Reznor MAPS III User Manual

Form O-MAPSIII Cabinet D (Version D)

CQS

Obsoletes Form O-MAPSIII Cabinet D (Version C)

Operation / Maintenance / Service

Applies to: Models RCB, RDB, RDCB,

™

RDDB, RECB, and REDB

Cabinet "D" Sizes

R-410A

Refrigerant

CQS

DANGER

This unit contains R-410A high pressure refrigerant. Hazards exist that could result in personal injury or death. Installation, maintenance, and service should

only be performed by an HVAC technician qualied in R-410A refrigerant and

using proper tools and equipment. Due to much higher pressure of R-410A refrigerant, DO NOT USE service equipment or tools designed for R22 refrigerant.

IMPORTANT: Do not release refrigerant to the atmosphere! If required service procedures include the adding or removing of refrigerant, the service technician must comply with all federal, state and local laws. The procedures discussed

in this manual should only be performed by a qualied HVAC technician.

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 1

Table of Contents

1.0 General ................................................................2

2.0 Maintenance Requirements .......................... 3-5

2.1 Maintenance Schedule ........................................3

2.2 Control Locations .................................................4

2.3 MAPSIII D Cabinet Sizes .....................................5

3.0 Maintenance/Service Procedures .............. 5-21

3.1 Filters ..................................................................5

3.2 Drive Components ...............................................6

3.3 Condenser Fans ..................................................6

3.4 Coil Maintenance .................................................7

3.5 Check Refrigerant Pressure and

Temperatures (subcooling and superheat) .........9

3.6 Compressor Maintenance and Replacement ....10

3.7 Thermostatic Expansion Valves .........................18

3.8 Dampers and Damper Controls .........................19

3.9 Other Controls ...................................................19

1.0 General

This booklet includes operation, maintenance, and service information on the MAPS®III Cabinet D Size systems. Before beginning any procedure, carefully review the information, paying particular attention to the warnings. Handling of refrigerant should only

be performed by a certied HVAC technician with knowledge of the requirements of R-410A refrigerant and in compliance with all codes and requirements of authorities

having jurisdiction. The instructions in this manual apply to the following MAPS®III models.

4.0 Gas Heat Section Maintenance - Models

RDCB and RDDB ........................................ 21-33

4.1 Heat Exchanger, Burner, and Venter

Maintenance .....................................................21

4.2 Gas Heat Section Controls ................................26

4.3 Gas Train ...........................................................30

4.4 Other Gas Heat Section Controls ......................32

5.0 Electric Heat Section Maintenance -

Models RECB and REDB ........................... 33-34

6.0 Troubleshooting ......................................... 35-42

6.1 Troubleshooting - All Models..............................35

6.2 Troubleshooting the Heat Section .....................36

INDEX ......................................................................43

REFERENCES .......................................................44

NOTE: To conrm that this

booklet is applicable, see list of D Cabinet Sizes in Paragraph 2.3, page 5.

Denitions of Hazard

Intensity Levels used in this Manual

Model Description RCB

RDCB

RECB

RDB

RDDB

REDB

There are warning labels on the unit and throughout this manual. For your safety, comply with all warnings during installation, operation, and service of this system. See

denitions of Hazard Intensity Levels of warnings below.

Makeup Air Cooling Packaged System, 5200-13000 CFM

Makeup Air Cooling Packaged System, 5200-13000 CFM, with Gas Heat Section (500-1600 MBH)

Makeup Air Cooling Packaged System, 5200-13000 CFM, with Electric Heat Section (120 & 180 kw)

Makeup Air Cooling and Re-heat Pump Reheat Cycle Packaged System, 5200-13000 CFM

Makeup Air Cooling and Re-heat Pump Reheat Cycle Packaged System, 5200-13000 CFM, with a Gas Heat Section (500-1600 MBH)

Makeup Air Cooling and Re-heat Pump Reheat Cycle Packaged System, 5200-13000 CFM, with Electric Heat Section (120 & 180 kw)

HAZARD INTENSITY LEVELS

1. DANGER: Failure to comply will result in severe personal injury or death and/or property damage.

2. WARNING: Failure to comply could result in severe personal injury or death and/or property damage.

3. CAUTION: Failure to comply could result in minor personal injury and/or property damage.

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 2

2.0 Maintenance Requirements

This unit will operate with a minimum of maintenance. To ensure long life and satisfactory performance, a system that is operating under normal conditions should be inspected according to the Maintenance Schedule. If in an area where an unusual amount of dust or soot or other impurities are present in the air, more frequent inspection is recommended.

Refer to the illustration in FIGURE 1, page 4, and follow the instructions in the referenced paragraphs to maintain this equipment. Maintenance requirements and procedures apply to all Models unless noted.

NOTE: If replacement parts are required, use only factory-authorized parts.

For information, go to www.ReznorHVAC.com or call 800-695-1901

WARNING

Lock power OFF before performing all maintenance procedures (except where power is required such as checking refrigerant pressure and temperature). Lock disconnect switch in OFF position. If the system has a heat section, when you turn off the power supply, turn off the gas. See Hazard Levels, page 2.

2.1 Maintenance Schedule

Monthly

□ Inspect lters; clean or replace as needed. See Paragraph 3.1. □ Inspect the condensate drain; clean as needed. For information, see Form

I-MAPSIII&IV, Paragraph 6.2.

Semi-Annually

□ Inspect the unit blower plenum fan and belt. Check belt for tension, wear, and

alignment. Adjust or replace as needed. Clean dirt from blower and motor. See Paragraph 3.2.

Annually

NOTE: Redo the cooling startup procedures when the cooling season begins. Refer

to Startup instructions in the installation manual, Form I-MAPSIII&IV, Paragraph 10.0.

Beginning of the cooling season or more frequently in year-round cooling climate (applies to all Models):

□ Inspect the wiring for any damaged wire. Replace damaged wiring. □ Inspect the condensate drain pan. Clean the coil cabinet, the drain pan, and ll the

trap. □ Inspect/clean condenser fans. See Paragraph 3.3. □ Inspect/clean all coils. See Paragraph 3.4. □ Check compressor operation. See Paragraph 3.6. □ Check refrigerant pressure and temperatures (superheat and subcool). These

checks are done when the system is operating. See Paragraph 3.5.

Models RDCB & RDDB with a gas heat section (beginning of the heating season) - See Section 4.0.

□ Clean all dirt and grease from the combustion air openings and the venter

assembly. □ Check the heat exchanger, burner, and venter for scale, dust, or lint accumulation.

Clean as needed. □ Check the gas valves to ensure that gas ow is being shutoff completely.

Models RECB & REDB with an electric heat section (beginning of the heating season) - See Section 5.0.

□ Check the wiring connections. □ Check the heat section and electric elements for dust or lint accumulation.

Carefully clean as needed.

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 3

2.0 Maintenance Requirements (cont'd)

High Voltage Panel

Control

Transformer

Distribution

Block

Distribution Block

Grounding

Lug

Terminal Blocks

Phase Loss Monitor

Contactor (Condenser Fan B & C)

Contactor (Condenser Fan A & D)

Contactor (Reheat Compressor E)

Contactor (Compressor D)

Contactor (Compressor C)

Contactor (Compressor B)

Contactor (Compressor A)

Motor Starter

Rear View

Side View

Front

View

75VA transformers

Optional Dirty

Filter Switch

Digital

Controller

Display

Wire Harness

Assembly

Optional

Relays

and Bases

Low Voltage Panel

Control Compartment Access Door

Heater Controls Access Door

Filter Access

Coil Access

Fan and Motor

Access

Condenser Section

2.2 Control Locations

FIGURE 1 - Access Panels and High and Low Voltage Control Locations

Door Hinge

Locked Unlocked

The lter, coil, and fan/motor cabinet

doors can be opened from the left or right. On the side of the door to be opened, unlock the two hinges with an allen key. Pull out unlocked "fronts" of hinges to 90 degrees to expose handles needed to open the door. Re-lock hinges when door is closed.

High Voltage Panel (behind low voltage panel; post is removed for less restricted view)

Low Voltage Panel (hinged; swings out to access rear side and high voltage panel behind)

Gas Heat Section Control Panel

(See Para 4.2.1.)

NOTE: Electric heat Models RECB and REDB have additional electrical panels in

the heat section; see

Paragraph 5.0, page

33.

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 4

(2) P/N 104102,

16x16x1

(2) P/N 104102,

16x16x1

(2) P/N 104102,

16x16x1

(2) P/N 104102,

16x16x1

(2) P/N 104102,

16x16x1

(2) P/N 104102,

16x16x1

(2) P/N 101609,

16x25x1

(2) P/N 101609,

16x25x1

(2) P/N 101609,

16x25x1

1) Loosen wing nuts and slide clamp.

2) Remove filters.

3) Repeat for all filters.

4) Wash and dry filters.

5) Re-install filters in hood. Be sure wing nuts are tight and filters secure.

Filters in Hood - Cabinet D

2.3 MAPSIII D Cabinet Sizes

Model

RCB

360

480

600

720

Model

RDB

418

444

484

538

564

602

658

684

722

804

842

Cabinet

Size

Cabinet

Size

Model RDCB

360

480

600

720

Model RDDB

418

444

484

538

564

602

658

684

722

804

842

Gas Heat Section Size

-500 -600 -700 -800 -1000 -1200 -1400 -1600

D D D D D D D D

Gas Heat Section Size

-500 -600 -700 -800 -1000 -1200 -1400 -1600

D D D D D D D D

Electric Heat Section

RECB120 RECB180

D D

Electric Heat Section

REDB120 REDB180

D D

3.0 Maintenance/

Service Procedures

3.1 Filters

The lter section is equipped with 4 inches of pleated disposable or permanent aluminum lters. To remove lters, open the door and slide lters out.

If equipped with permanent aluminum lters, there are sixteen 2"x20"x24" lters. Remove the lters, wash, rinse, allow to dry, and slide them back in the cabinet. The P/N for replacement or extra lter is 223065; quantity is 16.

If equipped with pleated disposable lters, there are eight 4"x20"x24" lters, either MERV8 or MERV13.. Replace dirty lters. Exposure to humid makeup air can accelerate lter degradation. Systems with disposable lters require more frequent lter inspection. The P/N for one replacement or extra MERV8 lter is 222480; quantity required is 8. The P/N for one replacement or extra MERV13 lter is 260828; quantity required is 8.

Dirty Filter Switch - If equipped with a dirty lter switch, check the condition of the

sensing tubes to be sure that they are not blocked. Check the wiring connections. To

set a new switch, see Installation Form I-MAPSIII&IV, Paragraph 8.1, Replacement

switch is P/N 105507.

Permanent Filters in the Outside Air Hood

If equipped with an outside air hood, there are 1" permanent, aluminum lters at the entrance of the hood. The lters act as a moisture eliminator and bird screen.

When inspecting the inlet air lters, inspect the outside air hood lters. If cleaning is needed, remove the lters, clean, rinse, dry and re-install. NOTE: If it is more conve- nient to keep an extra clean set of lters, lter sizes and part numbers are shown in

the illustration.

FIGURE 2 - Removing Filters from Outside Air Hood

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 5

3.0 Maintenance/

2-1/2” (63.5mm)

Fan and Motor Assembly showing Fan Blade Position

Cross-section of Installed Fan and Motor Assembly showing Cabinet Top

1.76” (44.7mm)

Top of Fan Blade

to Top of the

Cabinet Top Panel

Service Procedures (cont'd)

3.2 Drive Components

Bearings - Bearings with a grease tting should be lubricated twice a year with a high

temperature, moisture-resistant grease. (Type NLGI-1 or -2 standard grease is recommended.) Be sure to clean the grease tting before adding grease. Add grease with a

handgun until a slight bead of grease forms at the seal. Be careful not to unseat the seal by over lubricating. NOTE: If unusual environmental conditions exist (tempera-

tures below 32°F or above 200°F; moisture; or contaminants), more frequent lubrication is required.

CAUTION: If the blower is unused for more than three months,

bearings with a grease tting should be purged with new grease

prior to start-up.

Setscrews - Check all of the setscrews (bearing/blower hubs and pulleys). Torque pul-

ley setscrews a minimum of 110 in-lb to 130 in-lb maximum.

A bearing hub setscrew for a 1-3/8" to 1-3/4" shaft requires a 5/16" socket and a tightening torque of 165 in-lbs.

Belts - Check belt for proper tension and wear. Adjust belt tension as needed. Replace worn belts.

Blower systems are equipped with either Power Twist Plus

belt. The linked belts are designed in sections allowing for easy sizing and adjustment. The belt is sized at the factory for the proper tension. If the belt needs adjustment, the recommended method of shortening the belt length is to count the number of links and remove one link for every 24. (A link is made up of two joining sections of belt. For easier removal of links, turn the belt inside out. But be sure to turn it back before installing.)

If equipped with a solid belt, adjust the belt tension by turning the adjusting screw on

the motor base until the belt can be depressed 1/2" (13mm) on each side. After correct tension is achieved, re-tighten the locknut on the adjustment screw.

Proper belt tension is important to the long life of the belt and motor. Be sure belts are aligned in the pulleys. If a belt is removed or replaced, be sure to align

directional arrows on the belt to the proper drive rotation.

Motor and Blower - Inspect the motor mounts periodically. Remove dust and dirt accumulation from the motor and wheel.

The blower has cast iron, pillowblock, sealed bearings. Under most operating conditions, re-lubrication is unnecessary. If lubrication is required, use a lubricant compatible to Shell Alvania #2 (lithium base - Grade 2). Operating temperature range is -30 to 230°F.

"D" size cabinets have plenum fan blowers which have an extension to the grease tting on the side of the fan assembly.

If any drive parts need to be replaced, use only factory-authorized replacements designed for the application.

linked blower belt or a solid

3.3 Condenser Fans

FIGURE 3 - Condenser Fan Assembly Dimensions and Rotation

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 6

Depending on the size, there are two, three, or four fans in the condenser section. If parts need to be replaced, use only factory authorized replacement parts.

See FIGURE 3 for assembled dimensions and proper fan rotation direction.

Fan rotation is clockwise

3.4 Coil

Condenser Coils by Circuit

5 ton MC Coil

10 ton MC Coil

Inlet 1 Ø 0.879

Inlet 2 Ø 0.879

Outlet Ø 0.879

Discharge

Line Ø 0.500

Discharge

Line Ø 0.875

Discharge

Line Ø 0.875

Liquid Line Ø 0.875 Liquid Line Ø 0.875

Liquid Line Ø 0.500

Filter Drier

(See compressor locations on page 12.)

Suction Line Ø 1.375

Suction Line Ø 0.875

Suction Line Ø 1.375

RCB/RDCB/RECB 360 and RDB/RDDB/REDB 418, 444, and 484

(To TXV valves and

Distributors on

Evaporator Coils)

15 ton MC Coil

Inlet

Ø 0.506

Outlet Ø 0.506

Inlet

Ø 0.879

Outlet Ø 0.879

Outlet Ø1.380

Outlet Ø 0.879

Maintenance

Inspect all cooling system coils at the beginning of the cooling season or more often if

needed. Follow the cleaning instructions below. If additional cleaning is required or if a

coil must be removed for any reason, consult the factory. Be prepared to provide rating plate and installation information.

Condenser Coil Access - The bank of condensing coils is located on top of the unit.

Condenser Coil Cleaning Instructions:

1) Verify that the electrical power has been turned off and the disconnect switch

locked.

2) Use a soft brush to remove any dirt and debris from the coils.

3) Spray with cold or warm (not hot) water and a cleaning solution (non-acid based coil cleaner is recommended). Due to possible damage to the coil, do not use high pressure spray.

4) When clean, rinse with cool, clean water.

Evaporator Coil Access - The evaporative coils can be accessed by opening the coil cabinet door.

Inspect coils for debris, dirt, grease, lint, pollen, mold, or any element which would

obstruct heat transfer or airow. Inspect coils and tubing for physical damage. Inspect

feeders, piping connections, coil headers, and return bends for signs of fatigue, rubbing, and physical damage.

Clean the coils annually, or more often if needed. Use the proper tools and follow the instructions carefully to avoid damaging the coil. Use of a non-acid based coil cleaner is recommended. Due to possible damage to the coil, high pressure spray is not recommended.

FIGURE 4 - Coil Circuits (Views are from the control side of the system.)

Evaporator Coil Cleaning Instructions:

1) Verify that the electrical power has been turned off and the disconnect switch

locked.

2) Open the access panels.

3) Use a soft brush to remove any dirt and debris from both sides of a coil.

4) Spray with cold or warm (not hot) water and a cleaning solution (non-acid based coil cleaner is recommended). Due to possible damage to the coil, high pressure spray is not recommended. First spray the leaving airow side, then the inlet

airow side.

As much as possible, spray the solution perpendicular to the face of the coil. Follow the instructions on the cleaning solution. When cleaning process is

complete, rinse both sides with cool, clean water.

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 7

3.0 Maintenance/Service Procedures (cont'd)

Condenser Coils by Circuit

ADA

10 ton MC Coil

5 ton MC Coil

10 ton MC Coil

15 ton MC Coil

Inlet 1 Ø 0.881

Inlet 1 Ø 0.879

Inlet Ø 0.881

Inlet 2 Ø 0.881

Inlet 2 Ø 0.879

Inlet 1 Ø 0.881

Inlet 2 Ø 0.881

Outlet Ø 0.881

Outlet Ø 0.879

Outlet Ø 0.881

Discharge

Line Ø 0.875

Discharge

Line Ø 0.875

Discharge

Line Ø 0.875

Discharge

Line Ø 0.500

Discharge

Line Ø 0.875

Discharge

Line Ø 0.875

Liquid Line Ø 0.875

Liquid Line Ø 0.875 Liquid Line Ø 0.875

Liquid Line Ø 0.500

Liquid Line Ø 0.875

Filter Drier

Discharge

Line Ø 0.875

Discharge

Line Ø 0.875

Discharge

Line Ø 0.875

Discharge

Line Ø 0.875

Liquid Line Ø 0.875

Filter Drier

Outlet Ø 0.881

Inlet Ø 0.881

Inlet 2 Ø 0.881

Inlet 1 Ø 0.881

Inlet 2 Ø 0.881

Inlet 1 Ø 0.881

Inlet Ø 0.881

10 ton MC Coil

15 ton MC Coil

(See compressor locations on page 12.)

Evaporator Coils by Circuit (interlaced)

All three outlets Ø 1.380

All four outlets Ø 1.380

Suction Line Ø 1.375

Suction Line Ø 0.875

Suction Line Ø 1.375

RCB/RDCB/RECB 480 and RDB/RDDB/REDB 538, 564, and 602

RCB/RDCB/RECB 360 and RDB/RDDB/REDB 418, 444, and 484

RCB/RDCB/RECB 600 and RDB/RDDB/REDB 658, 684, and 722

Suction Line Ø 1.375

(To TXV valves and

Distributors on

Evaporator Coils)

(To TXV valves and

Distributors on

Evaporator Coils)

(To TXV valves and Distributors

on Evaporator Coils)

Condenser Coils by Circuit

15 ton MC Coil

Inlet

Ø 0.506

Outlet Ø 0.506

Inlet

Ø 0.879

Outlet Ø 0.879

Outlet Ø1.380

Outlet Ø 0.879

3.4 Coil Maintenance (cont'd)

FIGURE 4 (cont'd) - Coil Circuits (Views are from the control side of the system.)

RCB/RDCB/RECB 720 and RDB/RDDB/REDB 722, 804, and 842

Evaporator Coils by Circuit (interlaced)

All four

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 8

outlets Ø 1.380

Suction Line Ø 1.375

Filter Drier

on Evaporator Coils)

(To TXV valves and Distributors

15 ton MC Coil

Inlet 2 Ø 0.881

Inlet 1 Ø 0.881

Liquid Line Ø 0.875

(See compressor locations on page 12.)

Condenser Coils by Circuit

Inlet 1

Ø 0.881

15 ton

Inlet 2

Outlet Ø 0.881

Discharge

Line Ø 0.875

Liquid Line Ø 0.875

MC Coil

Outlet Ø 0.881

Ø 0.881

Discharge

Line Ø 0.875

Inlet 1 Ø 0.881

15 ton

MC Coil

Inlet 2 Ø 0.881

Discharge

Outlet Ø 0.881

Line Ø 0.875

15 ton MC Coil

Outlet Ø 0.881

Inlet 2 Ø 0.881

Inlet 1 Ø 0.881

Discharge

Line Ø 0.875

3.5 Check Refrigerant Pressure and Temperatures (subcooling and superheat)

DANGER

The refrigeration circuits are high pressure systems. Hazards exist that could result in personal injury or death. Removal, installation, and service of this scroll compressor must be

performed by a technician qualied in R-410A refrigerant.

DO NOT USE tools or service equipment designed for R22 refrigerant. See Hazard Levels, page 2.

Check SUBCOOLING

Measure and record temperature and pressure of the liquid line at the condenser coil

outlet.

STEP 1) Record Measurements: Temperature = ________°F (°C) and

Pressure = ________ psig

STEP 2) From Temperature/Pressure Conversion Chart (page 10), convert

Measured Pressure (STEP 1) to ________°F (°C)

STEP 3) Subtract Measured Temperature (STEP 1) from Temperature from

Conversion Chart (STEP 2): ________°F (°C) - ________°F (°C) =

________°F (°C) degrees of Subcooling

Recommended subcooling with outdoor temperature range of 70

to 95°F (21 to 35°C) is 10 to 12 degrees F (5.6 to 6.7 degrees C).

Too much subcooling indicates a refrigerant overcharge. To reduce the subcooling,

remove excess refrigerant. Too little subcooling indicates a refrigerant undercharge. To increase subcooling, slowly add R-410A refrigerant.

WARNING

Do not release refrigerant to the atmosphere. When adding or removing

refrigerant, the qualied technician must comply with all national, state/

province, and local laws.

Determine SUPERHEAT

Measure and record temperature (insulate probe from surrounding air temperature) and pressure in the suction line at the compressor inlet.

STEP 1) Record Measurements: Temperature = _______°F (°C) and Pressure

= _______ psig

STEP 2) From Temperature/Pressure Conversion Chart (below), convert

Measured Pressure (STEP 1) to ________°F (°C)

STEP 3) Subtract Measured Temperature (STEP 1) from Temperature from

Conversion Table (STEP 2): _______°F (°C) - ________°F (°C) =

________°F (°C) degrees of Superheat

Recommended superheat at is 8 to 12 degrees F (4.5 to 6.7 degrees C).

Typically, too much superheat indicates that the evaporator coil is undercharged. Too little superheat typically indicates that the evaporator coil is overcharged and

may potentially ood liquid refrigerant to the compressor. To reduce the superheat,

adjust the thermal expansion valve by turning the adjusting stem counterclockwise. To increase the superheat, adjust the thermal expansion valve by turning the adjusting stem clockwise.

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 9

3.0 Maintenance/Service Procedures (cont'd)

3.5 Check Refrigerant Pressure and Temperatures (subcooling and superheat) (cont'd)

Temperature/Pressure Conversion Chart

R-410A Refrigerant R-410A Refrigerant R-410A Refrigerant R-410A Refrigerant

Pressure Temperature Pressure Temperature Pressure Temperature Pressure Temperature

PSI °F °C PSI °F °C PSI °F °C PSI °F °C

1.8 -55 -48.3 56.4 6 -14.4 93.5 28 -2.2 143.3 50 10.0

4.3 -50 -45.6 57.9 7 -13.9 95.5 29 -1.7 156.6 55 12.8

7.0 -45 -42.8 59.3 8 -13.3 97.5 30 -1.1 170.7 60 15.6

10.1 -40 -40.0 60.8 9 -12.8 99.5 31 -0.6 185.7 65 18.3

13.5 -35 -37.2 62.3 10 -12.2 101.6 32 0.0 201.5 70 21.1

17.2 -30 -34.4 63.9 11 -11.7 103.6 33 0.6 218.2 75 23.9

21.4 -25 -31.7 65.4 12 -11.1 105.7 34 1.1 235.9 80 26.7

25.9 -20 -28.9 67.0 13 -10.6 107.9 35 1.7 254.6 85 29.4

27.8 -18 -27.8 68.6 14 -10.0 110.0 36 2.2 274.3 90 32.2

29.7 -16 -26.7 70.2 15 -9.4 112.2 37 2.8 295.0 95 35.0

31.8 -14 -25.6 71.9 16 -8.9 114.4 38 3.3 316.9 100 37.8

33.9 -12 -24.4 73.5 17 -8.3 116.7 39 3.9 339.9 105 40.6

36.1 -10 -23.3 75.2 18 -7.8 118.9 40 4.4 364.1 110 43.3

38.4 -8 -22.2 77.0 19 -7.2 121.2 41 5.0 389.6 11 5 46.1

40.7 -6 -21.1 78.7 20 -6.7 123.6 42 5.6 416.4 120 48.9

43.1 -4 -20.0 80.5 21 -6.1 125.9 43 6.1 444.5 125 51.7

45.6 -2 -18.9 82.3 22 -5.6 128.3 44 6.7 474.0 130 54.4

48.2 0 -17.8 84.1 23 -5.0 130.7 45 7.2 505.0 135 57.2

49.5 1 -17.2 85.9 24 -4.4 133.2 46 7.8 537.6 140 60.0

50.9 2 -16.7 87.8 25 -3.9 135.6 47 8.3 571.7 145 62.8

52.2 3 -16.1 89.7 26 -3.3 138.2 48 8.9 607.6 150 65.6

53.6 4 -15.6 91.6 27 -2.8 140.7 49 9.4 645.2 155 68.3

55.0 5 -15.0

3.6 Compressor

Maintenance and Replacement

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 10

The refrigeration circuits are high pressure systems. Hazards exist that could result in personal injury or death. It is therefore required that the removal and installation of this

scroll compressor be performed by a technician qualied in

R-410A refrigerant. See Hazard Levels, page 2.

Never use oxygen to pressurize a refrigeration system. Oxygen can explode on contact with oil and could result in personal injury or death. When using high pressure gas such as nitrogen for this purpose, ALWAYS USE A PRESSURE REGULATOR that can control the pressure down to 1 or 2 psig. Failure to use a regulator will result in extremely high pressure which could exceed the burst pressure of the compressor or other system components and result in personal injury or death. See Hazard Levels, page 2.

DANGER

WARNINGS

For your safety, wear eye protection, gloves, and protective clothing

when handling refrigerant and oil and when brazing. Have a re

extinguisher nearby. See Hazard Levels, page 2.

Compressor Handling

Do not lift compressor by copper tubing. To prevent internal damage, compressors

must ALWAYS be held upright.

The following instructions include major points of consideration that will ensure proper installation and protect you from potential personal injury. Please use the following 13 steps as a checklist, taking each item in order before proceeding to the next. If more

information is required, contact the Reznor Service Department for Reznor® products.

WARNING

To avoid electrical shock, power to the com-pressor(s) MUST REMAIN OFF during performance of Steps 1 through 9 below. LOCK DISCONNECT SWITCH OFF (open).

Step 1. Verify Proper Application

Verify that the replacement compressor is identical to the model being replaced.

All system components are matched to the compressor. Replacing a compressor

with a model other than the one specied for replacement will void the product

warranty. See part numbers for R-410A compressors on page 13.

Step 2. Determine Cause of Initial Failure and Remove the

Compressor

In order to prevent a second failure, the cause of the original failure must be

determined. Identify the cause and make the necessary repairs.

CAUTION: DO NOT LIFT compressor by copper tubing; damage will occur. Compressor must remain upright.

WARNING

Wear eye protection and gloves when handling refrigerant or oil and when brazing.

a) BEFORE REMOVING THE FAULTY COMPRESSOR, remove refrigerant charge

using proper recovery procedures. Call 1-800-441-9450 for the name of the nearest Dupont authorized distributor or 1-800-ASK-KLEA (IGI) for information on their refrigerant reclaim programs.

b) Disconnect wires. All compressor wiring is connected using a black molded

plastic plug. Remove the plug from the compressor.

c) Open access ports so that pressure does not build up in the system. Before

unbrazing stubs from the compressor, cut suction and discharge tubing with a tubing cutter.

WARNING

Have a re extinguisher near. The compressor contains oil. There is a risk of re when unbrazing stubs.

Use a high temperature torch to disconnect the suction line and the discharge line from the compressor.

d) Remove the mounting bolts and the compressor. Save the mounting hardware

to attach the grommets and sleeves shipped with the replacement compressor.

e) To test for acid and to assure excess oil does not remain in the circuit, remove

oil from the failed compressor. Measure the amount of oil.

CAUTION: In addition to the required eye protection and gloves, care should be taken in handling POE oil because it may cause damage to

certain plastics and roong materials. See Hazard Levels, page 2.

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 11

3.0 Maintenance/

Reheat compressor in Models RDB and RDDB

DH or E

Condenser

Bank B & C

Condenser

Bank A & D

Service Procedures (cont'd)

3.6 Compressor Maintenance (cont'd)

Step 2. Determine Cause of Initial Failure (cont'd)

Compressor Oil Charge (POE Oil)

Compressor

Model

ZP57K3E 1538 52

ZP83KCE 1656 56

ZP120KCE 3135 106

ZP182KCE 3135 106

cc oz

Important NOTES: These R-410A compressors use a polyolester (POE) lubricant. Types of recommended POE oil are Copeland Ultra 22 CC, Copeland Ultra

32 CC, Copeland Ultra 32-3MAF, Mobil EAL™, Arctic 22 CC, Uniqema Emkarate RL32CF, or Uniqema RL32-3MAF.

POE oil absorbs moisture much quicker and to a greater degree than standard mineral oil. The compressor must not be left open longer than 15 minutes during replacement. During installation the system must be swept with an inert gas such as dry nitrogen to keep moisture from entering the compressor and prevent the formation of oxides.

If the oil taken from the compressor and measured is found to be signicantly

lower than listed in the table above, clean the excess oil through use of suction

and liquid line lter driers. Beginning in Step 4, follow the same procedure as for burnout cleanup.

Use an acid test kit to check the oil for acid. If acid is found, beginning in

Step 4, follow procedures indicated for burnout cleanup.

Dispose of oil and compressor using an approved environmentally safe

disposal method.

□ Step 3. Mount the Replacement Compressor

Do not remove the dust cover or rubber shipping plugs until all other system

connections are complete (i.e. new liquid line lter drier(s) installed and all tubing

changes made - see Steps 4 and 5). The amount of time the compressor is open to the atmosphere must be kept to a minimum.

Use the new mounting grommets and sleeves that are shipped with the

compressor to mount it. The sleeves will prevent over compression of the grommets. Re-use the mounting bolts from the compressor that was removed. The mounting bolts will bottom out when tight.

FIGURE 5 - Identication of Compressors by Location

Compressor

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 12

Compressor Staging for Cooling (applies to Models RCB, RDB, RDCB, RDDB RECB, REDB)

MAPSIII

Cabinet D

360 418 444 484

480 538 564 602

600 658 684 722

720 804 842

DH or E (RDB/RDDB/REDB 418) 5 DH or E (RDB/RDDB/REDB 444) 7 DH or E (RDB/RDDB/REDB 484) 10

DH or E (RDB/RDDB/REDB 538) 5 DH or E (RDB/RDDB/REDB 564) 7 DH or E (RDB/RDDB/REDB 602) 10

DH or E (RDB/RDDB/REDB 658) 5 DH or E (RDB/RDDB/REDB 684) 7 DH or E (RDB/RDDB/REDB 722) 10

DH or E (RDB/RDDB/REDB 804) 7 DH or E (RDB/RDDB/REDB 842) 10

Compressor Cooling Staging

Circuit Tonnage 1 2 3 4 5 6 7 8

A 10 C 5 D 15

A 10 C 15 D 15

A 10 B 10 C 15 D 15

A 15 B 15 C 15 D 15

C A A+C D C+D A+C+D

A D A+D C+D A+C+D

B D A+B A+D C+D A+B+D B+C+D A+B+C+D

B B+C B+C+D A+B+C+D

Compressor Model and P/N by Tonnage and Voltage

Compressor Model

ZP57K3E 5 216686 216686 216687 216688

ZP83KCE 7 216689 216689 216690 216691

ZP120KCE 10 216695 216695 216696 216697

ZP182KCE

Wiring Harness

Crankcase Heater P/N 216402 P/N 216404 P/N 216405

ARI Tonnage

15 216454 216454 216455 216456

One each for each compressor

208V 230V 460V 575V

P/N 223028 P/N 223029 P/N 223030

Compressor P/N

□ Step 4. Install New Filter Driers (Select procedure that applies.)

IF the oil measured in Step 2 was not signicantly less than the amount shown

in the table on page 12 or the test for acid in Step 2 did NOT indicate burnout ,

install a new R-410A refrigerant liquid line lter drier. The lter drier must be rated

for no less than 600 psig and be the proper size for the circuit. Because R-410A

refrigerant requires POE oil which absorbs moisture quickly, it is important to change the lter drier any time the circuit is opened.

It is recommended to use a tubing cutter when cutting out a lter drier as the

desiccant absorbs and holds moisture better when it is cool. Heat from a torch may

cause moisture to leave the lter and be absorbed in the oil. Be careful to keep dirt, lings, and other contaminants out of the system.

Continue to Step 5. IF the oil measured in Step 2 was signicantly less than shown in the table on

page 12 or the test for acid in Step 2 did indicate compressor burnout, do the following:

a) Install a liquid line lter drier. If there is acid, install an acid removing lter drier.

Size the acid-removing lter drier at least one capacity size larger than normally required for the circuit.

b) Install a temporary lter drier in the suction line. When there is acid, a 100%

activated alumina suction lter drier is recommended. The suction line drier should be sized properly for the circuit and have a service access tting to

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 13

3.0 Maintenance/ Service Procedures (cont'd)

3.6 Compressor

Maintenance (cont'd)

□ Step 4. Install New Filter Driers (cont'd)

monitor pressure drop across the drier. (NOTE: Suction line lter drier must be removed after 72 hours of operation.)

Step 12 includes the remaining procedures required for cleanup of a burnout. Continue to Step 5.

□ Step 5. Braze on Suction and Discharge Lines

CAUTION; Do not leave system open to the atmosphere any

longer than minimum required for installation. POE oil in the compressors is extremely susceptible to moisture absorption. Always keep ends of tubing sealed during installation. See Hazard Levels, page 2.

Brazing materials must be able to withstand the high pressure of R-410A refrigerant. A high temperature, silver phosphate type brazing with 5% or greater alloy is recommended.

To prevent oxidation, purge tubing with 2-3 psig of regulated dry nitrogen while it is being brazed. Open the service valve as needed to release the nitrogen. Do not allow moisture to enter the system.

The installer is responsible for brazing and for complying with appropriate standard refrigerant piping procedures.

CAUTION: All brazing should be done using a 2 to 3 psig dry

nitrogen purge owing through the pipe being brazed. See Hazard

Levels, pg 2.

CAUTION: When brazing, protect all painted surfaces and

components from excessive heat. Wet wrap all valves but do not allow moisture to enter the tubing. See Hazard Levels, page 2.

□ Step 6. Check System for Leaks

After installation is complete, pressurize the circuit to approximately 75 psig using

nitrogen and a few ounces of refrigerant. Check for leaks using soap bubbles or other leak-detecting methods.

□ Step 7. Evacuate the Circuit

Evacuate one circuit at a time. Use a vacuum pump and micron gauge. Each

circuit must be evacuated to hold a 500 micron vacuum. Vacuum must be pulled on both the discharge (high) and suction (low) side. Do the suction side rst; and

the compressor discharge side second. To establish that a circuit is leak-free and moisture-free, a standing vacuum test is recommended. Close off the valve to the vacuum pump and observe the micron gauge. If the vacuum gauge does not rise above 500 microns in one minute, the evacuation should be complete. If the vacuum gauge does rise above 500 microns in one minute, evacuation is incomplete or the circuit has a leak. Repeat as needed until evacuation is complete. The evacuation process must be done on each circuit.

NOTE: Evacuation will not remove moisture from POE oil. Moisture must be

prevented from getting in the oil.

Continue and/or repeat Steps 6 and 7 until evacuation is complete.

CAUTION: Do not use the replacement compressor as an

evacuation assist and never apply voltage to a compressor while it is in a vacuum. See Hazard Levels, page 2.

Moisture and air are harmful to the system because they increase the condensing temperature, raise the discharge gas temperature, cause formation of acids, and cause oil breakdown.

Form O-MAPSIII Cabinet D, P/N 222918R9, Page 14

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