Norlake LAWD150RL4-YH Installation Manual

PRE-ASSEMBLED REMOTE and

PRE-ASSEMBLED, PRE-CHARGED

REMOTE CEILING MOUNT

REFRIGERATION SYSTEMS

Installation, Operation and

Maintenance Instructions

TABLE OF CONTENTS

INTRODUCTION 2

INSPECTION 2 SYSTEM SPECIFICATIONS 2 - 3 INSTALLATION 4 - 17

Unit Cooler Mounting 4 Condensing Unit Handling and Placement 5 Ceiling Mount with Optional Membrane Roof 5 Refrigerant Lines 6 - 11 Suction Lines 6 - 7 Liquid Lines 7 Line Size Charts 8 – 11 Defrost Time Switch 12 Pre-Charged Refrigerant Lines 12 - 13 Condensate Drain Line 13 - 14 Leak Testing 14 Evacuation 14 Electrical 15 Pre-Start Check Out 15 Start-Up and Final Refrigerant Charge 15 - 17 Operational Check Out 18 Sequence of Operation 18 - 19

MAINTENANCE 19 - 22 Service Diagnosis Chart 23

FINAL CHECKLIST FOR INSTALLATION 24 - 25

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INTRODUCTION

This refrigeration equipment has been engineered to meet specific end user requirements and is assembled using the highest quality components available. Please read and understand these instructions thoroughly before proceeding with the installation. Important information within these instructions will ensure a reliable installation.

To assure that the finished installation is done in accordance with equipment design criteria, local

code requirements, and to the end user’s satisfaction, only a qualified installation contractor should be used. Failure to comply with accepted industry standards and practices can result in

equipment failure and loss of factory warranty coverage. Installation/Maintenance instructions, wiring diagrams, and warranty documents should be

kept for future reference.

INSPECTION

RECEIVING

Shipments delivered must be carefully counted and inspected while the driver is still present and before the delivery receipt is signed. Check the Bill of Lading for the number of pieces that made up the shipment. Verify that the number of pallets, boxes, or crates agrees with that number. Note any shortage on the delivery receipt.

Examine each shipping container for signs of damage or mishandling. If a container is damaged, the contents may also be damaged. Ask that the container be opened and the contents examined while the driver is still present. Note any damage on the delivery receipt. If damage or a shortage is discovered after the driver has left, and was not noted on the delivery receipt, a request for an inspection by the carrier must be completed within 15 days. Retain all the crating material and do not relocate or install the equipment until an inspection has been completed. If damage or loss has occurred, a written claim must be filed with the carrier within nine months from the delivery date. Always feel free to call and ask Nor-Lake for assistance with freight claim questions.

Note: If the condensing unit arrives on its side or upside down, inspect for damage. If there is no damage, invert to correct position and let the unit sit in its upright position 24 hours prior to operation.

SYSTEM SPECIFICATIONS

CONDENSING UNITS

 Factory assembled using UL LISTED components  Accessible hermetic, welded hermetic, or scroll compressors  Air-cooled or optional water cooled condenser  Optional housing and low ambient controls, for outdoor use, are factory installed  Factory mounted to a galvanized steel rack

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UNIT COOLERS

 UL LISTED  Forced air type with low profile design  Designed for ceiling installation with air discharge parallel to the walk-in ceiling  Fan motors, guards, and multi fin or tube type direct expansion coil are enclosed in a heavy

gauge aluminum housing

 Include drain pan with suitable drain pipe connection  Freezer models have an automatic electric defrost system including heaters, time clock, defrost

termination and fan delay control, heated drain pan, and heater limit switch

 Defrosts are time initiated and temperature terminated with a built in fail safe control

REFRIGERANT

 R404A for high/medium temperature applications.  NOTE: R404A system’s compressors use POE oils. DO NOT leave the compressor service

valves open for over five minutes, as this will contaminate the oil with moisture and void the warranty.

ELECTRICAL

 No inter-wiring required between the evaporator and condensing unit  Two point electrical connection, one at the condensing unit and one at the unit cooler, provided

for field hook up

 Rack mounted control box that encloses factory pre-wired pressure controls and contactor for

three phase units

 NOTE: Nor-Lake wiring diagram is provided. Keep for reference. DO NOT use any other

diagram

PROVIDED EQUIPMENT FOR FIELD INSTALLATION

 Liquid line filter drier  Sight glass  Solenoid valve  Room temperature control  Expansion valve  Evaporator mounting kit  Defrost time clock

FIELD INSTALLATION REQUIREMENTS

 Refrigerant piping  Evaporator drain line  Freezer drain line heater

OPTIONAL FEATURES

 Pre-charged systems, up to 3 horsepower, with line sets up to 50 feet long using reusable quick

connect refrigerant line fittings

 Pre-piped with the liquid line filter drier, sight glass, and hand valve factory installed (not

applicable to pre-charged systems)

 Pre-wired to allow for a single point electrical connection at the condensing unit (will require field

inter-wiring between the evaporator and condensing unit)

NOTE: Nor-Lake will custom design and build refrigeration systems to meet the customer’s needs.

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INSTALLATION

GENERAL

Installation of all equipment, piping, and electrical must be done in accordance with local and national codes. Installation and service of this equipment must be performed by qualified and experienced refrigeration mechanics. Correct installation is necessary to obtain optimum performance and customer satisfaction.

UNIT COOLER MOUNTING

IMPORTANT: If the Walk-in box is located outdoors, the unit cooler must be installed before the installation of the membrane roof.

 Unit coolers are equipped with four or six mounting brackets, depending on size, capable of

supporting the weight of the unit cooler during shipping and mounting within the cold room.

 Care must be taken not to place the unit cooler on the drain pan to avoid damage to the

pan, drain fitting, or pan defrost heaters on low temperature unit coolers.

 The unit cooler has a draw through evaporator design, drawing air across the coil and

discharging it into the room from the fans. Therefore, for proper airflow, it is necessary to allow a minimum distance between the cold room wall and the air inlet side of the unit cooler of 12 inches for low profile, and 24 inches for standard profile, unit coolers.

 The unit cooler must be located to provide good air circulation to all areas of the cold room.  Units should not be located above or close to doors where outside air would be drawn into the

evaporator and cold room when the door is opened.

 Unit coolers must be located a sufficient distance from walls, beams, other units, or obstructions

to permit unrestricted air flow on both the entering and discharge air faces.

 Space at each end of the unit cooler is a concern for installation convenience and possible

future service. Twelve inches is normally a sufficient distance at the ends of the unit cooler for tubing and wiring connections.

 Unit coolers are designed to mount directly to the cold room insulated ceiling panel using the

nylon-threaded rods, nuts, and washers provided. Care must be taken to mount the unit cooler level so condensate drains properly. CAUTION: Do not drill any holes within a six-inch radius from the center of any panel lock access hole. See Figure 1.

1. Locate and mark the unit cooler mounting holes on the ceiling panel.

2. Move the unit cooler and drill the holes using a 3/8” drill bit.

3. Insert the nylon-threaded rod through the ceiling panel from the outside.

4. Using a hammer, carefully drive the pallet nut on the rod flush to the ceiling panel.

5. Mount the unit cooler and tighten the mounting nuts, being careful not to over tighten.

6. The seam between the top of the unit and the cold room ceiling panel must be sealed. A NSF LISTED sealant for this purpose is provided with the cold room hardware box.

Figure 1

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CONDENSING UNIT HANDLING AND PLACEMENT

 In order to minimize damage to the unit enclosure, the shipping crate should be left intact until

the unit is in its final location.

 The condensing unit rack must be mounted level and anchored using the mounting holes

provided in its base to prevent movement. Caution: If the unit is not mounted level, the compressor may not receive proper lubrication, which will result in premature failure.

 Locate the condensing unit rack as close to the unit cooler as possible for the most efficient and

least costly operation.

 When placing the condensing unit rack, care must be taken so as not to shroud or restrict the

air-in side (condenser) or the air-out side (discharge) of the unit.

 The condenser side of the unit must not be located closer to any building wall, roof parapet, or

obstruction than a dimension equal to the condenser height, and the air-out should discharge into free space.

 Do not locate multiple units so the air-out (discharge) from one unit is directed into the air-in

(condenser) end of another unit.

 When a condensing unit rack is installed indoors, an adequate supply of outside air must be

provided, 750 CFM per horsepower, as well as a means of exhausting the air from the room to

prevent heat buildup. Heat buildup will create inefficient operation and possible “trip out” on high

head pressure overload.

 On condensing units having externally spring mounted compressors, loosen the hold down nuts

and remove the spring steel shipping clips from the mounting springs to allow the compressor to float freely on the springs.

 If the condensing unit is water cooled, it must be installed in a location that isn’t subject to

freezing temperatures in cold weather. Ceiling Mount with Optional Membrane Roof

See the following illustrations for a ceiling mounted system when the Walk-In has an optional membrane roof. The fastener bracket will keep the unit from moving on the membrane roof.

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REFRIGERANT LINES

After the condensing unit and the evaporator coil are mounted in their respective positions, the refrigerant lines may be installed. The positions of the refrigerant lines relative to horizontal is important in guaranteeing oil return to the compressor. The three possible relative positions are as follows:

1. Condensing unit above the evaporator coil

2. Condensing unit on the same horizontal plane as the evaporator coil

3. Condensing unit below the evaporator coil

Caution: Tubing entrance holes must be positioned to clear any panel section joint or panel metal seam, and should not fall within a six-inch radius from the center of any panel lock access hole. See Figure 1 on page 4.

 Suction Lines: The suction line is the most critical line from a design and construction

standpoint. The suction line must be sized to maintain proper line velocities and practical line pressure drop. To ensure proper oil return, all horizontal lines should slope downward towards

the compressor with a slope of 1/2” per ten feet. Horizontal lines can be increased one or two

sizes for long runs. When the condensing unit is installed above the evaporator coil, an oil trap should be built into the suction line before the first riser. Additional oil traps should be installed for each additional 20 feet of rise. Refer to Table 2 or 3 to determine the proper size suction line and riser size.

Suction lines must be insulated. Use good quality insulation such as Rubatex or Armaflex

Tubing Insulation. Recommended wall thickness should be 3/4”. During installation, the ends of the insulation must be taped off and sealed to prevent condensation build up.

Determining Size of Suction Line:

1. Determine the approximate length (±10%) of the suction line from a sketch of the

proposed installation.

2. From Table 2 for R-404, along the top of the table, find the appropriate suction

temperature. Using the suction line length, round up to the nearest length matching one listed on the chart in the section under the selected temperature. This is the correct column to use.

3. Along the side of the table, find the system capacity in BTU/Hr. When the correct

capacity is found, follow the row over to where it intersects with the column found in step

2. This is the size of the line. Caution: This may not be the final answer. Continue with the following steps.

4. Determine the number of shut-off valves, globe or angle, elbows, and tees that will be

used in the suction line from the installation sketch completed in step 1.

5. From Table 1, establish the equivalent feet of pipe for the total number of each type of

valve and fitting. Based on the line size determined in step 3, find this line size along the top of the table and the valve or fitting along the left side. Where these two intersect is the equivalent number of feet.

6. Add together the total length of suction line from step 1 and the equivalent length in feet

of the valves and fittings from step 5.

7. Using the new total length calculated in step 6, repeat steps 2 and 3 to determine the

line size based on this new length, instead of using the length of the suction line only. This is now the final answer and the line size to use. Note: steps 2 and 3 were done the first time to get the approximate line size needed to calculate the valve and fitting equivalents in step 5.

8. The line size determined in step 7 is the recommended size to hold the pressure drop

within permissible limits.

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Line Sizing Example:

Copper Tube O.D. Type "L"

1/2 5/8 7/8 1-1/8 1-3/8 1-5/8 2-1/8 2-5/8 3-1/8 3-5/8 4-1/8 5-1/8 6-1/8

Globe Valve (Open) 14 16 22 28 36 42 57 69 83 99 118 138 168 Angle Valve (Open) 7 9 12 15 18 21 28 34 42 49 57 70 83 90¡ Turn Through Tee 3 4 5 6 8 9 12 14 17 20 22 28 34

Tee (Straight Through) Sweep Below

.75 1 1.5 2 2.5 3 3.5 4 5 6 7 9 11

90¡ Elbow or Reducing Tee

(Straight Through)

1 2 2 3 4 4 5 7 8 10 12 14 16

Find the Suction Line size under the following conditions. Refrigerant: R-404A

Suction Temp: -20°F (-28.89°C) Evaporator Capacity at 10° TD: 36,000 BTU/Hr Length of Line: 100 ft. Valves: 1 (Globe) Elbows: 4

Solution Step 1: Scaled or estimated at 100 feet

Step 2: From Table 3 under temperature of –20°F, find column under 100’

Step 3: Find 36,000 BTU/Hr along the side of Table 3. Follow this row to where it

intersects with column found in step 2. Line size of 1-3/8” O.D. Step 4: One globe shut-off valve and four elbows Step 5: From Table 1 under the 1-3/8” O.D. column – 1 Globe Valve = 36 4 Elbows (4x4) = 16 Total = 52 Step 6: Sum of the line length and equivalents is 100’ + 52’ = 152’ Step 7: Using the new total length, the line size should be 1-5/8” O.D. instead of 1-

3/8” O.D. in order to hold the pressure drop equivalent of 2°F.

 Liquid Lines: The major concerns for liquid line installations are to avoid excessive pressure

drop and to ensure a solid column of liquid to the expansion valve. Note: The expansion valve sensing bulb must be strapped to the suction line immediately exiting the evaporator on the right or left side. Refer to Table 2 or 3 to determine the proper liquid line size. The liquid line solenoid valve should be installed in the liquid line just ahead of the expansion valve. The solenoid valve should be disassembled prior to brazing to avoid possible heat damage. Use only refrigeration grade copper tubing Type K or Type L for suction and liquid lines, or in accordance with local codes.

All refrigerant piping should enter the condensing unit and evaporator coil through the knockouts as provided. Use only silver bearing hard solder such as silfos, unibraze, or similar type “hard solder”. Do not use soft solder for any brazed refrigeration line joints. A small amount of dry nitrogen should be bled into the piping during all brazing operations. This will help minimize scale formation and oxidation inside the copper tubing. Keep all tubing free of metal chips, foreign matter, and moisture during installation. The compressors for R-404A systems contain POE oil. DO NOT

leave service valves open to the atmosphere for over five minutes. This will contaminate the oil and cause damage to the system.

When making brazed connections, care must be taken so as not to damage any closures, wiring, or electrical connections. Secure all refrigerant line tubing with straps or hangers as required per code.

TABLE 1 – Equivalent feet for Valves and Fittings

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SUCTION LINE SIZE

Suction Temperature

System

Capacity

Equivalent Lengths Equivalent Lengths Equivalent Lengths Equivalent

BTU/Hr 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75'

1,000 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 1/2 3/8 3/8 3/8 1/2 1/2 1/2 3/8 3/8 1/2 3,000 3/8 3/8 1/2 1/2 1/2 5/8 3/8 1/2 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 5/8 7/8 1/2 1/2 5/8 4,000 3/8 1/2 1/2 1/2 5/8 5/8 1/2 1/2 1/2 5/8 5/8 7/8 1/2 5/8 5/8 5/8 7/8 7/8 1/2 5/8 5/8 6,000 1/2 1/2 5/8 5/8 7/8 7/8 1/2 1/2 5/8 5/8 7/8 7/8 1/2 5/8 5/8 7/8 7/8 7/8 5/8 5/8 7/8

9,000 5/8 5/8 7/8 7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 1-1/8 5/8 7/8 7/8 12,000 5/8 7/8 7/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 1-1/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 7/8 7/8 7/8 15,000 5/8 7/8 7/8 7/8 7/8 1-1/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 7/8 7/8 1-1/8 18,000 7/8 7/8 7/8 7/8 1-1/8 1-1/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 7/8 1-1/8 1-1/8 24,000 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 30,000 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 36,000 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-1/8 1-1/8 1-3/8 42,000 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 48,000 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 54,000 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-3/8 1-3/8 1-5/8 60,000 1-1/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-5/8 66,000 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-3/8 1-5/8 1-5/8 72,000 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-3/8 1-5/8 1-5/8 78,000 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1-5/8 1-5/8 1-5/8 84,000 1-1/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-5/8 1-5/8 2-1/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8 90,000 1-3/8 1-3/8 1-5/8 1-5/8 2-1/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-5/8 1-5/8 1-5/8 2-1/8

120,000 1-3/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 1-3/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 1-5/8 2-1/8 2-1/8 150,000 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 1-5/8 2-1/8 2-1/8 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 2-1/8 2-1/8 2-1/8 180,000 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-5/8 1-5/8 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 3-1/8 2-1/8 2-1/8 2-5/8 210,000 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-1/8 2-1/8 2-5/8 2-5/8 3-1/8 3-1/8 2-1/8 2-5/8 2-5/8 240,000 1-5/8 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 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 2-1/8 2-5/8 2-5/8 300,000 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 2-5/8 2-5/8 2-5/8 360,000 2-1/8 2-1/8 2-5/8 2-5/8 3-1/8 3-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 3-5/8 2-5/8 2-5/8 3-1/8 480,000 2-1/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 2-5/8 2-5/8 2-5/8 2-5/8 3-5/8 3-5/8 2-5/8 3-1/8 3-1/8 3-5/8 3-5/8 4-1/8 2-5/8 3-1/8 3-1/8 600,000 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 3-5/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 3-5/8 3-1/8 3-1/8 3-1/8 3-5/8 4-1/8 4-1/8 3-1/8 3-1/8 3-1/8

TABLE 2 – Recommended Line Sizes for R-404A Refrigerant

Note:

 Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not

exceed horizontal size. Properly placed suction traps must also be used for adequate oil return.

 All sizes shown are for O.D. type L copper tubing.  Suction line sizes selected at pressure drop equivalent to 2°F reduce estimate of system capacity accordingly. If

system load drops below 40% of design, consideration to install double suction risers should be made.

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TABLE 3 – Recommended Line Sizes for R-404A Refrigerant (Continued)

SUCTION LINE SIZE

LIQUID LINE SIZE

Suction Temperature

Receiver to

Expansion Valve

System

Lengths Equivalent Lengths Equivalent Lengths Equivalent Lengths

Capacity

100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' BTU/Hr

1/2 1/2 1/2 3/8 3/8 1/2 1/2 1/2 5/8 3/8 1/2 1/2 1/2 5/8 5/8 3/8 3/8 3/8 3/8 3/8 3/8 1,000 5/8 7/8 7/8 1/2 1/2 5/8 5/8 7/8 7/8 1/2 1/2 5/8 5/8 7/8 7/8 3/8 3/8 3/8 3/8 3/8 3/8 3,000 7/8 7/8 7/8 5/8 5/8 5/8 7/8 7/8 7/8 1/2 5/8 5/8 7/8 7/8 7/8 3/8 3/8 3/8 3/8 3/8 3/8 4,000 7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 1-1/8 3/8 3/8 3/8 3/8 3/8 3/8 6,000

7/8 1-1/8 1-1/8 5/8 7/8 7/8 7/8 1-1/8 1-1/8 5/8 7/8 7/8 7/8 1-1/8 1-1/8 3/8 3/8 3/8 3/8 3/8 3/8 9,000 1-1/8 1-1/8 1-1/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 3/8 3/8 3/8 3/8 3/8 1/2 12,000 1-1/8 1-1/8 1-3/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 3/8 3/8 3/8 3/8 1/2 1/2 15,000 1-1/8 1-3/8 1-3/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 3/8 3/8 3/8 1/2 1/2 1/2 18,000 1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 3/8 3/8 1/2 1/2 1/2 1/2 24,000 1-3/8 1-3/8 1-5/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 3/8 1/2 1/2 1/2 1/2 1/2 30,000 1-3/8 1-3/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1/2 1/2 1/2 1/2 1/2 5/8 36,000 1-5/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1/2 1/2 1/2 1/2 5/8 5/8 42,000 1-5/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1/2 1/2 1/2 5/8 5/8 5/8 48,000 1-5/8 1-5/8 1-5/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 2-1/8 1/2 1/2 1/2 5/8 5/8 5/8 54,000 1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 1/2 1/2 5/8 5/8 5/8 5/8 60,000 1-5/8 1-5/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1/2 1/2 5/8 5/8 5/8 5/8 66,000 1-5/8 1-5/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1/2 5/8 5/8 5/8 5/8 5/8 72,000 1-5/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 5/8 5/8 5/8 5/8 5/8 7/8 78,000 2-1/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 5/8 5/8 5/8 5/8 7/8 7/8 84,000 2-1/8 2-1/8 2-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 5/8 5/8 5/8 7/8 7/8 7/8 90,000 2-1/8 2-5/8 2-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 5/8 5/8 7/8 7/8 7/8 7/8 120,000 2-5/8 2-5/8 2-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-5/8 5/8 7/8 7/8 7/8 7/8 1-1/8 150,000 2-5/8 2-5/8 3-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 180,000 2-5/8 3-1/8 3-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 210,000 2-5/8 3-1/8 3-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 240,000 3-1/8 3-5/8 3-5/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 4-1/8 2-5/8 2-5/8 3-1/8 3-5/8 3-5/8 4-1/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 300,000 3-5/8 3-5/8 4-1/8 2-5/8 3-1/8 3-1/8 3-5/8 3-5/8 4-1/8 2-5/8 3-1/8 3-5/8 3-5/8 4-1/8 4-1/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-5/8 360,000 3-5/8 3-5/8 4-1/8 3-1/8 3-5/8 3-5/8 4-1/8 4-1/8 4-1/8 3-1/8 3-5/8 3-5/8 4-1/8 4-1/8 4-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 480,000 3-5/8 3-5/8 4-1/8 3-1/8 3-5/8 3-5/8 4-1/8 4-1/8 5-1/8 3-1/8 3-5/8 3-5/8 4-1/8 4-1/8 5-1/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 600,000

Note:

 Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not

exceed horizontal size. Properly placed suction traps must also be used for adequate oil return.

 All sizes shown are for O.D. type L copper tubing.  Suction line sizes selected at pressure drop equivalent to 2°F reduce estimate of system capacity accordingly. If

system load drops below 40% of design, consideration to install double suction risers should be made.

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TABLE 4 – Recommended Line Sizes for R-134A Refrigerant

Note:

 Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not

exceed horizontal size. Properly placed suction traps must also be used for adequate oil return.

 All sizes shown are for O.D. type L copper tubing.  Suction line sizes selected at pressure drop equivalent to 2°F reduce estimate of system capacity accordingly. If

system load drops below 40% of design, consideration to install double suction risers should be made.

 Consult factory for R-134a operation at winter conditions below 0° ambient. Heated and insulated receiver required

below 0° ambient. If system load drops below 40% of design, consideration to installing double suction risers should be made.

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TABLE 4 – Recommended Line Sizes for R-134A Refrigerant (Continued)

Note:

 Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not

exceed horizontal size. Properly placed suction traps must also be used for adequate oil return.

 All sizes shown are for O.D. type L copper tubing.  Suction line sizes selected at pressure drop equivalent to 2°F reduce estimate of system capacity accordingly. If

system load drops below 40% of design, consideration to install double suction risers should be made.

 Consult factory for R-134a operation at winter conditions below 0° ambient. Heated and insulated receiver

required below 0° ambient. If system load drops below 40% of design, consideration to installing double suction risers should be made.

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DEFROST TIME SWITCH

1. Setting the correct time of day: Simply rotate the minute hand clockwise until the correct time of day on the outer dial is aligned with the triangle marker on the inner dial. In referring to the illustration, the correct time of day shown is 8:00 a.m.

2. Number of defrosts per day: The time switch is factory set to provide four defrosts per day. If more defrosts are required, move additional white tabs at the desired time. No more than two

consecutive tabs should be set at any one time. Each white tab constitutes 15 minutes of

defrost time. If the four defrost periods provided are more than necessary, push white tabs back toward the center of the dial.

3. Fail-Safe feature: The fail-safe of the timer is factory set at 30 minutes. The function of this device is to terminate the defrost cycle and revert back to the cooling cycle if a system malfunction occurs during defrost. No adjustment of this device should ever be necessary. Lengthening the fail-safe time will not lengthen the

defrost cycle.

Note: The defrost times are factory set at 10:00 a.m., 4:00 p.m., 10:00 p.m., and 4:00 a.m. This

setting will provide adequate defrosting for a normal installation. WARNING: The fail-safe feature is a safety mechanism and should never be used to control the

length of defrost. This feature is provided to protect the contents of the freezer from damage should the system fail to revert to the cooling cycle because of mechanical difficulties.

PRE-CHARGED REFRIGERANT LINES (If applicable)

By employing self-sealing refrigeration couplings, the condensing unit, the unit cooler, and the connecting tubing are separately pre-charged with refrigerant and leak tested at the factory before shipment. Follow these simple steps to install the connecting tubing:

1. Carefully uncoil the suction line. This line is covered with a continuous length of sponge rubber insulating tubing.

2. Carefully uncoil the liquid line. This is the smaller diameter, bare copper tube.

3. Before making any connections, determine the routing of both lines and carefully hand bend them to suit the situation. Keep the bend radius rather large to prevent kinking of the tubing. It is a general practice to route the suction and liquid line parallel and close together in the installation.

4. The pre-charged lines will have a 90° bend on one end. If the pre-charged lines are to exit through the walk-in wall, the 90° end of the lines will be connected to the condensing unit. If the pre-charged lines are to exit through the ceiling of the walk-in, the 90° end of the lines will be connected to the unit cooler.

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5. Locate the tubing entrance holes. Center

punch the locations. Using the proper size hole saw, cut tubing holes straight in, not at an angle. Two-inch diameter holes, one for the suction line and one for the liquid line are sufficient for coupling clearance. Caution: Tubing entrance holes must be positioned to clear any panel section joint, panel metal seam, and should not fall within a six-inch radius from the center of any panel lock access hole. See drawing.

6. Remove the dust caps and plugs from the

couplings and inspect them to make sure the synthetic seals are intact.

7. Using a clean cloth, wipe the coupling seals

and threaded surfaces to prevent any dirt or foreign material from getting into the system.

8. Lubricate the synthetic seal in the male half of

the couplings with refrigeration oil and thread the two coupling halves together BY HAND to insure proper mating of the threads. Note: Make

certain that the insulated suction line is connected to the coupling half marked “Suction Line”

and that the bare tube liquid line is connected to the coupling half marked “Liquid Line”.

9. Using the proper size wrench on the union nut, tighten until the coupling bodies “bottom”, or until

a definite resistance is felt. Tighten an additional 1/6 to 1/4 turn. This final turn is necessary to insure that the knife-edge metal seal bites into the brass seat of the coupling halves, forming a leak-proof joint. Note: Always use two wrenches on the coupling body hex nut and on the union to prevent twisting of the tube while you are tightening.

10. All valves are shipped open and ready for operation. Remember that the refrigeration couplings

on this system are self-sealing and, if the need ever arises, the couplings may be disconnected without any loss of refrigerant.

11. It is the installing contractor’s responsibility to ensure that the quick-connect refrigerant

couplings are properly mated, tight, and leak free.

Note: All wall penetrations must be sealed. During installation the ends of the suction line insulation must be taped off and sealed. After the pre-charged lines are installed, the suction line insulation must be pulled over the quick connects, taped off, and sealed to prevent condensation build up.

CONDENSATE DRAIN LINE

All condensate water from an evaporator must be disposed of properly and not allowed to accumulate in the unit cooler drain pan or elsewhere causing a safety hazard. Condensate water must never be drained onto the cooler or freezer floor, or onto adjacent room floors or walkways. Drain properly to prevent personal injury.

a. All condensate drain plumbing must be installed in accordance with local codes. Caution: The

drain line hole must be positioned to clear any panel section joint, panel metal seam, and should not fall within a six-inch radius from the center of any panel lock access hole. See drawing above.

b. Drain lines must be copper tubing for freezer rooms. For cooler rooms, if code permits, the lines

may be PVC. c. Drain lines must not be smaller than the unit cooler drain connection. d. The length of drain lines within the refrigerated space must be kept as short as possible before

exiting the room. e. For proper drainage, drain lines must be pitched downward a minimum of four inches per foot in

freezer rooms, and a minimum of one inch per foot in cooler rooms.

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f. A “P” trap must be provided in the drain line outside the refrigerated space to prevent warm

moist air from being drawn into the unit cooler through the drain line. Note: When plumbing a combination cooler/freezer, each compartment should be plumbed separately.

g. The drain line must be run to an open drain, not directly to the sewer system. h. An electrical heating cable or heat tape must be wrapped on the entire drain line inside a

freezer, extending through the freezer wall up to and including the “P” trap. A heat input of 20

watts per lineal foot of drain line for 0°F and 30 watts per lineal foot for –20°F will be satisfactory. The heater must be energized continuously.

i. The entire length of heated drain line exposed within the refrigerated space must be insulated

with a suitable material, a minimum 1/2” wall thickness.

j. Condensate drain lines outside the refrigerated space that are exposed to below freezing

temperatures during the winter must be treated as in letters ”h” and “i” above.

LEAK TESTING

1. After all refrigerant lines are connected; the system must be leaked tested at a minimum of 150 psig with the compressor suction and discharge valves closed, and all other valves in the system open. If local codes require higher test pressures, such codes must be complied with.

2. Sufficient liquid refrigerant of the type to be used in the system must be charged to raise the pressure to 20 psig and dry nitrogen added to obtain the desired test pressure.

3. Leak test all joints and fittings with an electronic leak detector. If any leaks are found, isolate the defective area, discharge the gas using proper reclamation techniques and repair the leaks

4. Repeat the leak test to prove the entire system is leak free.

5. When the testing is complete, release all pressure using proper reclamation techniques.

EVACUATION

Caution: Do not use the refrigeration compressor to evacuate the system. Do not start the

compressor while it is in a vacuum.

1. A good, deep vacuum pump should be connected to both the low and high side evacuation valves with copper tube or high vacuum hoses, 1/4” ID minimum. If the compressor has service valves, they should remain closed. A deep vacuum gauge capable of registering pressure in microns should be attached to the system for pressure readings.

2. A shut off valve between the gauge connection and vacuum pump should be provided to allow the system pressure to be checked after evacuation. Do not turn off the vacuum pump when connected to an evacuated system before closing the shut off valve.

3. The vacuum pump should be operated until a pressure of 1,500 microns absolute pressure is reached, at which time the vacuum should be broken with the refrigerant to be used in the system through a drier until the system pressure rises above 0 psig.

4. Repeat this operation a second time.

5. Open the compressor service valves and evacuate the entire system to 200 microns absolute pressure. Raise the pressure to 2 psig with the refrigerant and remove the vacuum pump.

Note: EPA regulations are constantly being updated. To ensure that your procedure is proper, follow current regulations.

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ELECTRICAL INSTALLATION

Note: All field wiring must be done in accordance with the National Electric Code and/or other

applicable local codes. a. The field wiring should enter the condensing unit assembly and unit cooler assembly at

locations provided.

b. The specific wiring diagram for each system is located in the plastic bag shipped with the

condensing unit rack that contains warranty information.

c. The available power supply, voltage, frequency, and phase must coincide with the condensing

unit and unit cooler data plate.

d. Before operating, double check all wiring connections including factory terminals. Factory

connections can vibrate loose during shipment. e. Be certain field wiring is properly sized to handle the connected load. f. Cold room wall or ceiling wiring penetrations should only be made with UL labeled PVC conduit

or water- tight flexible conduit to avoid condensation on the warm side of the wall or ceiling. The

conduit end must be sealed to prevent moisture migration and the penetration itself must also

be sealed with silicone. g. On remote rack mounted systems, the room temperature control must be mounted in a location

within the cold room convenient for adjustment and that allows the control cap tube with feeler

bulb to be routed to sense the unit cooler return (inlet) air. h. The freezer defrost timer must be located near the unit cooler, preferably outside the cold room

in an upright position, unless the system configuration locates it in the condensing unit.

PRE-START CHECK OUT

Prior to final system charging and start-up, the following points must be checked:

1. On accessible hermetic compressors, observe the crankcase oil level. The oil level should be at

or slightly above the center of the sight glass. If oil must be added, use only oil approved by the

compressor manufacturer and suitable for the refrigerant used.

2. Check and adjust the cold room temperature control for the desired operation.

3. Set the defrost time switch on freezer systems. See the section titled “Defrost Time Switch”.

4. Check and adjust, if needed, the High/Low pressure control. Low side cut-in should be

set at 15-20 pounds, low side cutout at 1-5 pounds, and high-pressure cutout at 440 psi

for R-404A systems.

5. Check to make sure the condenser and unit cooler fan blades rotate without obstruction.

6. Check that all refrigerant tube runs are properly insulated, supported, and that electrical conduit

is properly supported.

7. Make sure cold room wall and ceiling penetrations are properly sealed.

8. Collect all wiring diagrams, instruction manuals, etc. to be filed for future reference.

START-UP AND FINAL REFRIGERANT CHARGE

Before attempting to start the system, make sure that all service valves are open and shipping blocks have been removed. Unit cooler fans must be operational before attempting to final charge the system. Note that cooler fans will operate continuously while freezer fans will be delayed by the fan control until the evaporator is reduced to approximately 25°F.

Scroll compressors are directional, i.e. they will compress in one rotational direction only. On singlephase compressors this is not an issue since they will always start and run in the proper direction,

except as described in the section “Brief Power Interruptions”. Three phase scrolls, however, will

rotate in either direction depending on the power phasing. Since there is a 50/50 chance of connected power being backwards, contractors should be warned of this.

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Observing that the suction pressure drops and the discharge pressure rises when the compressor is energized verifies the proper rotation. Additionally, if operated in reverse, the compressor makes more noise and its current draw is substantially reduced compared to tabulated values.

If suction pressure does not drop and discharge pressure does not rise to normal levels, check the power at the breaker. Reverse any two of the compressor power leads and reapply power to make sure the compressor was not wired to run in the reverse direction.

Caution: Although operation of the scroll in the reverse direction for brief periods of time is not harmful, continued operation will result in a failure due to insufficient lubrication of the drive bearing and scroll galling.

All three-phase compressors are wired identically internally. Once the correct phasing is determined for a specific system or installation, connecting properly phased power leads to the same Fusite terminals will maintain proper rotation.

Brief power interruptions Brief power interruptions, less than 1/2 second, may result in powered reverse rotation of single-

phase scroll compressors. High-pressure discharge gas expands backwards through the scrolls at power interruption, causing the scroll to orbit in the reverse direction. If power is reapplied while this reversal is occurring, the compressor may continue to run noisily in the reverse direction for several

minutes until the compressor’s internal protector trips. This does not have a negative impact on

durability. The internal protector will automatically reset once the internal temperature has returned to a safe operating range for the compressor. When the protector resets the compressor will start and run normally.

1. Start the system and finish charging until the sight glass indicates a full charge, the sight glass should be clear. Care should be taken so as not to overcharge the system at this point. When adding refrigerant to an operating system, it is necessary to add the refrigerant through the compressor suction service valve. Because the refrigerant leaving the refrigerant cylinder must be in liquid phase, care must be exercised to avoid damage to the compressor. It is suggested that a sight glass be connected between the charging hose and the compressor suction service valve. This will permit adjustment to the cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the compressor.

Rapid charging only on the suction side of a scroll equipped system or condensing unit can occasionally result in a temporary no-start condition for the compressor. The reason for this is that if the flanks of the compressor happen to be in a sealed position, rapid pressurization of the low side without opposing high side pressure can cause the scrolls to seal axially. As a result, until the pressures eventually equalize, the scrolls can be held tightly together, preventing rotation. The best way to avoid this situation is to charge on both the high and low side simultaneously at a rate that does not result in axial loading of the scrolls. The maximum charging rate can be determined through simple tests.

2. During start-up, keep a continual check on high and low side pressures as well as compressor amperage. Rated load amps are shown on the nameplate.

3. Outdoor condensing units which are equipped with a condenser flooding type head pressure control valve for low ambient operation must have the correct refrigerant charge added at initial start-up in order for the system to operate properly in all seasons. The extra winter charge, as calculated below, should be weighed into the receiver. To determine the extra charge required, calculate the total length of tubing in the condenser including the equivalent length for return bends. See Table 4. Multiply the total length in feet by the number of pounds per 100 feet for the proper refrigerant and condenser tube size from Table 4.

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