1 1/8 3/4 7/8 7/8 1 1/8 7/8 1 1/8

7000

5/8 1/2 5/8 1/2 3/4 1/2 5/8 1/2 3/4 1/2 3/4 1/2 3/4 3/4 7/8 3/4 1 1/8 3 /4 7/8 7/8 7/8 7/8 1 1/8 7/8 7/8 7/8 1 1/8 7/8 1 1/8

8000

5/8 1/2 3/4 1/2 3/4 1/2 5/8 5/8 3/4 5/8 7/8 5/8 3/4 3/4 7/8 3/4 1 1/8 3 /4 7/8 7/8 1 1/8 7/8 1 1/8 7/8 7/8 7/8 1 1/8 7/8 1 1/8

9000

5/8 1/2 3/4 1/2 3/4 1/2 5/8 5/8 3/4 5/8 7/8 5/8 7/8 7/8 7/8 7/8 1 1/8 7/8 7/8 7/8 1 1/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8

10000
12000
14000 1 3/8 1/2
16000 3/8 1/2
18000
20000
25000
30000
35000
40000
45000 2 1/8 3/4
50000 2 5/8 3/4
60000
70000
80000

90000
100000
110000
120000 3 1/8 1 1/8
130000 3 5/8 1 1/8
140000
150000
160000 3 5/8 1 1/8

5/8 5/8 3/4 5/8 7/8 5/8 3/4 5/8 3/4 5/8 7/8 5/8 7/8 7/8 1 1/8 7/8 1 1/8 7/8 7/8 7/8 1 1/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8
3/4 5/8 3/4 5/8 7/8 5/8 3/4 3/4 7/8 3/4 1 1/8 3/4 7/8 7/8 1 1/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 3/8
3/4 3/4 7/8 3/4 7/8 3/4 3/4 3/4 7/8 3/4 1 1/8 3/4 1 1/8 7/8 1 1/8 7/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8
3/4 3/4 7/8 3/41 1/8 3/4 7/8 7/8 7/8 7/8 1 1/8 7/81 1/81 1/81 1/81 1/81 3/81 1/81 1/81 1/81 3/81 1/81 3/81 1/81 1/81 1/81 3/81 3/81 5/81
3/4 3/4 7/8 3/4 1 1/8 3/4 7/8 7/8 1 1/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8
7/8 7/8 7/8 7/8 1 1/8 7/8 7/8 7/8 1 1/8 7/8 1 1/8 7/8 1 1/8 1 1/8 1 3/8 1 1/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8
7/8 7/8 1 1/8 7/8 1 1/8 7/8 1 1/8 7/8 1 1/8 7/8 1 3/8 7/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 3/8 1 1/8 1 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8

7/8 7/8 1 1/8 7/8 1 3/8 7/8 1 1/81 1/81 1/81 1/81 3/81 1/81 3/81 3/81 3/81 3/81 5/81 3/81 3/81 3/81 5/81 5/82 1/81 5/81 3/81 3/81 5/81 5/8 2 1/8
1 1/81 1/81 1/81 1/81 3/81 1/81 1/81 1/81 3/81 1/81 3/81 1/81 3/81 3/81 5/81 5/81 5/81 5/81 3/81 3/81 5/81 5/82 1/81 5/81 5/81 5/8 2 1/8 2 1/8 2 1/8
1 1/81 1/81 1/81 1/81 3/81 1/81 1/81 1/81 3/81 3/81 3/81 3/81 3/81 3/81 5/81 5/82 1/81 5/81 5/81 5/81 5/81 5/82 1/81 5/81 5/81 5/8 2 1/8 2 1/8 2 1/8
1 1/81 1/81 3/81 1/81 3/81 1/81 3/81 3/81 3/81 3/81 5/81 3/81 3/81 3/81 5/81 5/82 1/81 5/81 5/81 5/82 1/82 1/82 1/82 1/81 5/81 5/8 2 1/8 2 1/8 2 1/8
1 1/81 1/81 3/81 3/81 3/81 3/81 3/81 3/81 3/81 3/81 5/81 3/81 5/81 5/81 5/81 5/82 1/81 5/81 5/81 5/82 1/82 1/82 1/82 1/82 1/82 1/8 2 1/8 2 1/8 2 5/8
1 1/81 1/81 3/81 3/81 5/81 3/81 3/81 3/81 5/81 5/81 5/81 5/81 5/81 5/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 5/82 1/82 1/82 1/8 2 1/8 2 1/8 2 5/8
1 3/81 3/81 3/81 5/81 5/81 5/81 3/81 3/81 5/81 5/82 1/81 5/81 5/81 5/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 5/82 5/82 1/82 1/8 2 5/8 2 5/8 2 5/8
1 3/81 3/81 5/81 5/81 5/81 5/81 3/81 3/81 5/81 5/82 1/81 5/82 1/82 1/82 1/82 1/82 5/82 1/82 1/82 1/82 1/82 1/82 5/82 5/82 1/82 1/8 2 5/8 2 5/8 2 5/8
1 3/81 3/81 5/81 5/82 1/81 5/81 5/81 5/81 5/81 5/82 1/81 5/82 1/82 1/82 1/82 1/82 5/82 5/82 1/82 1/82 5/82 5/82 5/82 5/82 1/82 1/8 2 5/8 2 5/8 3 1/8
1 3/81 3/81 5/81 5/82 1/81 5/81 5/81 5/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 5/82 5/82 1/82 1/82 5/82 5/82 5/82 5/82 5/82 5/8 2 5/8 2 5/8 3 1/8
1 5/81 5/81 5/81 5/82 1/81 5/81 5/81 5/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 5/82 5/82 1/82 1/82 5/82 5/83 1/83 1/82 5/82 5/8 2 5/8 2 5/8 3 1/8
1 5/81 5/82 1/81 5/82 1/81 5/81 5/81 5/82 1/82 1/82 1/82 1/82 1/82 1/82 5/82 5/82 5/82 5/82 5/82 5/82 5/82 5/83 1/83 1/82 5/82 5/8 2 5/8 2 5/8 3 1/8
1 5/81 5/82 1/82 1/82 1/82 1/81 5/81 5/82 1/82 1/82 1/82 1/82 1/82 1/82 5/82 5/82 5/82 5/82 5/82 5/82 5/82 5/83 1/83 1/82 5/82 5/8 3 1/8 3 1/8 3 5/8
1 5/81 5/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 5/82 1/82 1/82 1/82 5/82 5/83 1/83 1/82 5/82 5/82 5/82 5/83 1/83 1/82 5/82 5/8 3 1/8 3 1/8 3 5/8
1 5/81 5/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 5/82 5/82 1/82 1/82 5/82 5/83 1/83 1/82 5/82 5/83 1/83 1/83 1/83 1/82 5/82 5/8 3 1/8 3 1/8 3 5/8
1 5/81 5/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 1/82 5/82 5/82 5/82 5/82 5/82 5/83 1/83 1/82 5/82 5/83 1/83 1/83 1/83 1/82 5/82 5/8 3 1/8 3 1/8 3 5/8

1/2 1/4
1/2 1/4
5/8 5/16

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

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

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

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

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

Table 2

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All vertical risers will have an appropriate “P” trap at the beginning of the riser and every 20 ft above this point. If the
total rise is less distance than can be evenly divided by 20, the P-traps will be located at the beginning and in the cente r
of the distance so that the total distance between any two traps does not exceed 20 ft.

Keep the refrigeration lines as short as possible and use as few fittings as practicable, being especially careful not to
“kink” the lines. Keep the layout as simple as possible and properly support the piping to absorb vibration and the
normal expansion and contraction caused by temperature changes.

Liquid line filter driers, TXV, and solenoids will be installed on all systems that are single compressor per single
evaporator coil and Master-Bilt has provided the evaporator coil.

The TXV sensing Bulb must be properly mounted on the horizontal portion of the refrigerant suction line and properly
insulated. For systems with a suction line 7/8” OD or larger, surface temperature may vary slightly around the
circumference of the tube. Because of this, Sporlan recommends that sensing bulbs be mounted at the 4 or 8 o’clock
position. For smaller lines, the bulb may be mounted at any point (other than the bottom) on the horizontal suction
line.

Add appropriate amount of oil per compressor manufacturer recommendatio ns to compensate for longer refrigeration
line runs.

When brazing, dry nitrogen
the tubing and fittings. All flux will be removed from the joints when brazing is complete.

MUST be passed through the lines at low pressure to prevent scaling and oxidation inside

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

Silver brazing wire is to be utilized (high temperature alloy of minimum of 5% silver content on all copper connections,
and high temperature alloy of 45% silver content on all dissimilar metal connections.

The refrigeration contractor will be responsible for providing and installing the liqu i d line solenoid valve and coil for all
systems where multiple evaporator coils are used or for “multiplexed” systems.

V. LEAK CHECK

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

Add the proper refrigerant to 60 psig, and then boost the 175 psig with dry nitrogen. Leak checks should be done on all
joints with an electronic leak detector or 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 refrigeration system. This requires a two­stage 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.

.

13