KeepRite K40-CU-IM-13 Installation And Maintenance Instructions Manual Download

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K40-CU-IM-13

1068155

Installation and Maintenance

Instructions

for

Air-Cooled, Remote and Water-Cooled

Condensing Units

National Refrigeration and Air Conditioning Canada Corp.,

159 Roy Blvd., P.O. Box 2020, Brantford, Ontario, N3T 5Y6

Phone: 800-463-9517, 519-751-0444 Fax: 519-753-1140

Visit our web site at www.keepriterefrigeration.com

Summary of Contents for K40-CU-IM-13

Page 1: ...for Air Cooled Remote and Water Cooled Condensing Units National Refrigeration and Air Conditioning Canada Corp 159 Roy Blvd P O Box 2020 Brantford Ontario N3T 5Y6 Phone 800 463 9517 519 751 0444 Fax 519 753 1140 Visit our web site at www keepriterefrigeration com ...

Page 2: ...k Testing Evacuation Dehydration 20 Line Insulation 21 Refrigerant Charging 21 23 Compressor Oils 24 25 System Start up Check List 26 27 Low Temperature Room Pull Down 27 Checking Compressor Evaporator Superheat 28 System Operational Check List 29 System Troubleshooting 30 32 Customer Instructions 33 Maintenance Program 33 Service Parts Availability 33 Finished Goods Warranty Service Log 34 Warran...

Page 3: ...ge or loss Check shipping list against material received to ensure shipment is complete IMPORTANT Remember you the consignee must make any claim necessary against the transportation company Shipping damage or missing parts when discovered at the outset will prevent later unnecessary and costly delays If damage or loss during transport is evident make claim to carrier as this will be their responsi...

Page 4: ...d and a specific location chosen it is advisable to obtain written approval of this location from the building and or condensing unit owner This may be a means of avoiding disagreement and expense at a later date A fully qualified and properly equipped crew with the necessary tackle and rigging should be engaged to locate the condensing unit in position When lifting the unit spreader bars and chaf...

Page 5: ...acers c Install the rubber cone washers located in the electrical box d Replace the upper mounting nuts washers e Allow 1 16 inch space between the mounting nuts washers and the compressor foot On units equipped with rigid mounted compressors check the compressor mounting bolts to insure they have not vibrated loose during shipping WALLS OR OBSTRUCTIONS All sides of the unit must be a minimum of 4...

Page 6: ...ype Air Quantity Air cooled condensing units for horizontal air flow units 1 000 cfm 472 L s per Hp Air cooled compressors with remote condensers 250 cfm 118 L s per Hp Suction cooled or water cooled compressors 200 cfm 94 L s per Hp with remote or water cooled condensers All of the above mentioned air quantities are based on relatively short discharge line runs within the machine rooms If using l...

Page 7: ...32 V All systems should use a liquid line solenoid valve installed at the evaporator and should be energized by the room or fixture thermostat For systems with a defrost time clock the liquid line solenoid and thermostat should be energized by the time clock Initially set the defrost time clock model 8145 as follows Air defrost evaporators 3 per day every 8 hours with the time termination at 45 mi...

Page 8: ...8 Electrical Wiring Diagram Horizontal Air Flow Condensing Units K Line ...

Page 9: ...9 Electrical Wiring Diagram Horizontal Air Flow Condensing Units K Line ...

Page 10: ...10 Electrical Wiring Diagram Horizontal Air Flow Condensing Units K Line ...

Page 11: ...11 Electrical Wiring Diagram Horizontal Air Flow Condensing Units KE Line ...

Page 12: ...12 Electrical Wiring Diagram Horizontal Air Flow Condensing Units KE Line ...

Page 13: ...13 Electrical Wiring Diagram Horizontal Air Flow Condensing Units KE Line ...

Page 14: ...14 Electrical Wiring Diagram Vertical Air Flow Condensing Units ...

Page 15: ...ld be sized on the basis of a maximum total pressure drop equivalent to a 2o F 1 1o C change in saturated temperature At 40o F 4 4o C suction temperature this is approximately 3 psig 20 7 kPa for R 22 At 20o F 28 9o C suction temperature this is approximately 1 3 psig 9 0 kPa for R 404A Horizontal liquid lines should be sized on a basis of a maximum pressure drop equivalent to a 2o F 1 1o C drop i...

Page 16: ...d preferably 1 250 to 1 500 fpm 6 to 8 m s Important A suction trap must be installed at the base of all suction risers of four 4 feet or more in order to trap oil and allow entrainment in the suction gas IMPORTANT PIPING NOTE If steps of capacity control are supplied on a compressor provisions must be made for oil return by sizing suction risers to maintain adequate gas velocities at reduced refr...

Page 17: ...n at a lower condensing temperature without resulting in a high water flow rate consumption Higher water inlet temperatures above 85 o F require the condensing temperature to be higher to avoid excessive water flow rates Refer to the water flow rate chart to estimate the flow rate GPM US gallon per minute at given water temperatures and loads The TD temperature difference is the difference between...

Page 18: ... 0 168 Evaporating Temperature SERIES PARALLEL WATER FLOW REQUIREMENTS Gallon Per Minute Per 1 MBH Evaporator Load LOWER WATER FLOW RATES 30 o TD Condensing Temperature Entering Water Temperature PARALLEL Condensing Temperature Evaporating Temperature 20 o TD Condensing Temperature Entering Water Temperature HIGHER WATER FLOW RATES SERIES Condensing Temperature 1 0 6 2 2 3 4 2 2 2 4 0 3 4 8 7 1 2 ...

Page 19: ...e compressor oil sump e A LIQUID LINE SOLENOID VALVE must be installed at the evaporator Installing a solenoid valve will allow all of the refrigerant to be pumped out of the low side evaporator and suction line when the thermostat has been satisfied This reduces the risk of refrigerant migrating or flooding back to the compressor Locating the solenoid at the evaporator instead of the condensing u...

Page 20: ...sable gas problems Moisture problems causing compressor failure will void warranty Follow the recommended procedure carefully CAUTION Do not use the refrigeration compressor to evacuate the system Never start the compressor or perform a megger insulation test while the system is in a vacuum Dehydration Procedure Use only a high vacuum pump capable of drawing a vacuum of 100 microns Change the vacu...

Page 21: ...olding capacity of the receiver DO NOT assume that bubbles in a sight glass when located at the condensing unit indicates the system is undercharged Note To estimate the total system requirement refer to the manufacturer s evaporator and condensing unit specifications on typical operating charges and include the amount for the liquid lines see tables below Allow an extra 10 to 15 safety factor Ens...

Page 22: ... 19 8 6 L 11 5 10 0 6 L 19 3 16 8 7 1 2 M 19 6 17 1 7 1 2 M 28 5 24 8 7 1 2 M 25 5 22 2 7 1 2 M 38 9 33 0 7 1 2 L 16 3 14 2 7 1 2 L 22 8 19 8 9 L 19 6 17 1 9 L 28 5 24 8 10 M L 23 5 20 4 10 M L 38 0 33 0 15 M L 32 6 28 3 15 M L 54 3 47 2 20 M 47 9 41 7 20 M 65 3 56 8 20 L 36 7 31 9 20 L 54 3 47 2 25 M L 47 9 41 7 25 M L 72 2 62 8 30 M L 47 9 41 7 30 M L 72 2 62 8 Above conditions are with condense...

Page 23: ...62 4 72 7 115 8 60 H 79 2 92 4 148 2 70 H 93 6 93 6 167 5 80 H 99 5 99 5 189 2 100 H 128 8 128 8 235 7 30 M 62 4 58 9 70 8 106 2 66 2 97 0 40 M 62 4 58 9 70 8 106 2 66 2 97 0 50 M 76 4 72 1 86 6 129 7 81 0 118 5 60 M 96 6 91 1 109 9 165 6 102 6 151 1 70 M 113 6 107 4 113 6 187 6 107 4 171 7 80 M 125 1 117 4 125 1 214 8 117 4 195 4 100 M 160 2 150 9 160 2 267 1 150 9 243 9 20L 38 3 36 9 57 8 64 0 5...

Page 24: ... is to remove the compressor and drain the oil through the suction connection and recharge with the correct factory charge refer to unit specifications DO NOT re use drained oil that has been exposed to the atmosphere DO NOT re fill at any one time more than a total of 110 of the compressor s factory specified charge Allow time for some of the oil to circulate into the system R 12 R 22 R 502 Copel...

Page 25: ...ter oils the quantity of refrigerant dissolved in the oil is more than doubled as compared with conventional lubricants Special care should be taken Refer to Bitzer Technical Bulletin KT 510 2 section 5 for additional information Not Acceptable Not Acceptable Not Acceptable Mineral Oils Alkyl Benzene A B M O Mix HFC s R 134a R 404A R 507 R 407C Polyol Ester Lubricant Type H CFC R 22 Interim Blends...

Page 26: ...d initial operation process DO NOT add oil while the system is low on refrigerant charge unless the oil level is dangerously low 10 Continue to charge the system until it has enough charge for proper operation DO NOT OVERCHARGE THE SYSTEM Note that bubbles in the sight glass may not necessarily mean a shortage of refrigerant It could be caused by a restriction 11 DO NOT leave the system unattended...

Page 27: ...ost termination and time clock so that the coil and drain pan are COMPLETELY free of frost ice at termination Too short of a defrost cycle will allow residual ice to grow Too long of a defrost will allow the coil s to steam at the end of the cycle The steam will condense and freeze fans fan guards and create frosting on the ceiling of the room The evaporator fan delay must allow any condensate lef...

Page 28: ...oil and will result in piston ring wear piston and cylinder wall damage If adjustment to the suction superheat is required it should be done either by adjusting the thermostatic expansion valve at the evaporator the use of liquid to suction heat exchanger or suitable use of suction line insulation Evaporator Superheat Once the refrigerated space is at its design temperature or close to design temp...

Page 29: ... can be much lower than the compressor nameplate values 6 To check the high pressure control setting it is necessary to build up the head pressure to the cut out point of the control This can be done by stopping the condenser fan s air cooled condensing units or pump and watching the pressure rise on a high pressure gauge to make sure the high pressure control is operating at the setting 7 Check t...

Page 30: ... Compressor starts but trips on overload protector 1 Improperly wired 2 Low line voltage 3 Loose wiring 4 Defective start or run capacitor 5 Defective start relay 6 Excessive suction or discharge pressure 7 Tight bearings or mechanical damage in compressor 8 Defective overload protector 9 Motor windings damaged 10 Overcharged system 11 Shortage of refrigerant 12 Suction or discharge pressure too h...

Page 31: ...ion pressure too high 1 Excessive load 2 Compressor internal valves broken 3 Incorrect unit selection undersized 4 Improper TXV bulb charge Suction pressure too low 1 Shortage of refrigerant 2 Evaporator dirty or iced up 3 Clogged liquid line filter drier 4 Clogged suction line filter or compressor suction strainers 5 Expansion valve malfunctioning 6 Condensing temperature too low 7 Improper TX va...

Page 32: ...mostat improper setting defective time clock 2 Electric heaters defective miswired low voltage 3 Not enough defrosts per day 4 Air defrost evaporator operating at too low of temperature require electric defrost 5 Defective miswired interlock at compressor contactor 6 Defective defrost contactor or coil Ice building up in drain pan 1 Improper slope in pan 2 Blocked drain line unheated not insulated...

Page 33: ...igeration service mechanic should carry out this semi annual inspection The main power supply must be disconnected and locked off to avoid accidental start up of the equipment 1 Check electrical components and tighten any loose connections 2 Check all wiring and electrical insulators 3 Check contactors to ensure proper operation and contact point for wear 4 Check that fan motors if applicable are ...

Page 34: ...t abuse negligence misuse riot fire flood or Acts of God b damages caused by operating the product in a corrosive atmosphere c damages caused by any unauthorized alteration or repair of the system affecting the product s reliability or performance d damages caused by improper matching or application of the product or the product s components e damages caused by failing to provide routine and prope...

Page 35: ... reached Refrigerant Type________Total Charge________System evacuation of times______Final micron _______ Ambient at start up ______o F Operating box temperature______o F Thermostat setting ______ o F Defrost settings ______ day Minutes fail safe ______ Condensing unit electrical rating Volts__________Phase__________Hz __________ Voltage at compressor terminals L1 L2___________ L2 L3 ____________ ...

Page 36: ...517 519 751 0444 FAX 519 753 1140 Due to National Refrigeration s policy of continuous product improvement we reserve the right to make changes without notice National Refrigeration Air Conditioning Canada Corp USA 985 WHEELER WAY LANGHORNE PA 19047 USA PHONE 1 888 KEEPUS1 OR 1 888 533 7871 ...

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