Russell 10H22, DLD10M44 Installation Manual

Safety Information and Guidelines.....................................................…….....

Receiving and Handling ................................................................………......

Locating and Mounting Condensing Units ....................................………......

Locating and Mounting Evaporators........................................……......…......

Piping .............................................................................................……......

Leak Testing ................................................................................…...……....

Suction Line Design ...............................................................…….…...........

Equivalent Feet of Tube ........................................................…….........….....

Weight of Refrigerant in Copper Tube.................................…….....….…........

Recommended Line Sizes ..........................................................…….….....

Field Wiring.....................................................................................…….......

Field Wiring Diagrams ................................................................……..….....

Evacuation .................................................................................…….….......

Charging and Start-Up .................................................................…….….....

Charging Flooded Condenser Systems .................….......................………...

Pressure Control Settings ..............................................................………...

Indoor Condensing Unit Ventilation ................................................………....

Defrosting Evaporators ...................................................................…...…...

Product Loading and Air Circulation .............................................…….….....

Operating Pressures and Temperatures .......................................……...…...

System Start-Up Check List ...........................................................…...…....

System Service Check List ...........................................................………....

Trouble-Shooting Systems ............................................................…….......

System Maintenance .....................................................................…….......

Ordering Replacement Parts .......................................................………......

SYSTEMS

IOM 550.1

JULY, 2003

THE GUIDE FOR

INSTALLING, STARTING - UP,

OPERATING and MAINTAINING

RUSSELL REFRIGERATION SYSTEMS

TABLE OF CONTENTS

2
2

3
4 - 5
6 - 7

7

8

9

9

10 - 13

14

14 - 16

17
18
19
20
20

21 - 22

22
23
24
25

26 - 27

28
28

221 S. Berry St. • P.O. Box 1030 • Brea, CA 92822-1030 • Tel: [phone] • FAX [phone]

SAFETY INFORMATION

!

LOCK

disconnects in the

OFF

position to prevent accidental turning on and injury.

!

Check all items against the bill of lading to make sure all crates and cartons have been received.

If there are any shortages or damage, report it immediately to the carrier and file a freight claim.

Damaged equipment is the delivering carrier's responsibility. Take care not to damage equipment

when uncrating. Check for concealed damage. Do not return damaged equipment to the factory

without prior approval. A Return Material Authorization (RMA) must be obtained in advance.

Check the unit specplate. Verify that the specplate voltage agrees with the available power supply.

Large condensing units, remote condensers, and evaporators should be left on their shipping skid

until at their final location. Do not use the shipping skid as a permanent base.

Good rigging and handling practice must be used to protect units from damage. Having proper

handling equipment at the jobsite is most important and should be planned in advance. Always use

spreader bars when lifting with cable, chain, or slings. Do not hoist a crate from it's upper members.

If rigging is required, support the crate from the skid. All crates are blocked up for forklift handling.

Do not forklift against sheetmetal panels or coils. Always lift against a structural part of the skid or

unit at the center of gravity. Secure units to a forklift to prevent slipping off.

Large condensing units have compressors mounted near one end that offsets the center of gravity.

Find the center of gravity near the compressor end to prevent tipping when lifting. Smaller, lighter

units may be carefully manhandled for short distances. Observe the units for additional lifting and

rigging decals.

READ THESE INSTRUCTIONS ALL THE WAY THROUGH BEFORE STARTING WORK

Make sure all power sources are disconnected before doing any service work.

Commercial refrigeration equipment should be installed, started-up, maintained, and
serviced by trained and certified personnel having experience with this type of equipment.

All field wiring must conform to the requirements of the equipment, applicable local
codes and the National Electrical Code. Always use correct size copper conductors.

Sheet metal and coil surface have sharp edges that are a potential injury hazard.
Handle carefully, using gloves and other protective safety wear to prevent injury.

COMPLY WITH SAFETY AND CAUTION LABELS ON THE EQUIPMENT

THINK SAFETY! WORK SAFELY

RECEIVING YOUR EQUIPMENT

INSPECTION

« « « « Items returned without an RMA label will be refused. « «« «

RIGGING and HANDLING

2

3

LOCATING AND MOUNTING CONDENSING UNITS

Condensing units must be located where there is an
unrestricted supply of clean, fresh air. Areas with
corrosive vapors or materials should be avoided, as
should areas with polluted air. Do not locate units
where air discharge from one will enter into the air
intake of others. Avoid locating units in restricted
spaces where heat will build up and can enter the
condenser. Condensing units with horizontal air
flow should be positioned so that the direction of air
flow through the condenser is the same as the
prevailing wind. Make sure there is room around
the unit for regular inspection and service. Mount
all condensing units level.

Roof mounted condensing units must have
adequate support for their operating weight plus a
safety factor. They should be mounted above
supporting walls, over hallways, storage areas, or
auxillary areas that are not sensitive to noise or
vibration. Mount them where sound levels are not
an important factor.

Pad mounted condensing units should be mounted
on smooth and level pads a minimum of 4 inches
above ground level. They should be mounted
away from windows, doors, and other areas
sensitive to noise. The area surrounding a pad
mounted unit preferably will be concrete, asphalt, or
other smooth, hard, clean level surface. This
will keep the condenser coil clean from grass, dirt,
and weed clippings. A security fence also helps to
keep leaves and other debris out of the coil.
Protecting the condensing unit also protects the
product stored in the cooler or freezer!

Condensing units, piping and disconnects should
not be accessible to unauthorized persons. To
protect the equipment from tampering and
vandalism and protect people from accidental

injury, a security fence with locked access is highly
recommended. Condensing units accessible to the
general public often receive damage to the coil,
piping, fans, or other components. Protect your
equipment, your products in storage, and protect
yourself from liability. Prevent accidents and loss.

Condensing units must be mounted to pads or
structural rails with adequate size bolts to prevent
the unit from shifting or changing postion.
Mounting holes are provided for proper size
fasteners. Iso-pads are recommended to absorb
vibration and reduce noise. Seismic isolators may
be required in some localities. Follow the isolator
manufacturers recommendation when selecting and
applying isolators. Mount units level.

Condensing units with spring mounted compressors
are shipped with blocks or retainers under the
compressor feet to keep it from shaking during
shipment. On Copeland H and K model
compressors, remove the blocks and loosen the
mounting nut to have 1/16 inch between the nut and
rubber spacer. On 3 HP and larger models,
mounting nuts must be removed to insert the
rubber spacer. Remove the blocks, insert the
rubber spacer over the mounting stud, replace the
nuts and tighten to 1/16 inch from the spacer. Do
not tighten mounting nuts tight against the rubber
spacer or foot. Units with iso-pad mounted
compressors are shipped with the mounting nuts
tight and they should be checked to be sure they
have not loosened in shipment.

Observe minimum clearance recommendations
below. Do not locate any unit to be bordered by tall
walls or obstructions on three or more sides, even
when the clearance are observed. The minimum
space between units is 2x dimensions shown.

Table 1

CONDENSING MINIMUM

UNIT DIMENSION (Inches)

DESCRIPTI ON A B C

MiniCon 1/2 thru 2 HP 60 24 36

MiniCon 3 thru 6 HP 72 24 36

D Series 3 thru 22 HP 72 30 48

V Series 20 thru 80 HP 48 48 48

B

CONDENSING UNIT

DISCHARGE AIR INTAKE AIR

A C

B

Drawing 1

12"

15"

18"

24"

30"

36"

42"

48"

*

H

LOCATING WALK-IN EVAPORATORS

Table 2

EVAPORATOR

HEIGHT (Key Dim.)

H

Critical Minimum Dimension

Front wall

Door

MINIMUM DIMENSION FOR GOOD AIR CIRCULATION

AND EVAPORATOR PERFORMANCE

Unit to

Back Wall *

1 x H

Unit to

Side Wall

1 x H

Unit

to Unit

2 x H

12" 12" 24" 60"
15" 15" 30" 75"
18" 18" 36" 90"
24" 24" 48" 120"
30" 30" 60" 150"
36" 36" 72" 180"
42" 42" 84" 210"
48" 48" 96" 240"

H = Height of Evaporator ‡ Minimum walk-in height of 7'-0"

Obstruction

Free
Area

Air

5 x H Min.

Product Storage Area

Unit to

Front Wall

5 x H

Air Product

Unit

to Floor

3 x H

60" ‡
60" ‡
60" ‡
72"

90"
108"
126"
144"

Evap.

12"

3 x H

* Refer to Table 2 for dimension H Floor

SIDE VIEW

Drawings are not to scale
No doors at side or back of evaporators. Back wall

H

H 2 x H H

Side Evaporator
wall

Air Air

Evaporator

5 x H Side

Alternate wall
Door location

* Refer to Table 2 for dimension H Door Front wall

TOP VIEW

4

Locate evaporators for the air pattern to cover all of the piping, and personnel. Heavy zinc plated or stainless

LOCATING AND MOUNTING WALK-IN EVAPORATORS

See Table 3

See Table 3

room. Do not restrict the inlet or outlet air stream. steel bolts should be used to mount evaporators. We
Avoid placing evaporators above or close to doors. recommend a minimum 5/16" diameter for All-Temp,
Direct the air stream toward the door when possible Flow-Temp and Ceiling-Temp units. A minimum 3/8" diameter
or arrange to blow down an aisle. Allow sufficient should be used with Inter-Temp and Ultra-Temp units.
clearance for air circulation and servicing the unit. Use flat washers next to hanger bars and tighten all fasteners
The ceiling structure must have adequate strength to
support all mechanical equipment, components,

Drawing 4 Drawing 5

Air

condensate draining. All drain lines must be trapped.

securely. Hang all unit coolers level to insure positive

Air

2 x H* 2 x H*

EVAP.

Air

EVAP.

Air

*Refer to Table 2 for dimension H

TOP VIEW - Large coolers or freezers where one wall will not accommodate all evaporators or desired air throw is excessive.

Drawing 6 Drawing 7

Air

A C

EVAP. B EVAP.

A A

C

EVAP.

Air Air

Air Air D

C

Air

TOP VIEW - Single Centermount Unit

TOP VIEW - Multiple Centermount Units

RECOMMENDED SPACING FOR CENTERMOUNT EVAPORATORS

Table 3

A B C

Min. Min. Max. Max. Min. Max.

Dimensions are in feet. One foot minimum between bottom of unit and top of product.

Max. Min.

1' 2' 16' 12' 8' 24'

8' 3'

D

5

PIPING

Condensing Unit and Evaporator coils are thoroughly
cleaned and dehydrated at the factory. Care must be
taken when field piping to prevent foreign materials
and moisture from entering the system. Do not leave
units or piping open to the atmosphere any longer
than necessary. Use ACR grade Copper tube,
keeping it dry, clean, and capped. If type “L” tube is
used, it should be thoroughly cleaned internally.
When brazing, always pass dry nitrogen through the
tubing to prevent oxide and scale from forming. A
suitable silver alloy solder should be used on suction
and liquid lines. Use only Wrot Copper fittings. Long
radius elbows should be used. Install all piping and
components in accordance with local and national
codes and in conformance with good refrigeration
practice for proper operation of the systems.

The suction line and its components must be selected
and installed with extreme care. The suction line
must be sized for high enough refrigeration velocity to
assure good oil return, and low enough pressure drop
to prevent excessive system capacity loss. The
optimum line size for a system will result in a
reasonable velocity at minimum pressure drop. Total
suction line pressure loss should not exceed 2°F
equivalent loss.

Suction line risers must be carefully selected, have
an oil trap at the bottom and at 15 foot intervals up
the riser. The should be the same size as the vertical
riser connected to its outlet. Riser should not be
larger in diameter than horizontal runs.

Horizontal runs of suction line should slope 1 inch per
10 feet in the direction of flow. A 1/4 inch male flare
Schrader fitting should be installed in the suction line
at the evaporator outlet to obtain accurate evaporator
pressure and superheat readings. Refer to pages 8
though 13 for line size recommendations and piping
diagrams. Note the maximum size for suction line
risers.

Liquid lines, both horizontal and vertical, are normally
the same size. In vertical lines with upward flow
there will be a pressure loss similar to that in water
line riser, due to the lift involved. If ignored, this pres­sure loss can result in liquid line flash gas that will
prevent good expansion valve and system
performance. Sizing the liquid line too small will also

result in flash gas. Sizing a liquid line larger than

necessary will increase the system refrigerant charge.
Flash gas can be avoided by adding subcooling to
the system, however, subcooling should not be
considered as an acceptable alternative to properly
sized liquid lines.

One method to obtain liquid subcooling and return
gas superheat is to join the liquid and suction line
together and then insulate them. This economical
method is often used on vertical lines. Another
alternative is to use a manufactured liquid-suction
heat exchanger. This type of heat exchanger is
usually located inside the cooler or freezer, near the
evaporator. D series and V series condensing units
include an integral liquid subcooling circuit in the
condenser coil. Any one of these methods will
normally provide enough subcooling to offset the
liquid line pressure loss due to friction and lift. Liquid
lines with more than 30 feet of vertical lift need
special attention!

A liquid line solenoid should be installed near the
expansion valve inlet. If there are multiple
evaporators, locate the solenoid near the branch line
to the first evaporator.

Before installing the expansion valve on the
distributor, check the distributor to be sure it has
a nozzle installed or is a venturi type. For optimum

performance, the expansion valve outlet should be
installed directly to the distributor. If reducing
couplings or adapters are required keep them close
coupled. Do not have elbows between the expansion
valve and distributor. The expansion valve must be

selected to match the system capacity. Follow the

expansion valve manufacturers ratings when select­ing the valve and use the appropriate capacity multi­plier if liquid is subcooled below 70°F. If the amount
of liquid subcooling may vary, a balanced port expan­sion valve should be used.

Evaporators with 1/2 inch flare nut (FN) inlet
distributors can be converted to a sweat type inlet.
All distributors have room to remove the flare with a
mini-cutter. The inlet would be 1/2 inch OD and an
expansion valve with 1/2” ODF outlet would fit. Alco
type HFS or Sporlan type EG, SBF or S expansion
valves are available with 1/2” ODF extended Copper
outlet connections. To protect the valve(s), wrap
them with a wet rag while brazing. Disassembly of
the valve is not required.

6

Expansion valves are supplied with clamps for
securing the bulb to the suction line. The bulb must
be secured at the evaporator outlet, on the side of a
horizontal run of suction line, at the 4 o’clock or 8
o’clock position, before any traps. The bulb must be
in uniform contact with clean Copper tube and must
not bridge any fitting or uneven surface. A thermal
mastic or heat transfer compound may be used with
the expansion valve bulb and suction line for quicker
expansion valve response. DO not overtighten bulb
clamps or deform the bulb in any way.

Drain lines should be the size of the evaporator drain
pan connection or larger. They should not be
reduced in size. Plastic drain lines are often used in
coolers, however, Copper or metal lines are
recommended if room temperature is below 35°F. All
drain lines must be protected from freezing. All drain
lines must be trapped

and run to an open drain.
Drain lines should be sloped 4 inches per foot to
insure positive drainage. Never connect a
condensate drain directly to a sewer line. Never
drain onto a floor or walkway, creating a safety
hazard. Traps must be in warm ambient or be
protected from freezing. It may be necessary to run
heat tape the entire length of the drain line and trap
to prevent freezing. Insulating the drain line is
recommended with the heat tape energized
continuously. Drain properly and safely!

All piping must be adequately supported to prevent
vibration and breaking. Tube clamps should have a
gasketed surface to prevent abrasion. Inspect all
piping while the equipment is operating and add
supports to prevent stress and vibration. When the
liquid solenoid opens and closes, the liquid line will

tend to move forcefully. Without proper support the
joints at the liquid solenoid, expansion valve,
distributor, and distributor leads can fracture. Take
care to secure the liquid line at the evaporator. Line
supports are inexpensive compared to downtime and
refrigerant loss. All piping must be protected where
it passes through walls or ceilings. Precautions
should be taken to see that the piping does not touch
any structural members and is properly supported in
order to prevent the transmission of vibration into the
building. The piping chase must be thoroughly
sealed to protect the tube and prevent ambient air
from entering the refrigerated space. Seal around
the drain line where it passes through the wall. Air
leaks can cause equipment problems, damage the
structure and product, increase load, increase
operating cost, and can cause a safety hazard.
Eliminate all air leaks. See Table 11 for
recommended line support spacing.

In low temperature application, or where proper oil
circulation cannot be maintained, an oil separator
may be required. When operating at evaporator
temperatures of -20°F and lower, oil separators
should be considered in order to minimize the
amount of oil in circulation.

In addition to the critical nature of oil return, there is
no better invitation to system difficulties than an
excessive refrigerant charge. A reasonable pressure

drop is far more preferable than oversized lines which

can contain refrigerant far in excess of the systems
needs. On systems with a larger refrigerant charge,

or on systems where liquid floodback is likely to

occur, a suction line accumulator is strongly
recommended.

LEAK TESTING

After all refrigerant connections are made, have been

visually inspected and secured, add proper system

refrigerant until the pressure is 25 to 35 PSI. Then
pressurize with dry nitrogen up to 120 to 140 PSI.
Always use a pressure reducing regulator. Wait 20 to
30 minutes for the refrigerant to reach all parts of the
system. Using an electronic leak detector, check all
connections and components, both factory and field
installed

. The compressor, evaporator coil, and
condenser coil must be checked. Valves and
controls must be checked. Repair any leaks found
and re-check until no leaks are located and the
pressure holds steady. Leave the system

pressurized overnight to verify that the pressure
remains unchanged.

Unlocated leaks can mean unprofitable call back,
additional refrigerant cost, higher energy cost, and
possible internal contamination and failure of the
system. With highly hygroscopic polyol ester (POE)
lubricants, leak detection is essential to prevent
moisture from entering a system. The system
installation must be leak free!

After leak testing has been completed, the system
must be thoroughly evacuated before charging.

7

DOUBLE RISER
WHEN REQUIRED

LOOP TO PREVENT
LIQUID DRAINING
INTO COMPRESSOR

SLOPE

EVAPORATORS ABOVE

COMPRESSOR

DOUBLE RISER

WHEN REQUIRED

EVAPORATORS BELOW

COMPRESSOR

EVAPORATOR ABOVE

COMPRESSOR

EVAPORATOR BELOW

COMPRESSOR

SMALLER

DOUBLE RISERDOUBLE TRAP

15' MAX

ADD
TRAP

SLOPE

RISER

SLOPE

LARGER
RISER

SLOPE

SLOPE

EVAPORATORS ABOVE

COMPRESSOR

SLOPE

SUCTION LINE DESIGN

8