Russell U-U, U-L, U-M, UAH Installation Manual

221 S. Berry St., Brea, CA 92821 • Tel: [phone] • Fax: [phone]

Visit us on the Web: www.russellcoil.com

ULTRA - TEMP
INSTALLATION AND
MAINTENANCE
MANUAL

IOM 101.2

August, 2003

Models: U•U, U•L, U•M, & UAH

1 Thur 6 Fans
Air, Electric, & Hot Gas Defrost

Table of Contents

Inspection 2
General Safety Information 2
Installation

Piping Considerations 2-4
Expansion Valve Selection And Installation 5
Unit Cooler (Internal) Wiring Diagrams 6-8

Typical Field Wiring — Sequence of Operations

General Information 9
Air Defrost 9
Hot Gas Defrost 10

Electric Defrost 11-13
Start-Up Procedure 14
Maintenance 14
Troubleshooting Chart 15
Replacement Parts and Nomenclature 16

2

INSPECTION

GENERAL SAFETY INFORMATION

INSTALLATION

Equipment listed on the bill of lading but not received,
along with any equipment damaged in transit, should
be reported immediately to the carrier and a claim filed.

Also, check unit nameplates to make sure the voltage
is correct before installing.

1. Installation and maintenance are to be performed
by qualified personnel who are familiar with this
type of equipment.

2. Make sure all field wiring conform to the
equipment requirements and all applicable national
and local codes.

3. Avoid contact with sharp edges and coil surface.
They are a potentialinjury hazard.

4. Disconnect all power sources before performing
service or maintenance.

Our unit coolers are designed to draw air in through
the coil and discharge it through the fans.For most
efficient operation, units should be located so that air
from an open door cannot be drawn directly into the coil.

FIGURE 1

A = 2.0 Ft. for U•U1-118 to 2-236; U•M1-164 to 2-329

U•L1-125 to 2-304; UAH1-182 to 2-365

A = 3.0 Ft. for U•U3-474 to 6-1620; U•L2-361 to 6-2070

U•M2-390 to 6-2480; UAH2-433 to 6-2730

Figure 1 shows the air flow direction and recommended
minimum clearances to walls or other obstructions.

All units, except single-fan type, are shipped upright as
in the mounting position. Remove the top and sides of
the crate from the unit leaving the unit sitting on the
shipping skid. Using the fastener slot/holes in the unit
mounting hangers as a guide, locate the mounting
fasteners in the ceiling of the refrigerated room. 5/16”
threaded rod is sufficient.

Single-fan units can be lifted into place by hand.All
other units can be lifted into place by sliding the forks
of a fork lift under the skid to avoid damage to the
drain pan.

IMPORTANT: Hot Gas units must be mounted using
the galvanized steel channel “Pitching Spacer” (one
provided per unit) to allow proper drainage of
condensate coming off the evaporator coil.The unit
may be pitched toward either end since two drain
connections are provided.The unused connection
should be capped off with the plastic cap supplied. See
the instructions attached to the “Pitching Spacer” channel.

Drain Line

The condensate drain line should be at least 3/4” I.P.S.
and should be installed with a minimum of 1/2” of slope
per foot of horizontal run. Keep the length of drain
line within the refrigerated space as short as possible.
Provide a trap in the line outside of the refrigerated
space. On freezer units, the drain line within the
refrigerated space must be wrapped with heat tape and
insulated to prevent water from freezing in the
line during the defrost cycle.

Refrigerant Piping

Install all refrigeration components in accordance with
accepted piping practices. Liquid and suction lines
should be sized according to ASHRAE recommend­ations for the intended conditions of operation.

All horizontal suction lines should be sloped toward
the compressor at the rate of 1/8” per foot for good
oil return. Ver tical suction r isers of more than five feet
should be trapped with a P-Trap at the bottom.

Hot Gas Piping

Hot Gas defrost systems can be described as either
Re-Evap Type “H” (three-pipe) or Reverse Cycle
Type “G” (two-pipe) types. Figures 2 and 3 represent
typical piping arrangements for hot gas defrost units.

Hot Gas Defrost units may be ordered so that they are
capable of operating on either of the two systems
mentioned above.All units are equipped with a hot gas
drain pan loop.

Re-Evap System — Uses three pipes as shown in
Figure 2 - one for the liquid, one for the suction and
one for the hot gas.In addition, a heat exchanger/re­evaporator is used at the suction line outlet of the
evaporator. The hot gas is taken from the discharge
line between the compressor and the condenser,
through a hot gas solenoid valve, then to the
evaporator drain pan loop. From there it enters the
distributor at the side inlet then goes through the
coil in the same direction as the normal refrigeration
flow. The condensed refrigerant is trapped in the

A A

A

AIR

FLOW

3

Table 1: Liquid Line Selection Table 2: Suc tion Line Selection

Line

Equiv.

Unit Cooler Capacity Line

Equiv.

Size Lgth.

BTUH

Size Lgth. R-404A

(O.D.) (Ft.) R-22 R-404A (O.D.) (Ft.) Suction Temperature °F Suction Temperature °F

-20 0 20 -40 -20 0 20

25 48,000 25,000 25 7,800 12,000 18,000 8,500 8,500 12,000 16,000

50 30,500 17,000 50 3,575 5,500 12,000 4,000 6,000 9,000 12,000
100 18,000 10,000 100 2,600 4,000 9,000 3,000 3,000 6,000 7,500
150 15,200 7,000 150 2,275 3,500 6,500 1,000 2,000 3,000 5,000

25 90,350 65,000 25 16,835 25,900 48,000 19,500 17,000 28,000 35,000

50 61,450 42,000 50 11,700 18,000 30,200 11,000 15,000 20,000 28,000
100 42,100 35,000 100 9,880 15,200 24,100 9,500 1,000 15,000 19,500
150 33,650 30,000 150 7,865 12,100 18,200 8,000 6,000 1,100 14,000

25 165,100 125,000 25 44,700 68,150 103,650 45,000 52,000 73,000 80,000

50 112,350 85,000 50 30,500 46,500 70,750 21,000 38,000 49,000 63,000
100 76,800 68,000 100 21,100 32,100 48,450 18,000 20,000 33,000 40,000
150 61,450 59,000 150 16,750 25,400 38,820 14,000 15,000 25,000 29,500

25 438,000 310,000 25 77,350 118,550 180,750 67,000 75,000 110,000 130,000

50 299,150 215,000 50 53,000 81,000 124,120 55,000 60,000 85,000 98,000
100 204,100 165,000 100 36,200 55,120 84,100 45,000 37,000 55,000 70,000
150 163,100 125,000 150 29,500 44,350 67,150 29,000 33,000 42,000 55,000

25 750,000 625,000 25 123,120 186,100 264,100 110,000 125,000 160,000 250,000

50 600,500 440,000 50 84,150 127,000 180,100 85,000 95,000 125,000 160,000
100 180,000 275,000 100 57,400 87,100 123,200 72,000 77,000 84,000 93,000
150 360,500 240,000 150 46,120 69,500 98,750 64,000 71,000 78,000 87,000

25 257,100 391,100 597,000 220,000 250,000 325,000 450,000

50 175,000 267,100 408,100 125,000 175,000 230,000 335,000
100 120,100 182,100 278,120 110,000 125,000 175,000 235,000
150 96,150 146,100 223,110 88,000 96,000 135,000 180,000

25 452,100 683,100 1,040,100 350,000 475,000 750,000 1,087,500

50 308,100 467,100 710,100 350,000 350,000 575,000 835,000
100 210,000 318,100 484,100 200,000 240,000 425,000 300,000
150 168,120 254,500 387,100 140,000 175,000 220,000 240,000

25 698,100 1,120,100 1,660,100 550,000 750,000 975,000 1,490,000

50 477,100 762,100 1,351,500 320,000 600,000 785,000 1,140,000
100 325,120 520,100 774,120 250,000 300,000 575,000 851,000
150 260,100 416,500 620,150 210,000 225,000 350,000 475,000

2 1/8

2 5/8

3 1/8

1 1/8

Unit Cooler Capacity — BTUH

R-22

5/8

7/8

1 1/8

1 3/8

1 5/8

3/8

1/2

5/8

7/8

re-evaporator as it leaves the coil, there to be
metered as a heavy vapor into suction line flow
back to the compressor.

Reverse Cycle

- Is a technique in which the hot gas
flows backwards (i.e.opposite to the nor mal refrig­erating flow) through the evaporator. Systems employing
the reverse cycle principle are divided into two types:

Alternating Evaporator and Heat Pump systems.

Alternating Evaporator System

— This is the system
commonly referred to as “Reverse Cycle Defrost”. It
must have multiple evaporator coils on the same
system to operate.

Evaporator coils are defrosted in groups of one or
more coils per group.65% to 75% of the coils will
continue to refrigerate while 25% to 35% are on defrost.
The defrosting coils produce liquid refrigerant which
is used to operate the coils which are still refrigerating.

The simplest design is a system with one condensing
unit and three evaporator coils. One coil will defrost at
a time, while the other two continue to refrigerate.

A hot gas line is run from the discharge line of the
compressor close to the junction of the main suction
line with the three individual suction lines.There the
hot gas line branches into three hot gas lines. Each of
these three lines has a hot gas solenoid valve;the
leaving side of each solenoid valve is teed into one of
the three branch suction lines. Each suction line has a
suction-stop valve installed between the main suction
line and the hot gas tee-in to keep hot gas from
entering the main suction line to the compressor.In
this way, each evaporator coil has a source for hot
gas, controlled by its own defrost solenoid valve.A
modular multi-circuit defrost timer is normally employed
to synchronize the three defrosts.

The timer initiates defrost on a given coil, opening its
hot gas solenoid (and closing its suction-stop valve),
allowing hot gas to flow backwards through the
suction line towards the coil. Utilizing the piping
shown in Figure 3, the hot gas goes first to the drain
pan loop of the unit, then into the suction inlet of the
coil. As it leaves the coil, the condensed liquid flows
through a bypass line around the expansion valve into
the liquid line. It flows backwards through the branch
liquid line until it reaches the main liquid line, where

4

Expansion Valve Installation

All units use an externally equalized type valve. See
tables 4 and 5 for expansion valve selection.It may be
desirable to use a pressure-limiting type expansion
valve on low temperature systems to prevent possible
overloading of the compressor on initial start-up or
after defrost. Mount the valve directly on the
distributor of the unit.

Locate the expansion valve bulb on a horizontal
section of the suction line as close to the suction
hearer as possible.If a P-Trap is installed, locate the
expansion valve bulb between the trap and the unit.
Make sure the surfaces of the suction line and bulb are
clean and make good contact for the full length of the
bulb when the bulb is mounted.Insulate the bulb to
insure accurate superheat control.

it is re-introduced into the refrigerating part of the system.
The main liquid line is made to operate at a lower
pressure during defrost so that it will accept the liquid
from the defrosting coil.

A much larger Alternating Evaporator system will still
operate in much the same way. Such a system might
have a larger compressor or a parallel compressor rack
operating with many more evaporator coils than
described above.Now there will be a

groups of coils

defrosting at once instead of just one. It is important,
however, that no one defrost group is larger in refrig­erating capacity than 25% to 35% of the total. A given
hot gas line and solenoid valve will now service its
evaporator group instead of only one evaporator.

Heat Pump System

— It is not recommended for

refrigeration defrost purposes.

Table 3: Hot Gas Defrost Line Selection

Total Maximum Evaporator Capacity - Tons

Line

R-22

R-404A

Size Short Long Short Long

1/2 1.5 1.0 1.3 0.8
5/8 2.8 2.0 2.5 1.5

7/8 7.0 5.0 6.0 3.5
1 1/8 16.0 11.0 13.0 9.0
1 3/8 23.0 17.0 21.0 15.0
1 5/8 40.0 27.0 30.0 23.0
2 1/8 76.0 52.0 66.0 44.0
2 5/8 145.0 100.0 130. 0 80.0

CAPACITY AND DIMENSIONS

EVAPORATOR MODEL A B C D

CAPACITY NO. (OD) (OD)

UP TO 6,000 HEA-1A 9-3/4 5 7/8 3/8

6,000 TO 12,000 HEA-2A 15-3/4 5 1-1/8 1/2
12,000 TO 24,000 HEA-3A 27-3/4 5 1-3/8 1/2
24,000 TO 36,000 HEA-4A 37-3/4 5 1-5/8 5/8
36,000 TO 55,000 HEA-5A 45-3/8 6 2-1/8 5/8
55,000 TO 80,000 HEA-6A 64-3/8 6 2-5/8 7/8

NOTE: Short - Runs under 50 equivalent feet

Long - Runs over 50 equivalent feet

"C" SUCTION OUT

"D" LIQUID IN

"D" LIQUID OUT

"C" SUCTION IN

A

B

Russell HEAT EXCHANGER-ACCUMULATOR

NOTE: Level mount the Heat Exchanger­Accumulator within refrigerator space
as close to evaporator as possible.

TXV

LIQUID
LINE

SUCTION LINE

LIQUID LINE

SUCTION LINE

HOT GAS

CHECK VALVE

BY OTHERS

CHECK VALVE
SUPPLIED

CHECK VALVE
BY OTHERS

TXV

LIQUID
LINE

SUCTION LINE

HEAT EXCHANGER - A CCUMULATOR

LIQUID LINE

SUCTION LINE

HOT GAS

Figure 2 - Re-Evap Type

Figure 3 - Reverse Cycle

Type

5

TABLE 4:

BTU/HR

@ 10° TD Sprolan Alco Sporlan Alco

Low Temperature Units — U•U

U*U1-11812400 SBFVE-A-ZP40 HFESC -1-1/2-H W 35 SBFSE-A-ZP H FESC -1-1/4-SW 45
U*U2-236 24700 SBFVE-B-ZP40 H FESC -2- 1/2-H W 35 SBFSE-C-ZP H FESC -3- 1/2-SW 45
U*U2-355 37100 SB FVE-C-ZP 40 H FESC-5- 1/2-H W 35 EB SSE-6- ZP H FESC -3-1/2-SW 45
U*U3-474 49500 SBFVE-C-ZP40 H FESC -5- 1/2-H W 35 EB SSE-7-1/2-ZP H FESC -5- SW 45
U*U4-711 72800 EB SVE-11-ZP 40 H FESC -8- HW 35 EB SSE-10-ZP HFESC-10-SW 45
U*U4-851 89000 (2) EB SVE-8- ZP40 (2) HFESC -5-1/2-HW 35 (2) EB SSE-6-ZP (2) H FESC -5-SW 45
U*U4-1080 112900 (2) EB SVE-8- ZP40 (2) HFESC -5-1/2-HW 35 (2) EB SSE-7-1/2-ZP (2) HFESC-7- SW 45
U*U5-1350 141000 (2) EB SVE-8-ZP 40 (2) HFESC-8- HW35 (2) EBSSE-10-ZP (2) H FESC -10-SW 45
U*U6-1620 169400 (2) EBSVE-11-ZP 40 (2) HFESC -10-HW 35 (2) EBSSE-13-ZP (2) HFESC-10-SW 45

Low Temperature Units — U•L

U*L1-125 11700 SBFVE-A-ZP 40 H FESC -1-1/2-H W 35 SB FSE-A-ZP H FESC -1-1/4-SW 45
U*L1-152 14200 SBFVE-A-ZP 40 H FESC-1-1/2-H W 35 SBFSE-A-ZP H FESC-1-1/2-SW 45
U*L1-193 18100 SB FVE-B-ZP 40 H FESC -1-1/2-H W 35 SBFSE-B-ZP HFESC -2-SW 45
U*L2-240 22400 SB FVE-B-ZP 40 H FESC -1-1/2-H W 35 SB FSE-C-ZP H FESC -2-SW 45
U*L2-304 28400 SB FVE-C-ZP 40 H FESC -1-1/2-H W 35 SB FSE-C-ZP H FESC -3-1/2-SW 45
U*L2-361 33800 SB FVE-C-ZP 40 H FESC -1-1/2-H W 35 EBSSE-6-ZP H FESC -3-1/2-SW 45
U*L2-408 38200 SB FVE-C-ZP 40 H FESC -1-1/2-H W 35 EBSSE-6-ZP H FESC -3-1/2-SW 45
U*L3-445 41600 SBFVE-C-ZP 40 H FESC -1-1/2-H W 35 EB SSE-6-ZP H FESC -5- SW 45
U*L3-540 50500 EB SVE-8-ZP 40 H FESC -1-1/2-H W 35 EBSSE-7- 1/2-ZP HFESC -5-SW 45
U*L3-613 57300 EBSVE-8-ZP40 H FESC -1-1/2-H W 35 EB SSE-7-1/2-ZP HFESC -7-SW 45
U*L3-660 61700 EB SVE-8- ZP40 HFESC-1-1/2-H W 35 EB SSE-7-1/2- ZP HFESC -7-SW 45
U*L4-722 67500 EB SVE-8-ZP 40 H FESC -1-1/2-H W 35 EB SSE-10-ZP H FESC -7-SW 45
U*L4-817 76400 EBSVE-11-ZP 40 H FESC -1-1/2-H W 35 EB SSE-10-ZP HFESC-10-SW 45
U*L4-950 88900 (2) EB SVE-8- ZP40 (2) H FESC -5-1/2-HW 35 (2) EB SSE-6- ZP (2) H FESC -5- SW 45
U*L4-1100 102900 (2) EB SVE-8- ZP40 (2) H FESC -5-1/2-HW 35 (2) EB SSE-7-1/2-ZP (2) H FESC -5-SW 45
U*L4-1260 117800 (2) EB SVE-8-ZP40 (2) H FESC -5-1/2-HW 35 (2) EB SSE-7-1/2- ZP (2) H FESC -7-SW 45
U*L4-1380 129000 (2) EB SVE-8-ZP 40 (2) H FESC -8-HW 35 (2) EB SSE-10-ZP (2) H FESC -7-SW 45
U*L5-1575 147300 (2) EB SVE-11-ZP40 (2) HFESC-8- HW35 (2) EB SSE-10-ZP (2) HFESC -10-SW 45
U*L5-1725 161300 (2) EB SVE-11-ZP 40 (2) H FESC -8-HW 35 (2) EB SSE-10-ZP (2) H FESC -10-SW 45
U*L6-1890 176700 (2) EB SVE-11-ZP40 (2) H FESC -10-HW 35 (2) EB SSE-13-ZP (2) H FESC -10-SW 45
U*L6-2070 193500 (2) EB SVE-15-ZP 40 (2) H FESC -10-HW 35 (2) EB SSE-13-ZP (2) H FESC -10-SW 45

TABLE 5:

BTU/HR

@ 10° TD Sprolan Alco Sporlan Alco

Medium Temperature Units — U•M

U*M1-164 16400 SBFVE-A-C H FESC -1-1/2-H C SB FSE-A-C H FESC-1-SC
U*M1-209 20900 SBFVE-A-C HFESC-1-1/2-H C SB FSE-B-C HFESC-1-1/4-SC
U*M2-270 27000 SB FVE-B-C HFESC -2- HC SB FSE-B-C H FESC -1-1/2-SC
U*M2-329 32900 SB FVE-B-C HFESC -2- 1/2-H C SBFSE-B-C H FESC -2-SC
U*M2-390 39000 SB FVE-B-C HFESC -2- 1/2-H C SBFSE-C-C H FESC -3-1/2-SC
U*M2-441 44100 SBFVE-B-C H FESC -3- HC SB FSE-C-C H FESC -3-1/2-SC
U*M3-583 58300 SB FVE-C-C HFESC -5- 1/2-H C EB SSE-6- C H FESC -3-1/2-SC
U*M3-662 66200 SB FVE-C-C HFESC -5- 1/2-H C EB SSE-6- C HFESC -5-SC
U*M4-780 78000 SB FVE-C-C HFESC -5- 1/2-H C EB SSE-6- C HFESC -5-SC
U*M4-882 88200 E B SVE-8-C H FESC -5-1/2-H C EB SSE-6-C H FESC -7- SC
U*M4-1100 110000 EB SVE-8-C H FESC -8-H C EB SSE-7-1/2-C HFESC -7-SC
U*M4-1320 132000 E B SVE-8-C H FESC -10-H C EBSSE-10-C HFESC -10-SC
U*M4-1656 165600 E B SVE-11-C H FESC -15-H C EBSSE-13-C H FESC -10-SC
U*M5-2065 206500 EB SVE-11-C H FESC -15-HC EB SSE-13-C HFESC-13-SC
U*M6-2480 248000 EBSVE-15-C H FESC -15-HC OSE-21-C TRAE-20-SC

High Temperature Units — UAH

UAH1-182 1 8200 SB FVE-A-C HFESC-1-1/2-H C SB FSE-A-C HFESC-1-1/4-SC
UAH1-232 23200 SB FVE-A-C H FESC -1-1/2-H C SBFSE-B-C H FESC -1-1/2-SC
UAH2-300 30000 SBFVE-B-C H FESC -2-H C SB FSE-B-C HFESC -2-SC
UAH2-365 36500 SBFVE-B-C HFESC -2- 1/2-H C SBFSE-B-C HFESC -3-1/2-SC
UAH2-433 43300 SBFVE-B-C H FESC -3-H C SB FSE-C-C HFESC-3- 1/2-SC
UAH2-490 49000 SBFVE-C-C H FESC -3-H C SB FSE-C-C HFESC-3- 1/2-SC
UAH3-530 53000 SBFVE-C-C H FESC -3-H C EB SSE-6-C H FESC -3-1/2-SC
UAH3-648 64800 SBFVE-C-C HFESC -5- 1/2-H C EBSSE-6- C H FESC -5-SC
UAH3-736 73600 SBFVE-C-C HFESC -5- 1/2-H C EBSSE-6- C H FESC -5-SC
UAH4-866 86600 EB SVE-8-C H FESC -5-1/2-H C EBSSE-6-C H FESC -5- SC
UAH4-980 98000 EB SVE-8-C H FESC -8-H C EB SSE-7- 1/2-C H FESC-7-SC
UAH4-1100 110000 EB SVE-8-C H FESC -8-H C EB SSE-7-1/2-C HFESC-7- SC
UAH4-1452 145200 E B SVE-11-C H FESC -10-H C EBSSE-10-C H FESC -10-SC
UAH4-1821 1821 00 EB SVE-11-C H FESC -15-H C EBSSE-13-C HFESC -10-SC
UAH5-2275 227500 EBSVE-15-C H FESC -15-HC OSE-21-C TRAE-20-SC
UAH6-2730 273000 EB SVE-20-C HFESC-20- HC OSE-21 -C TRAE-20-SC

Expansion valve selection @ -20°F Suction Temperature

Expansion valve selection @ +20°F Suction Temperature

Model

R-2 2

R-404A, 507

Model

R-2 2

R-404A, 507