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Century Refrigeration IOM

1. CONDENSER FAN A CONDENSER FAN B Figure 11A FAN CYCLE WITH POSITIVE START Includes in addition to fan cycling controls a positive start control circuit to ensure that the compressor will start at low ambient All Century Refrigeration condensing units operate on a pumpdown cycle During low ambient sufficient low side pressure may not develop to start the compressor upon a call for cooling The positive start time relay momentarily bypasses the low pressure operating control to ensure compressor operation for 90 seconds At the end of this timed period the system pressure will be up to normal operating levels The timer contacts open returning compressor control to the low pressure operating control See Figures 11B and 11C for typical wiring of the positive start circuit 115V LO X TD 21 XX POS START TIMER R22 XX POS START RELAY 4 LLS 1 4 R20 XX S XX a gt R21 XX POS RELAY Figure 11C COMPRESSOR COMPARTMENTS CIRC 2a CIRC is circ OJOO 1 5 cr 5 1 1 JC JC CO CO amp G C C G9 DENOTES HEADER END FOR 3 OR 4 CIRCUIT UNITS REFERENCE THE WIRING DIAGRAM FOR FAN CONFIGURATION Figure 11D PRESSURE SWITCH SETTINGS Set for job site requiremen
2. 5 Kelvin Features 5 1 Pumpdown Feature The Kelvin II will initiate a pumpdown when Auxiliary Tem perature sensor terminals are shorted If desired this temper ature connection could be set up as a dry contact When a pumpdown is desired the contact should be closed The pump down will be ended when the short is removed provided that there are no sensor alarms 5 2 Manual Valve Position Feature The Kelvin II has the ability to manually control the valve To enable this manual control via the local or remote displays simply open the setpoint menu and edit the SPoS setpoint When the value is displayed for this setpoint the user is manu ally controlling the valve The valve position can be changed by rotating the knob clockwise or counterclockwise There is an inactivity timer of 60 minutes while in manual control The timer is reset each time the user moves the valve The manual control of the valve is ended when the user presses the knob to go back to displaying SPoS or a timeout has been reached 6 Kelvin Alarms The Kelvin II has 4 alarms The following table lists the possible alarms and the text that is seen on the controller The controller s alarm status can be viewed via MODBUS Network Master and local and remote displays Table 5 Alarms Alarm Text Meaning NoAL No Alarms active PSAL Pressure Sensor alarm TSAL Tout Sensor alarm Alarm Text Meaning HSAL High S
3. SMOOTH HARD LEVEL SURFACE Figure 2C Figure 2D Figure 2E UNIT COOLER CLEARANCE DRAWINGS A amp BOC SERIES RECOMMENDED PLAN VIEW PLAN VIEW Total height of evaporator coil surface Figure 3A ONE EVAPORATOR a a ee S S 3 minimum for heater removal H Total height of evaporator coil surface Figure 3B TWO EVAPORATORS FH SERIES RECOMMENDED PLAN VIEW 11 2 11 11 2H Total height of evaporator coil surface Figure 3C ONE EVAPORATOR ua jue 3 minimum for heater removal Total height of evaporator coil surface Figure 3D TWO EVAPORATORS IV RIGID MOUNTED COMPRESSOR Some products use rigid mounted compressors Check the compressor mounting bolts to ensure they have not vibrated loose during shipment See Figure 4A Figure 4A Washer Compressor Mounting Foot PIPING A B All piping must be in accordance with applicable local and state codes Refrigerant piping split systems should be designed and installed in accordance with recommended practices as outlined in ARI or ASHRAE piping guides Water piping chillers should be designed and installed to meet application requirements Provisions must be made to prevent freezing if design ambient temperatures di
4. 5 DEW POINT gt DEW POINT m 58 DEW POINT 5555 Figure 22A 22 SPORLAN PRESSURE TEMPERATURE CHART SPORLAM PRESSURE TEMPERATURE CHART Vr at SEA LEVEL Vr at SEA LEVEL TEMPERATURE F 124 M 134a 3 502 R 46 49 51 54 57 59 62 64 67 69 71 73 o M d db 26 28 30 32 34 38 38 40 41 43 45 46 48 49 51 52 54 55 57 59 61 62 63 65 58 67 68 69 L do I Inches mercury belew atmosphere APPROXIMATE PRESSURE CONTROL SETTINGS Prevyare Pounds Per Square lech gt amp amp G NO Meer Reach Thru Service On Seafood Mult Dec Fresh Meat Froren Glass Door T N _ Presusrte cortrol som gs assume 1 suction pressure loss tQuws ent 2 F 8ssRsSSESPREUS T 5 SRESSSESSRERSBSRRESKE CARRYING CAPACITY OF REFRIGERATION LINES Tors of Refrigeration 200 Feet Equivalent Bh g SRRSHSSESSKRERSESS 6 0075 5 2 Figure 23A Reincerares 22 1342 804A OPF cad semperatae 1 Refrigerare 717 ammon a sre based on ST ad temperature anc ZTF evaporator temperature Both soctea an mid Lee valves are basod o a pressure equivalent to change ie satiation temperare Fer addi
5. UID High pressure from the high side returns with the oil from the OIL SEPARATOR to the RESERVOIR In a period of time enough pressure could build up to adversely affect the float and needle assembly in the OIL LEVEL REGULATOR For protection a vent line is installed from the top of the OIL RESERVOIR a fitting is provided back to the low pressure suction line This line permits the pressure in the OIL RESERVOIR to be approximately the same as the pressure in the suction line and the crankcases of the compressors Oil in the OIL RESERVOIR feeds down through 3 8 inch and 1 4 inch OD tubing and keeps the OIL LEVEL REGULATORS supplied with oil A REGULATING VALVE is mounted on the suction line vent connection on top of the OIL RESERVOIR and will maintain 20 pounds pressure differential over the crankcase This positive pressure will keep the oil line to the OIL LEVEL REGULATORS filled and ready The valve on the top of the OIL RESERVOIR automatically receives oil from the OIL SEPARATOR open position To add oil to the OIL RESERVOIR manually close the valve and fill the OIL RESERVOIR through the 1 4 inch flare connection on the side of the valve Open valve after filling The valve on the bottom of the OIL RESERVOIR is the distribution valve to the OIL LEVEL REGULATORS open position To remove oil from the OIL RESERVOIR close the valve and use the 1 4 inch flare connection on the side of the valve to drain the oil out Op
6. ENTRY REFRIGERATION DIVISION RAE CORPORATION INSTALLATION OPERATION MANUAL Table of Contents Receiving and Inspection Equipment Rigging Equipment Mounting Compressor Mounting Unit Clearance Drawings Equipment Piping Equipment Wiring System Evacuation System Charging Start Up High Pressure Control Low Pressure Control Temperature Control Freeze Protection Control Thermostatic Expansion Valve Hot Gas Bypass Shut Down System Restart After Shut Down Warranty Oil Control System Head Pressure Control Air Cooled Condensing Units Low Ambient Operation Fan Cycle Fan Cycle with Positive Start Compressor Compartments Pressure Switch Settings A20 Flood Control B20 Flood Control Refrigerant Piping Hot Gas Bypass Control Effects of Unbalanced Voltage Trouble Shooting Chart Installation Operation and Maintenance for Unit Coolers Series A BOC amp PFE Series FH Series FV Sequence of Operation Defrost Cycle Electric Defrost Models Coil Recooling Cycle Electric Defrost Models Fan Delay Control Maintenance Condensing Units and Evaporators Maintenance Schedule Appendix A Temperature Pressure Chart Appendix B Approved Oil Types Appendix C Electronic Expansion Valves Appendix D Superheat Controller Appendix E Kelvin Controller Appendix F Maintenance Chart A C INSTALLATION OPERATION amp MAINTENANCE INSTRUCTIONS CENTURY REFRIGERATION AIR COOLED CONDEN
7. Pressing the UP button will increase the set point by 100 degrees Pressing the DOWN button will decrease the set point by 100 degrees Pressing the ENTER button will change the flashing digit from 100 s digit to the 10 s digit Pressing the UP button will increase the set point by 10 degrees Pressing the DOWN button will decrease the set point by 10 degrees Pressing the ENTER button will change the flashing digit from 10 s digit to the 175 digit Pressing the UP button will increase the set point by 1 degree Pressing the DOWN button will decrease the set point by 1 degree Pressing the ENTER button will change the flashing digit from 175 digit to the 100 s digit 31 Press and hold the UP button and ENTER button simultaneously for 5 sec onds to save the set point The digits will stop blinking MODE Press and hold the UP button and ENTER button simultaneously for 5 sec onds to enable the Maximum Operating suction Pressure set point to be changed The set point is displayed and the 100 s digit will blink Pressing the UP button will increase the set point by 100 PSI Pressing the DOWN button will decrease the set point by 100 PSI Pressing the ENTER button will change the flashing digit from 100 s digit to the 10 s digit Pressing the UP button will increase the set point by 10 PSI Pressing the DOWN button will decrease the set point by 10 PSI Pressing the ENTER button will change the flashing digit from
8. Series evaporator is designed to be mounted directly to ceiling or suspended by rods The top of the evaporator must be closed and sealed to the ceiling or suspended to provide sufficient clearance so it is readily accessible for cleaning Do not mount unit with less than 15 inches between coil face and wall Ample space should be allowed at each end to adjust expansion valve or service electrical controls if required Fan side of unit must be kept clear for proper air distribution NOTE Unit must be mounted level for proper condensate draining PIPING A PFE FH amp FV Series evaporators are designed for use with remote condensing units All connecting piping must be installed by qualified personnel in accordance with applicable local and national codes All piping traps risers and line sizes should be in accordance with good piping practices for proper operation The drain line piping located inside the refrigerated space should be kept as short as possible and pitched a minimum of 1 2 inch per foot If room is held below freezing drain line must be wrapped with heat tape and insulated Do not overlap heat tape unless otherwise instructed by manufacturer Do not trap drains immediately after exit from low temperature area WIRING The nameplate on the unit is marked with the current characteristics to be used for wiring the unit If control circuit voltage is differ
9. VI Power quality must industrial standards comply with SYSTEM EVACUATION A With refrigerant piping completed and leak tested equipment is ready to evacuate Do not use compressor to evacuate system A quality vacuum pump capable of a 350 micron vacuum is necessary for adequate and dependable system vacuum Moisture in a refrigeration system can cause corrosion expansion valve freeze up and oil sludge Attach vacuum pump to both high and low side of system through compressor service valves and evacuate to 350 microns all service valves hand valves and solenoids must be open to ensure complete evacuation throughout the system It is suggested that vacuum pump be run for a period of time after vacuum of 350 microns has been reached Service valves are back seating valves and must be in mid position to open to both sides of the system CAUTION Ensure all sectors of refrigeration system are evacuated VII SYSTEM CHARGING Less Flooded Head Pressure Control With system wired piped and evacuated unit is ready for refrigerant charging All charging lines and manifolds must be evacuated prior to admitting refrigerant into system to prevent contaminating system with noncondensibles See Appendix B for proper oil usage A VIII SYSTEM CHARGING Connect charging line to receiver outlet valve and admit liquid refrigerant into high side of system until flow stops due to pressure equalization
10. p o o p io in E a I3 2 a z e 5 lt m o AC use BUBBLE POINT values Temperature SUPERHEAT fe 68 PSIG at bulb Q FORM 2 04 COPYRIGHT 2004 BY SPORLAN VALVE COMPANY WASHINGTON MO 63099 Printed in U S A MAKE A SYSTEMATIC ANALYSIS based on the complaint and measurements taken Changing Parts Might Be The First Reaction BUT 1 May not be necessary and 2 Does not always solve the problem SUPERHEAT AND SUCTION PRESSURE symptoms can provide the real cause wou POSSIBLE CAUSES Moisture dirt wax Undersized valve High superheat adjustment Gas charge condensation Dead thermostatic element charge Wrong thermostatic charge Evaporator pressure drop no external equalizer External equalizer location Restricted or capped external equalizer Low rafrigerant charge Liquid line vapor Vertical lift b High friction loss c Long or small line d Plugged drier or strainer Low pressura drop across valve Same as 11 above b Undersized distributor nozzle or circuits c Low condensing temperature Zoo uonmrow Sucnoy fot Sunt POSSIBLE CAUSES 1 Oversized valve 2 TEV seat leak 3 Low superheat adjustment 4 Bulb installation a Poor thermal contact b Warm location 5 Wrong thermostatic charge 6 Bad Compressor low capacity 7 Moisture dirt wax 8 Incorrec
11. RAE Corp will repair or replace free of cost to Purchase User F O B RAE Corp factory any part or parts that in RAE Corp s judgment is defective Upon RAE Corp authorization the said part or parts should be returned to RAE Corp transportation prepaid by purchaser for inspection and judgment RAE Corp assumes no responsibility for the expense of labor or materials necessary to remove a defective part or install repaired or new parts The Express Limited Warranty 1 subject to the terms and conditions described herein EXTENDED EXPRESS LIMITED WARRANTY A four year Extended Express Limited Warranty Extended Warranty may be purchased at the time of purchase The warranty runs until an additional 4 years after expiration of the Express Limited Warranty The Extended Warranty must be purchased prior to the start up date RAE Corp at its sole discretion may authorize the purchase of an extended warranty after the unit is initially started based on approval of the provided start up documentation The Extended Warranty is limited to the original purchaser and may not be transferred to subsequent purchasers The Extended Warranty is subject to the terms and conditions described herein IIl GENERAL DISCLAIMERS AND IV LIMITATIONS ON WARRANTY RAE CORP DISCLAIMS AND MAKES NO WARRANTY OF MERCHANTABILITY AND NO WARRANTY OF FITNESS FOR ANY PARTICULAR PURPOSE NOR DOES IT MAKE ANY WARRANTY EXPRESS OR IMPLIED OF
12. amp Solid State Relay for Liquid Line Solenoid Kelvin II w Local Display 2 Kelvin Connections The Kelvin II has screw terminals on the each side of the controller The controller should be wired as follows and as shown in Figure 1 Figure 1 Black 5VDC Green Ground White Sense Pressure 9 T2 29 T3 Aux gt lt T3 Item Wire line Power 24VAC 1 24 VAC 2 SEI SER ESX N C Gray 4 Black Orange 5 valve White Yellow 6 Green Red 7 Red Black 8 Ground 13 RS 485 14 15 d ate Line 19 Liquid Line Solenoid Load 20 Auxiliary Temperature Sensor 27 Displayed menu item 3 28 Room Temperature Sensor 29 Displayed menu item CtP 30 Coil Out Temperature Sensor 31 Display option tout 32 P Transd Sense WHITE 33 Ground GREEN 34 Displayed menu item SucP 5 VDC BLACK 35 3 Kelvin Display Upon the first power up from Sporlan the Kelvin II will en ter the setup menu This menu allows the user to set some critical setpoint values seen in Table 1 before the controller will operate These critical values can be set via the local or remote displays MODBUS or Network Master Note Only the Valve Type and Refrigerant have to be set via MODBUS or Network Master for the controller to operate Once these
13. service department The Start Up Warranty Checklist must be 1 completed at the time of start up 2 dated and signed by the technician and 3 forwarded with the warranty registration card to the RAE Corp service department for warranty validation within 10 days after start up The Start Up Warranty Checklist and Warranty registration Card are included with each product sold I II EXPRESS LIMITED WARRANTY Subject to the terms limitations and disclaimer provisions set forth herein RAE Corp warrants to the original Purchaser that products manufactured by RAE Corp shall be free from defects in material and workmanship under normal use and service This warranty as to material and workmanship shall extend for a period of 1 year from original date of installation 18 months from the date of shipment from RAE Corp plant whichever occurs first This warranty 1s issued only to the original Purchaser 15 not transferable applies only to a unit installed within the United States of America its territories or possessions and Canada and 15 in lieu of all other warranties expressed or implied RAE Corp neither assumes nor authorizes any other person to issue or assume for RAE Corp any obligations or liabilities not herein stated It is agreed that in the event of breach of any of the express warranties described herein the liability of RAE Corp shall be limited to RAE Corp repairing or replacing the non conforming goods
14. 10 s digit to the 175 digit Pressing the UP button will increase the set point by 1 PSI Pressing the DOWN button will decrease the set point by 1 PSI Pressing the ENTER button will change the flashing digit from 175 digit to the 100 s digit Press and hold the UP button and ENTER button simultaneously for 5 sec onds to save the set point The digits will stop blinking CTSP MODE Press and hold the UP button and ENTER button simultaneously for 5 sec onds to enable the cut out suction pressure set point to be changed The set point is displayed and the 100 s digit will blink Pressing the UP button will increase the set point by 100 PSI Pressing the DOWN button will decrease the set point by 100 PSI Pressing the ENTER button will change the flashing digit from 100 s digit to the 10 s digit Pressing the UP button will increase the set point by 10 PSI Pressing the DOWN button will decrease the set point by 10 PSI Pressing the ENTER button will change the flashing digit from 10 s digit to the 175 digit Pressing the UP button will increase the set point by 1 PSI Pressing the DOWN button will decrease the set point by 1 PSI Pressing the ENTER button will change the flashing digit from 175 digit to the 100 s digit Press and hold the UP button and ENTER button simultaneously for 5 sec onds to save the set point The digits will stop blinking NOTE CTSP set point is used to help stop nuisance l
15. 51 1 to 65 6 C Read Input sen pin Registers ipe Temperature 0x04 Variables 51 1 to 65 6 C 4 Room 60 to 125 F Temperature p 51 1 to 65 6 C a 0 0 to 100 0 Open 5 Valve Capacity 0 0 to 100 0 60 to 125 F ster 51 1 to 65 6 C 7 Relay Status 0 Deenergized 1 Energized 5 The maximum value varies based on which refrigerant is selected 410A is 300 PSI r744 is 500 PSI and all others are 150 PSI 6 The maximum value varies based on which refrigerant is selected 410A is 300 PSI 744 is 500 PSI and all others are 150 PSI 36 Page4 MODBUS Function Mapped Data Data Map Range If Bit setthen alarm is active Bit 0 Suction Transducer Failure Bit 1 Tout Sensor Failure Bit 2 High Superheat Bit 3 Low Superheat If Bit set then mode is active Bit 1 Setup Mode Bit 2 Off Cycle Bit 3 Cooling Cycle Bit 4 Pump down Cycle Bit 5 Manual Valve Override Mode 0 Disabled Bit 0 Manual Valve 1 Enabled Enabled Flag The Manual Valve duration Bit is read only The max number of registers written at a time is 1 The limits can be seen above in the Read Holding Register definition 8 Alarm Status Read Input Registers 0x04 Process Variables 9 System Cycle Status Manual Valve Control Write Single Coil 0x05 Write Single Register 0x06 Setpoints Same as above
16. ANY NATURE WHATSOEVER WITH RESPECT TO PRODUCTS SOLD BY RAE CORP OR THE USE THEREOF EXCEPT AS IS SPECIFICALLY SET FORTH ON THE FACE HEREOF THIS WARRANTY WHICH IS GIVEN EXPRESSLY AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED CONSTITUTES THE ONLY WARRANTY MADE BY THE SELLER RAE CORP SHALL IN NO EVENT BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL CONSEQUENTIAL OR PENAL DAMAGES RAE CORP MAKES NO WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED TO CONSUMERS AS THAT TERM IS DEFINED IN SEC 101 OF PUBLIC LAW 93 637 THE MAGNUSON MOSS WARRANTY FEDERAL TRADE COMMISSION IMPROVEMENT ACT RAE CORP SHALL NOT BE LIABLE FOR ANY DAMAGE OR DELAYS OCCURRING IN TRANSIT FOR ANY DEFAULT OR DELAYS IN PERFORMANCE CAUSED BY ANY CONTINGENCY BEYOND ITS CONTROL INCLUDING WAR GOVERNMENT RESTRICTIONS OR RESTRAINTS STRIKES SHORT OR REDUCED SUPPLY OF RAW MATERIALS FIRE FLOOD OR OTHER ACTS OF GOD NOR FOR DAMAGE OR LOSS OF ANY PRODUCTS REFRIGERANT PROPERTY LOSS OF INCOME OR PROFIT DUE TO MALFUNCTIONING OF SAID UNIT ANY AND ALL CONTROVERSIES ISSUES CLAIMS OR DISPUTES RELATING TO THIS PURCHASE AND SALE TRANSACTION INCLUDING BUT NOT LIMITED TO ANY CONTROVERSIES ISSUES CLAIMS AND DISPUTES CONCERNING THE INTERPRETATION OR ENFORCEMENT OF ANY WARRANTY OR ANY LIMITATION OR OTHER ASPECT THEREOF SHALL BE GOVERNED BY OKLAHOMA LAW SPECIFIC LIMITATIONS TO WARRANTY PARTS ONLY This warranty is limited to repair or re
17. Before disassembling the valve be sure the refrigerant pressure in the system has been reduced to a safe level 0 psig 2 Disconnect the line voltage to the valve controller 3 Refer to the exploded view of the SEI SEH for the remaining instructions Using the appropriate wrenches or a vice to properly support the valve body remove the motor assem bly from the valve body by loosening the lock nut To pre vent permanent damage to the motor DO NOT attempt to disassemble the motor housing CAUTION Regardless of whether the valve is in the sys tem or in a vise care must be taken to prevent distorting the valve parts when tightening 4 The motor assembly may be removed for inspection and cleaning 5 If the motor fails to operate properly check the resistance of each motor phase Resistance between the black and white leads or between the red and green leads should be as shown in Table 1 Differences of more than 10 between phases indicate a defective motor Resistance between black and red or any lead and housing should be infinite any resistance reading will indicate a shorted winding and the motor will need to be replaced 6 If you have access to a SMA test instrument operation of the valve may be proven Connect the motor leads to the proper color coded connector on the SMA Set the rate to 200 PPS and toggle in the OPEN direction The white driver piston should retract into the driver guide adaptor After approxi m
18. CHART DATE COMPRESSOR DISCHARGE SUCTION EVAP SUPERHEAT TEMP PRESSURE TEMP PRESSURE SUPERHEAT DISCHARGE SUCTION EVAP NOTES TEMP PRESSURE TEMP PRESSURE SUPERHEAT COMPRESSOR DISCHARGE SUCTION EVAP NOTES SUPERHEAT TEMP PRESSURE TEMP PRESSURE SUPERHEAT ALL CENTURY REFRIGERATION EQUIPMENT MUST BE STARTED AND SERVICED BY QUALIFIED REFRIGERATION SERVICE PERSONNEL We reserve the right to change or revise specifications and product design in connection with any feature of our products Such changes do not entitle the buyer to corresponding changes improvements additions or replacement for equipment previously sold or shipped CENTURY REFRIGERA DIVISION RAE CORPORATION P O Box 1206 Pryor OK 74362 918 825 7222 Fax 800 264 5329 www century refrigeration com Bulletin C IOM 0911 P N QE0016A
19. Valve 2 connections on left block when used 1 Black 1 Green 1 Red Red Green W White B Black 2 Temp Sensor 2 TS1 Temp Sensor 1 24 VAC 40 VA Transformer PB1 2 Temperature Sensor Pressure Transducer Pumpdown Relay optional Evaporator SD 257 305 2005 Parker Hannifin Corporation mmm 33 APPENDIX KELVIN CONTROL SD 324 112009 Sporlan Kelvin II Refrigeration Controller User s Manual Description The Kelvin II is a standalone superheat controller The Kelvin II may be connected with a MODBUS master or a Network Master to give remote access to pressure and temperature readings in addition to viewing and editing the controller s setpoints The user can also take advantage of the easy to use local display or a Remote Display to accomplish the same tasks 1 Kelvin Configuration Specifications m Input Voltage 24 VAC 10 40 VA minimum to board with external transformer m Operating ambient temperature 40 F to 120 F m LED One Power LED m Communications 1 RS485 Port 1 USB port Not operational m 4 Digit 7 segment display m Inputs Optical Encoder Knob One Pressure Input Three Temperature inputs m Valve Control of all Sporlan Electric Expansion Valves EEV m 3 Solid State Relay for Liquid Line Solenoid Kelvin II w o Local Display m
20. damage Remove top and sides of crate Leave unit on skid in shipping position to do necessary electrical work and assemble expansion valve to coil The shipping skid may be used to support unit while installing The Series A BOC BALV amp PFE evaporators are designed to be mounted directly to ceiling or suspended by rods The top of the evaporator must be closed and sealed to the ceiling or suspended to provide sufficient clearance so it is readily accessible for cleaning Do not mount unit with less than 30 inches between coil face and wall Ample space should be allowed at each end to adjust expansion valve or service electrical controls if required Fan side of unit must be kept clear for proper air distribution After unit is securely fastened in position shipping legs may be removed from Series A units NOTE Unit must be mounted level for proper condensate draining SERIES FH MOUNTING The FH Series evaporators are shipped in the inverted position Check equipment for shipping damage If shipping damage has occurred a claim should be made with the transportation company The local Century representative should be advised of the nature of the damage Remove top and sides of crate or box Leave unit on skid in shipping position to do necessary electrical work and assemble expansion valve to coil Turn unit to mounting position and remove skid Take necessary precautions not to damage the drain pan The FH
21. in Figure 1 the controller is provided with hardware and input output connections for a number of user specified purposes See below One valve control One pressure input transducer supplied by Sporlan One digital input from external switches or relays Two temperature inputs Sporlan supplied surface or air sensors Optional battery backup for onboard time clock and fail safe valve closure Two digit LED readout One green LED indicator One red LED indicator Two push buttons for set point alarm cancellation etc RS 485 port Panel Display jack Please note that although RS485 port appears on the Superheat Board standard software does not support communication Custom propri etary software must be written for anything other than superheat con trol Please contact Sporlan for more information INSTALLATION When handling the boards electrostatic protection procedures should be followed The installer should be grounded through a ground strap If ground straps or other ESD protection is not available ONLY handle the board by its edges or by the battery holders DO NOT TOUCH ANY COMPONENTS ON THE BOARD EXCEPT THE BATTERY HOLDER AND RELAYS 1 The board should be mounted in a dry protected environment using the predrilled mounting holes in each corner Make sure none of the printed circuit paths or components are touching the metal panel or anything conductive See Figure 3 Connections are to be made to terminal bl
22. problem the purchaser must notify and contact the RAE Corp service department or the selling representative and provide the unit Model Number Serial Number complete problem description and estimate for repair If repairs are authorized by RAE Corp the RAE Corp service department may A Authorize the job site contractor to make the repairs B Select a different contractor to make the repairs C Dispatch a factory technician to make the repairs If field repairs are authorized a RAE Corp purchase order will be issued in the amount of the approved VI VII repair cost including parts material and labor and repairs can beperformed Upon completion ofrepairs the contractor is to send the invoice referencing the purchase order number to the service department with supporting documentation including a service report and parts material invoices No back charges or service billings will be accepted without prior authorization by the service department A DOA problem is a defect in material or workmanship that prevents a successful start up of the unit The problem will be discovered prior to or at the time of start up A DOA claim is not valid after the date of initial unit start up Shipping damage is not a DOA problem or a warranty issue COMPRESSOR REPLACEMENTS In the event a compressor fails RAE Corp service department must be notified by telephone or e mail within 24 hours of discovering the compressor failure fo
23. shown in Figure 12A during the normal cycle the valve will prevent flow from the discharge line into the receiver and allow free flow of liquid from the condenser As the receiver pressure drops the valve will modulate allowing discharge gas to enter the receiver and restrict liquid flow from the condenser The valve continues to modulate in this manner maintaining a constant receiver pressure Applicable to TSI CRI RSI B20 FLOOD CONTROL Includes in addition to flooding valve s a positive start control circuit to insure that the compressor will start at low ambient All standard Century Refrigeration condensing units operate on a pumpdown cycle During low ambient sufficient low side pressure may not develop to start the compressor upon a call for cooling The positive start time relay momentarily bypasses the low pressure operating control to ensure compressor operation for 90 seconds At the end of this timed period the system will be up to normal operating levels The timer contacts open returning compressor control to the low pressure operating control See Figures 11B and 11C for typical wiring SUBCOOLER COIL HOT GAS DISCHARGE LINE FROM COMPRESSOR AIR COOLED HEAD CONDENSER PRESSURE CONTROL SCH VALVE RECEIVER SUBCOOLER Figure 12A COIL 12 REFRIGERANT PIPING INTRODUCTION Good equipment performance depends to a large extent on correct refrigerant line sizing Friction losses oil r
24. tubes water cooled condenser clogged spray nozzles evaporative condenser dirty tube and fin surface air cooled condenser Non condensibles in system System overcharged with refrigerant Discharge shut off valve partially closed Condenser undersized High ambient conditions Faulty condenser temperature regulation Suction shut off valve partially closed Insufficient refrigerant in system Low suction pressure Compressor operating unloaded Condenser too large Low ambient conditions Excessive load Expansion valve overfeeding Compressor unloaders open Lack of refrigerant Evaporator dirty Clogged liquid line filter drier Clogged suction line or compressor suction gas strainers Expansion valve malfunctioning Condensing temperature too low Compressor will not unload Insufficient water flow Close switch Check electrical circuits and motor winding for shorts or grounds investigate for possible over loading replace fuse or reset breakers after fault is corrected Overloads are auto reset check unit closely when unit comes back on line Repair or replace contactor or coil Determine type and cause of shutdown and correct it before resetting safety switch None Wait until unit calls for cooling Repair or replace coil Check motor for opens short circuit or burnout Check all wire junctions tighten all terminal screws Check setting of expansion valve Relocate add or remove hangers Replace compressor Readjust
25. unit must be mounted level with the top of the hangers Unit is a blow through type with air entering at the bottom and discharging out both sides Ample space at each end to adjust expansion valve or service electrical controls is required For proper air distribution both sides and bottom of unit must be kept clear 17 SEQUENCE OF OPERATION NORMAL REFRIGERATION CYCLE 1 Power is supplied to unit terminals designated on wiring diagram 2 The defrost heaters are off electric defrost units Compressor operates in accordance with the demands of the refrigeration system temperature 4 The unit cooler fan s operates continually DEFROST CYCLE ELECTRIC DEFROST MODELS 1 Defrosting of the evaporator is started automatically by the timer at predetermined times Typical settings ofthe timer would be four defrost periods per 24 hours 2 Timer breaks circuit to evaporator fan motors and compressor thereby shutting them off At the same time current is supplied to the heater circuit 3 The properly positioned heaters warm up the evaporator coil above 32 F causing the frost to melt 4 Frost on the evaporator is melted and defrost water drips into the heated drain pan and flows down the drain 5 When the frost is melted the evaporator coil continues to warm up to ensure a frost free coil COIL RECOOLING CYCLE ELECTRIC DEFROST MODELS 1 When the coil warms up to approximately 55 F the defrost termination the
26. values are entered the Kelvin II will then begin its control If the setup menu is displayed on the local or remote displays N C N C N C XX YN A 15 RS 485 B gt lt D RS485 RS 485 A Ground ZN N C N C N C N C SER SEI SEH Red Zw X ZN X3 ZN ESX Black Red Yellow ISS Green White Black N C X3 ZN Orange AN Gray X3 ZN 1S ZN INN 34 Page2 and the user sets these values via MODBUS then the Kelvin II will automatically leave the setup menu Table 1 Setup Menu Displayed Menu Item Description Selections StEP Valve Type 1596 3192 2500 6384 400 r22 134A 402A 404A rEFr Refrigerant 407A 407C 410A 417A r507 422d r744 245F PtYP Pressure Sensor gAUg AbSL un T Temperature Units FAHR CELS un P Pressure Units PSI BAR After setup the Kelvin II defaults to showing the Superheat value The user can then turn the knob to view the other pro cess values of their system The screen will alternate between the process values identity and value alternating every 3 sec onds For ease of use the value that is displayed for a process value may come in the form of text to eliminate the need of looking up the meaning The menu text and meanings for process values are described in Tab
27. water regulating valve investigate ways to increase water supply Clean Purge the non condensibles Remove excess refrigerant Open valve Check condenser rating tables against the operation Check condenser rating tables against the operation Check condenser control operation Open valve Check for leaks repair and add charge See corrective steps for low suction pressure section See corrective steps for compressor will not load or unload section Check condenser rating tables against the operation Check condenser rating tables against the operation Reduce load or add additional equipment Check remote bulb regulate superheat See corrective steps for compressor will not load or unload section Check for leaks repair and add charge Clean chemically Replace cartridge s Clean strainers Check and reset for proper superheat replace if necessary Check means for regulating condensing temperature See corrective steps for compressor will not load or unload section Adjust GPM 15 Compressor will not load or unload Compressor loading unloading intervals too short Little or no oil pressure Compressor loses oil Motor overload relays or circuit breakers open Compressor thermal protector switch open Freeze protection opens a b C d a b a b d e f g h 1 j k a b 4 b c d e f g a b c a b c TROUBL
28. 0 1596 SEI 30 KS SEI 30 0621 016 75 10 3193 SEI 50 KS SEI 50 0123 002 75 x 10 6386 SEH I 100 and 175 KS SEH100 175 None required 75 10 6386 28 Page 4 SEI 50 Motor and Adapter Assembly SEI 0 5 to SEI 30 Motor Assembly 123 002 Gasket included in motor kit e 621 016 Gasket e SEH Motor and Adapter Assembly Motor kits supplied with 24 lead wire with butt splice connectors Sporlan Division S POR LAN Parker Hannifin Corporation 206 Lange Drive Washington MO 63090 636 239 1111 FAX 636 239 9130 PRINTED IN U S A A www sporlan com SD 243 108 29 APPENDIX D SUPERHEAT CONTROLLER SUPERHEAT CONTROLLER Installation and Servicing Instructions The Superheat Controller will control one Sporlan Electric Expansion Valve by means of pressure temperature control Pressure temperature superheat control for one of four common refrigerants may be selected Controllers can be ordered configured for R 22 R 134a R 404A R 407C and R 507 The refrigerant type can be changed in the field by use of the optional Panel Display Onboard readouts show actual superheat super heat set point and valve position Two push buttons are provided on the board to change the superheat set point as well as open close or position the valve Proportional and Integral set points are also included to change responsiveness of the valve As illustrated
29. 1 744 0 03 12 245F 2 Delay On Relay 010 60 seconds 3 Delay Off Relay 0to 60 seconds 4 Delay Steps 0 to 100 Open 5 Cut outSuction 010 1509 PSI 0 to 1034 Pressure Bar 0 to 10 34 Bar MODBUS Function Mapped Data Data Map Page 3 6 Operation 010 150 PSI 0 to 1034 Pressure Bar 0 to 10 34 Bar 60 to 125 F 7 Temperature to 516 C 51 1 to 51 6 C 60 to 124 F 8 511 to 511 C 51 1 to 51 1 C 9 Valve Maximum 20 to 100 96 10 Supermarket E Mode 0 OFF 1 ON 11 P 100 12 1 100 13 0 100 0 1596 1 3192 14 Valve 2 2500 3 6384 4 400 15 Manual Valve Read Holding Position 010 100 Open Register Setpoints 0 MODBUS 0 03 16 Network Type 1 Network Master 17 Unit Address 110255 18 Pressure Units 0 PSI 1 BAR 19 Temperature o FAHR 1 CELS Units 20 Pressure Sensor 0 GauG 1 ABSL Type 5 to 5 F CU UR Offset 94 to 34 Bar 0 34 to 0 34 Bar 22 Suction 5 to 5 F Temperature 27 to 27 C Calibration Offset 2 7 to 2 7 C 23 Room 5 to 5 F Temperature 27 to 27 C Calibration Offset 2 7 to 2 7 C 24 Auxiliary 5 to 5 F Temperature 27 to 27 C Calibration Offset 2 7 to 2 7 C 0 to 165 F 0 Superheat 0 to 916 C 0 to 91 6 C 0 to 150 PSI 0 to 1034 Bar 0 to 10 34 Bar 60 to 150 F EE P
30. E SHOOTING CHART PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS Defective capacity control Unloader mechanism defective Faulty thermostat stage or broken capillary tube Stages not set for application Erratic water thermostat Insufficient water flow Clogged suction oil strainer Excessive liquid in crankcase Oil pressure gauge defective Low oil pressure safety defective Worn out pump Oil pump reversing gear stuck in wrong position Worn bearings Low oil level Loose fitting on oil lines Pump housing gasket leaks Flooding of refrigerant into crankcase switch Lack of refrigerant Velocity in risers too low Oil trapped in line Excessive compression ring blow by Low voltage load conditions Defective or grounded wiring in motor or power circuits Loose power wiring High condensing temperature Power line fault causing unbalanced voltage High ambient temperature around the overload relay Failure of second starter to pull in on part winding start system during high Operating beyond design conditions Discharge valve partially shut Blown valve plate gasket Thermostat set too low Low water flow Low suction pressure a Replace capacity control b Replace unloader mechanism c Replace thermostat stage or capillary tube d Reset thermostat setting to fit application a Replace water thermostat b Adjust GPM a Clean suction oil strainer b Check crankcase heater reset expansion valve for high
31. FC R401a R 12 M H HCFC R401b R 12 L M HCFC R402a L M HCFC R402b L M 1 Service only HCFC R408a R 502 L M AB amp MIN POE 32 amp MIN POE 32 PX10 y M H R 22 L M R 22 L M H HFC R422a d R 22 L M EE Service only Suva HP8 POE 32 amp MIN POE 32 POE 32 amp MIN POE 32 Service on AB amp MIN POE 32 amp MIN POE 32 FX56 Suva HP62 Forane FX70 Genetron AZ50 Suva 9000 KLEA 66 ZP amp ZB KCP Copeland Scroll models only POE 32 POE 32 L POE 32 Discus supermarket racks only Discus supermarket racks only ISCEON MO99 ZC Copeland Scroll models only ZO Copeland Scroll models only Mineral Oil Mineral oils are interchangeable for top off purposes Alkyl Benzene Polyolester Contact Application Engineer for oil details Polyalkylene Glycol Oil Minimum 50 POE Minimum 50 Alkyl Benzene Freezer applications Low temperature application Medium temperature application High temperature application 25 APPENDIX ELECTRONIC SPORLAN MECHATRONICS SEI 0 5 11 STEP MOTOR EXPANSION VALVES OPERATION The SEI and SEH series valves are step motor operated electric expansion valves Step motors are designed to provide discrete segments of angular motion or rotation in response to an elec tronically generated signal The advantages of step motors in valve applications are high resolution repeatability and reli abi
32. R 22 134A for refrigerant R 134a 407C for refrigerant R 407C and 404A for refrigerant R 404A and R507 for refrigerant R 507 Note not all controllers have both R 507 and R 407C LRGE SMAL MEDM LRGE if the EEV used is an SEI 50 or larger SMAL if the EEV used is smaller than an SEI 25 and all SER MEDM if the EEV used is a SEI 25 SHSP Superheat set point 0 to 16 F Default is 10 F MOPD Maximum operating suction pressure set point 0 to 153 PSI Default is 153 PSI CTSP suction pressure set point 0 to 153 PSI CALP Calibrate pressure transducer for AC circuit 1 CALT Calibrate temperature sensor for AC circuit 1 PROP Proportional gain set point Number of steps per degree that super heat is above or below the superheat set point 5 to 255 steps per degree Default is 45 for LRGE setting 22 for MEDM setting and 11 for SMAL setting INTG Integral set point Number of seconds the controller waits to update the reference valve position 1 to 120 seconds Default is 10 sec onds DLCN Time to open and keep valve open DLST steps when the pump down signal is removed 0 to 120 seconds Default is 0 DLST Number of steps to open valve when the pumpdown signal is removed 0 to 6386 Default is 0 SPORLAN Figure 2 CONTROLLER MENUS ENTER Will toggle display between one of the displays described above and the numeric value read for that particular display UP Will scroll through the men
33. R 4IOAIZ R 407CIN R 1342J Prassura Pounds Per Square Inch Gauge Bold Figures TEMPERATURE REFRIGERANT SPORLAN CODE 4 RAICAIZ H 1244 4 4 3855858552 58530212385 m Q u g Q 8285925252852555525 j 2 gt a io gt gt ma oo io io 2324 S88 ouo 110 0 112 2 114 4 116 7 118 9 121 2 5923892882588 33238333333332838832235355555553 3822 0255052100155555 55528559 41 123 6 125 9 128 3 130 7 133 2 135 6 138 2 140 7 143 3 156 6 170 7 185 7 201 5 218 2 235 9 254 6 274 3 295 0 316 9 339 9 364 1 389 6 416 4 444 5 474 0 505 0 537 6 571 7 607 6 645 2 z o 715 37 0 73 0 745 76 1 77 6 792 80 8 824 84 1 92 6 101 6 111 3 121 5 132 2 143 7 155 7 168 4 181 9 196 0 210 8 2264 242 8 260 0 278 1 297 0 3167 337 4 359 1 3817 405 4 yyy sJ 333828338 00590 gt mn 106 0 116 2 127 0 138 5 150 6 163 5 177 0 191 3 206 4 222 3 239 0 256 5 274 9 294 2 314 5 335 7 357 8 380 9 405 1 430 3 456 6 ERGSRFSSEI LALSS ESBS Q OWN WOH N OONN 4 OoOo 2255 LI PI 213 5 229 2 245 6 262 8 281 0 To determine sabcowling for refri Figure 21A Figure 21B Temperature here reads gt gt BS to
34. RAE Corp will not be responsible for shipping damage or for parts lost in transit or for any claims of concealed damage It is the responsibility of the receiving party to thoroughly inspect the equipment upon delivery for damage refrigerant leaks or dry nitrogen pressure loss in transit and to verify that any loose parts have been included in the shipment The bill of lading will indicate if parts are shipped loose in the unit If shipping damage has occurred or loose parts are missing the receiving party must resolve the issue through the claim process with the company responsible for transporting the equipment REFRIGERANT Refrigerant is excluded from the warranty RAE Corp at its sole discretion may preauthorize the inclusion of refrigerant No payment will be made for any leak that occurs at a threaded mechanical joint defined as flare joints pipe thread joints or rotolock joints It is the responsibility of the Contractor to check these joints upon arrival of the equipment or prior to charging the system Any claim for refrigerant reimbursement must be pre authorized by RAE Corp s service department and a purchase order issued Any claims received without a RAE Corp purchase order will be disallowed Should an obligation be approved by RAE Corp RAE Corp specifically reserves the right to provide the refrigerant or replace the refrigerant in a like quantity to the user DOA WARRANTY PROBLEMS In the event of a DOA
35. SERS CONDENSING UNITS amp PACKAGED CHILLERS I RECEIVING AND INSPECTION Immediately upon receiving shipment equipment should be inspected for evidence of any damage received in transit Suggestion photograph unit for documentation If shipping damage has occurred a claim should be made with the transportation company and the local Century Refrigeration representative should be advised of the nature of the damage Equipment should be inspected for compliance with original order acknowledgment equipment model numbers voltages etc System should be checked for positive pressure RIGGING A Equipment is equipped with lifting eyes or sling points These should be used to prevent structural damage Equipment should be lifted in a near level condition to prevent undue stress on structural members Figure 1A MOUNTING A B Equipment should be mounted on a smooth hard level surface Mounting surface should be rigid and provision should be made to prevent noise transmission structural to surrounding areas Air cooled equipment should not be installed under low structural overhangs which can cause condenser air recirculation or restriction Adequate area approx 1 unit width must be provided around equipment for unrestricted air flow and service Two units side by side should have a minimum of 1 1 2 unit width between them See Figures 2A through 2E and Figures 3A through 3D Care sho
36. STALLATION INSTRUCTIONS and to establish the zero open position The controller then keeps track of the valve s position for normal operation During this initialization phase a light clicking sound may be heard which will serve as proof of the valve s operation and closure valves are tight seating and uniquely characterized by pin and port combinations for exceptional control of refrigerant flow The seats require no service and are not replaceable The motor may be easily replaced without removing the valve body from the system INSTALLATION The SE series valves are electronically controlled Step Motor Expansion Valves and are installed before the distributor and evaporator Just as one would install a Thermostatic Expansion Valve The valves are directional and the inlet is clearly marked Location should be planned to provide serviceability and to allow controller installation within the maximum cable length of forty feet The valve may be installed in the refriger ated space and may be mounted in any position except with the motor housing below the liquid line Cable routing should avoid any sharp edges or other sources of potential physical damage such as defrost heaters and fan blades For neatness and pro tection the cable may be fastened to the suction or liquid lines with nylon wire ties The flare version is supplied with brass fittings and should be installed using properly made flare conn
37. ary On unloading type compressors it 1s necessary that dual suction risers be used whenever the suction line rises vertically It is also necessary to provide suction line traps if this vertical rise exceeds 10 to 12 feet A suction line trap 1s nothing more than an 5 bend which will trap oil and form a seal when the compressor is running in the unloaded condition All horizontal lines are to slope approximately 1 inch downward per 10 feet in the direction of flow DISCHARGE HOT GAS LINE Excessive discharge line pressure drops cause higher compressor discharge pressure reducing volumetric efficiency and increasing power consumption Discharge lines are usually sized for a pressure drop approximately equivalent to 1 F which normally will result in adequate hot gas velocity for oil return Discharge lines are sized for a higher velocity than are suction lines and therefore are less critical LIQUID LINE The liquid line from the receiver to the expansion valve 1 usually sized for a pressure drop approximately equivalent to 1 F The liquid line from the condenser to the receiver is usually sized for a liquid velocity of 100 FPM to allow vapor generated in the receiver to return to the condenser Excessive line pressure drops may cause some of the liquid to flash into vapor before entering the expansion valve reducing system capacity Liquid lines are not as critical as suction lines as oil will remain in solution w
38. ately 30 seconds the driver should be fully retracted and a light clicking or ratcheting sound may be heard this is normal to the valves and proves operation of the motor If the SMA is toggled in the CLOSE position after approxi mately 30 seconds the white polyester driver piston should disengage the lead screw and can be removed Inspect the driver piston for damage To replace the driver toggle the SMA to the OPEN position and carefully engage the driver to the lead screw CAUTION Whenever the motor is powered while not in place on the valve the driver must be fully retracted into the guide before the valve is reassembled Failure to do this will permanently damage the valve 7 If the motor responds to step 6 above the valve body itself should be checked for obstruction Check for contaminants in the port or strainer if used 8 If the valve body and strainer are clear and the motor oper ates as in step 6 above the valve is considered operational and the problem lies in the controller or power supply The manufacturer of these components should be contacted for further assistance MOTOR ADAPTOR ASSEMBLY REPLACEMENT SER 30 50 amp SEH Only If the motor is found to be defective in the above the entire motor assembly must be replaced 1 Remove all power from the valve and controller 2 Cut the existing valve cable at a convenient point at the dri est or most protected location 3 Splice
39. between high side and drum pressure Backseat outlet valve and disconnect charging line Energize equipment and check sight glasses If sight glass is not clear continue to admit liquid into liquid side of system until liquid line sight glass clears indicating a fully charged system it may be necessary to defeat low pressure control on initial start to prevent nuisance trip until low side pressure is above cut out point of control With Flooded Head Pressure Control A B Initial charging is the same as outlined in Section VII adjustable flood control valves need to be adjusted according to proper refrigerant type and application Set hot gas regulating valves and unloaders if supplied to load compressors to 10096 while charging Add additional charge through liquid side liquid as outlined in Section VII Item B IX START UP This is a continuation of system charging and must be performed before equipment can be left operating and unattended This will involve the checking and adjusting of all safety and operating controls pressure and temperature controls need to be adjusted according to proper refrigerant type and application and it is desirable to confirm that settings are correct and controls function properly Do not attempt to function safety controls without some means of stopping compressor in event of extreme high or low pressure conditions that could damage the equipment If controls fail t
40. charge pressure See Piping Illustration Figures 10A and 10B J PRV Servi ie Direct Acting Water rA Regulating Valve oe From Main Condenser Pump Figure 10A 3 Way Water 2 Regulating Valve a PRV Service Valve Bypass Balancing Valves or Cocks Condenser Main Condenser Water Supply E From Pump Figure 10B 10 AIR COOLED CONDENSING UNITS LOW AMBIENT OPERATION Refrigeration systems utilizing air cooled condensing units operating at ambient temperatures below design will require some means to stabilize high side pressure In order to maintain sufficient high side pressure the condenser capacity must be reduced in response to decreasing high side pressure This may be accomplished by either reducing the air flow across the condenser or reducing effective condenser surface by flooding the condenser with liquid refrigerant Century Refrigeration offers both means of control factory installed and preset FAN CYCLE Controls head pressure by cycling condenser fan s in response to a decrease in high side pressure This system is normally satisfactory during mild conditions Each step of control is accomplished by a pilot duty pressure control s fused fan motor contactor s completely installed wired and factory calibrated See Figure 11A for typical fan cycle wiring FUSE CONTACTOR C7 FAN MOTOR A
41. ctate All piping must be cleaned and flushed before opening the system to the chiller All mechanical connections rotolock connections flare fitting packing glands etc should be checked for tightness before pressure testing and evacuation of the system When piping is completed a thorough leak test should be performed before evacuation start up Do not exceed 150 psig dry nitrogen CO test pressure on system for leak checking WIRING A All local and state codes must be strictly adhered to and good electrical practices should be followed to achieve the best installation possible Power wiring to equipment must be adequately sized for minimum ampacity as shown on unit nameplate A disconnect should be located adjacent to unit for both safety and servicing purposes Equipment wiring diagram should be examined and thoroughly understood before field wiring connections are made Power supply should be checked to be certain that supply voltage agrees with equipment nameplate Serious damage to compressors and motors can occur if improper voltage is applied All unit wiring terminals should be checked for tightness before power is applied to the equipment When wiring is completed motors should be checked for proper rotation in accordance with function All equipment has been factory wired to operate with the same rotation If rotation is found to be incorrect reverse two of the three leads on main incoming power G
42. ds to enable the integral set point to be changed The set point is displayed and the 100 s digit will blink Pressing the UP button will increase the set point by 100 seconds Pressing the DOWN button will decrease the set point by 100 seconds Pressing the ENTER button will change the flashing digit from 100 s digit to the 10 s digit Pressing the UP button will increase the set point by 10 seconds Pressing the DOWN button will decrease the set point by 10 seconds Pressing the ENTER button will change the flashing digit from 10 s digit to the 175 digit Pressing the UP button will increase the set point by 1 second Pressing the DOWN button will decrease the set point by 1 second Pressing the ENTER button will change the flashing digit from 175 digit to the 100 s digit Press and hold the UP button and ENTER button simultaneously for 5 sec onds to save the set point The digits will stop blinking CHANGING REFRIGERANTS Press and hold the UP button and ENTER button simultaneously for 5 sec onds to enable the controller to change to another type of refrigerant 4 digits will start to blink Pressing the UP button or the DOWN button will change the display to other refrigerants 32 Page 4 SD 257 When the display shows the desired refrigerant press and hold the UP button and ENTER button simultaneously for 5 seconds The controller will save and use the selected refrigerant s table for saturated temperature The di
43. ections A drop of refrigerant oil should be used to prevent galling of the threads when tightening Inlet strainers that are removable for clean ing are supplied as part of the flare connection 26 Page 2 The sweat version has copper connections and any solder or brazing alloy may be used to install the valve There is no need to disassemble the valve for installation however the torch flame should be directed away from the motor housing and cable Care must be taken to assure that the cable is not dam aged either directly from the flame or indirectly from contact with hot piping The valve is shipped in the open position to prevent heat being conducted into the motor but it is strongly suggested that the valve body be wrapped with a wet cloth dur ing the soldering operation Inlet strainers are supplied option ally with ODF style valves and if used should be oriented in the proper direction as shown on the strainer package The valve should be completely installed and reassembled before connecting to the controller and applying power The wiring is color coded and the controller manufacturer should be con sulted for the proper attachment to the controller FIELD SERVICING INSTRUCTIONS SEI amp SEH Only e s oA The following steps are necessary for the proper disassem bly inspection cleaning and reassembly of all valves except SER 1 5 6 11 and 20 whether in or out of the refrigerant piping 1
44. en factory set to maintain desired leaving fluid temperature The temperature control can be field adjusted To calculate the proper set point add the specified leaving fluid temperature and the design temperature difference of return to supply TD Temperature control adjustment should be made as follows EXAMPLE FOR REFERENCE ONLY This is for 10096 H O fluid application Design conditions 10 F TD 55 F entering return fluid 45 F leaving supply fluid and 5 psi fluid side pressure drop at rated flow 1 Check proper flow through cooler Pressure gauges at the entering and leaving nozzles should be used Adjust flow by balancing valves or throttling valves on discharge side of the cooler to corresponding pressure drop 2 The system fluid temperature should be at 60 F or above to simulate a pull down for proper start up and check out 3 Adjust temperature control dial to 55 F This will produce 45 F leaving fluid temperature at designed flow rate 4 Observe the pressures as the return fluid temperature continues to fal the compressor s and or unloader s are staged by the temperature control The suction temperature at the compressor should not fall below approximately 32 F during all stages of compressor s operation The compressor s will eventually be staged off by the temperature control When this occurs the return fluid temperature must rise to the cut in set point of the temperature contro
45. en valve after draining NEW SYSTEM START UP NOTE On system start up of a new parallel system oil should be added to the OIL RESERVOIR to the upper sight glass portion NOT ABOVE IT It is commonly accepted that in a new refrigeration system some oil will be absorbed by the refrigerant as the system becomes balanced out After two hours of operation the OIL RESERVOIR if necessary should again be filled to the upper sight glass After two days by which time the entire refrigeration system should be balanced out check oil again Then the OIL RESERVOIR must be observed on each service call No oil should be added again until the oil level falls below the lower sight glass port EXISTING SYSTEM START UP When installing this OIL CONTROL SYSTEM on a parallel system that has been in operation for some time the amount of oil should be added cautiously With the efficiency of the new OIL SEPARATOR the oil return could likely be sufficient to fill the OIL RESERVOIR Fill the OIL RESERVOIR to the lower sight glass port only Observe for one day After the second day if the oil level has not risen to the upper sight glass add oil If the oil level has risen above the upper sight glass port remove the excess oil from the OIL RESERVOIR NOTE Only approved oil types and viscosities should be added to a system See Appendix B HEAD PRESSURE CONTROL Since air cooled systems are normally subjected to varying load requirem
46. ent from nameplate voltage a separate decal is located by the electrical box marked Control Circuit Voltage All internal wiring is completed at the factory A wiring diagram is furnished with each unit showing field connections and internal wiring Access to internal connections may be made by removing end panel opposite expansion valve end of unit All power must be turned off before removing any access panels All wiring should be done in strict accordance with local and national electrical codes AN WARNING The unit cabinet must be grounded SERIES FV MOUNTING The FV Series evaporators are shipped in the inverted position Check equipment for shipping damage If shipping damage has occurred a claim should be made with the transportation company The local Century representative should be advised of the nature of the damage Remove top and sides of crate Leave unit on shipping skid to do necessary electrical work and assemble expansion valve to coil Remove bolts from skid turn unit to mounting position and place back on skid taking necessary precautions not to damage unit The FV Series evaporator is designed to be mounted directly to the ceiling or suspended from rods The top of the evaporator must be closed and sealed to the ceiling or suspended to provide sufficient clearance so it is readily accessible for cleaning Unit is pitched with the hangers for proper condensate drainage therefore
47. ents and fluctuating ambient temperatures it is difficult to design units to operate satisfactorily and with optimum efficiencies without some means of control of discharge pressures In order to achieve proper system operation it is necessary that adequate discharge pressures be maintained to ensure that the expansion valve will feed correctly to prevent low suction conditions The expansion valve is sized to meet capacity requirements at a pressure differential between discharge pressure and design suction pressure If discharge pressure is allowed to drop below a point which will not maintain this design differential the suction will also drop due to starving of the evaporator When this happens nuisance tripping of low pressure control or low evaporator temperature will occur Normal system design will allow satisfactory operation with discharge pressure down to approximately 95 F On air cooled equipment a number of methods can be used to maintain this minimum discharge pressure The most common and suitable for applications where ambient temperatures are not extreme is fan cycling When closer control or extreme ambient differentials are encountered condenser flooding and fan cycling are preferred methods On water cooled equipment discharge pressures are much easier to control and the most common would be by the use of condenser water regulating valves directly sensing dis
48. er superheat check liquid line solenoid valve operation c Repair or replace keep valve closed except when taking reading d Replace safety switch e Replace pump f Reverse direction of compressor rotation g Replace compressor h Addoil i Check and tighten system j Replace gasket k Adjust thermal expansion valve a Check for leaks and repair add refrigerant b Check riser sizes c Check pitch of lines and refrigerant velocities d Replace compressor a Check supply voltage for excessive line drop b Replace compressor motor c Check all connections and tighten d See corrective steps for high discharge pressure section e Check supply voltage notify power company do not start until fault is corrected f Provide ventilation to reduce heat g Repair or replace starter or time delay mechanism a Add facilities so that conditions are within allowable limits b Open valve c Replace gasket a Reset to 40 F or above b Adjust GPM c See low suction pressure section 16 INSTALLATION OPERATION amp MAINTENANCE FOR UNIT COOLERS SERIES A BOC BALV amp PFE MOUNTING The amp PFE Series are shipped in the upright position Check equipment for shipping damage If shipping damage has occurred a claim should be made with the transportation company The local Century representative should be advised of the nature of the
49. essing the DOWN button will decrease the CAL number by 0 2 PSI or degree Pressing the ENTER button will change the flashing digit from 0 1 s digit to the 10 s digit Press and hold the UP button and ENTER button simultaneously for 5 sec onds to save the CAL number The digits will stop blinking PROP MODE Press and hold the UP button and ENTER button simultaneously for 5 sec onds to enable the proportional gain set point to be changed The set point is displayed and the 100 s digit will blink Pressing the UP button will increase the set point by 100 steps per degree Pressing the DOWN button will decrease the set point by 100 steps per degree Pressing the ENTER button will change the flashing digit from 100 s digit to the 10 s digit Pressing the UP button will increase the set point by 10 steps per degree Pressing the DOWN button will decrease the set point by 10 steps per degree Pressing the ENTER button will change the flashing digit from 10 s digit to the 175 digit Pressing the UP button will increase the set point by 1 step per degree Pressing the DOWN button will decrease the set point by 1 step per degree Pressing the ENTER button will change the flashing digit from 175 digit to the 100 s digit Press and hold the UP button and ENTER button simultaneously for 5 sec onds to save the set point The digits will stop blinking INTG MODE Press and hold the UP button and ENTER button simultaneously for 5 sec on
50. eturn and piping cost must all be considered in determining the best sizes for discharge liquid and suction It must be understood that this brief treatise is a guide only for approximating typical line sizing Detailed data in ASHRAE or ARI Data Books should be consulted for actual conditions found in specific applications Century Refrigeration does not warrant the adequacy of this data for any particular job as field and installation conditions are not within our control GENERAL It is necessary to determine 1 circuit capacity 2 equivalent length of lines and 3 line configuration Lines must be sized to ensure oil return to the compressor and to keep frictional line losses to a minimum A Circuit Capacity This will be the actual compressor capacity at operating conditions It will be necessary to provide a double suction riser for any circuit having a vertical lift from the evaporator and variable refrigerant flow compressor unloading or hot gas bypass back to the suction side of the compressor B Equivalent Length of Lines This will be the actual length plus allowance for valves fittings etc On normal air conditioning installations it can be assumed that the equivalent length will be approximately two times the actual length C Line Configuration This requires the actual piping layout to determine valves elbows risers etc This is also the time to determine if oil traps and dual risers are necess
51. from 17 digit to the 100 digit Press and hold UP button and ENTER button simultaneously for 5 seconds to save the set point The digits will stop blinking DLST MODE Press and hold UP button and ENTER button simultaneously for 5 seconds to enable this set point to be changed The number of steps to open will be displayed and the 1000 s digit will blink Pressing the UP button will increase the set point by 1000 steps Pressing the DOWN button will decrease the set point by 1000 steps Pressing the ENTER button will change the flashing digit from 1000 s digit to the 100 s digit Pressing the UP button will increase the set point by 100 steps Pressing the DOWN button will decrease the set point by 100 steps Pressing the ENTER button will change the flashing digit from 100 s digit to the 10 s digit Pressing the UP button will increase the set point by 10 steps Pressing the DOWN button will decrease the set point by 10 steps Pressing the ENTER button will change the flashing digit from 10 s digit to the 1 digit Pressing the UP button will increase the set point by 1 step Pressing the DOWN button will decrease the set point by 1 step Pressing the ENTER button will change the flashing digit from 175 digit to the 1000 s digit Press and hold UP button and ENTER button simultaneously for 5 seconds to save the set point The digits will stop blinking Figure 3 25 typical SUPERHEAT CONTROLLER WIRING SCHEMATIC
52. gits will stop blinking CHANGING VALVE TYPES LRGE SMAL or MEDM Press and hold the UP button and ENTER button simultaneously for 5 sec onds to enable the controller to change to the other type of valves 4 dig its will start to blink Pressing either the UP button or the DOWN button will change the display between the different valve types Press and hold the UP button and ENTER button together for 5 seconds to save the selection The digits will stop blink ing Pressing the UP button and the DOWN button simultaneously will toggle the display between AC circuit 1 and AC circuit 2 DLCN MODE Press and hold th UP button and ENTER button simultaneously for 5 seconds to enable the DLCN set point to be changed The set point is displayed and the 100 s digit will blink Pressing the UP button will increase the set point by 100 seconds Pressing the DOWN button will decrease the set point by 100 seconds Pressing the ENTER button will change the flashing digit from 100 s digit to the 10 s digit Pressing the UP button will increase the set point by 10 seconds Pressing the DOWN button will decrease the set point by 10 seconds Pressing the ENTER button will change the flashing digit from 10 s digit to the 175 digit Pressing the UP button will increase the set point by 1 second Pressing the DOWN button will decrease the set point by 1 second Pressing the ENTER button will change the flashing digit
53. ifferential adjustment pin clockwise until the fan motors start This 1 the final setting of the differential adjustment pin 18 MAINTENANCE FAN MOTORS The fan motors are lifetime lubricated for trouble free operation If fan motors should require servicing the fan guard must be removed If a motor does not operate or it cycles on thermal overload the problem could be that the coil is blocked with ice DEFROST HEATERS ELECTRIC DEFROST MODELS Heaters are maintenance free If evaporator fails to defrost properly check for defective heater Series A amp BOC defrost heaters can be replaced by removing side panel for access Series FH amp FV defrost heaters can be replaced by removing the drain pan for access MAINTENANCE CONDENSING UNITS AND EVAPORATORS Under normal usage and conditions it is recommended that the following list of preventive maintenance steps should be examined quarterly 1 Inspect electrical wiring components and connections Verify that all connections are tight and complete as required Water Treatment Water Chillers and Water Cooled Units The water should be tested by a local testing agency and their recommendations adhered to Check contactors and relays for proper operation replace if points are worn Check fan motors tighten motor mount bolts nuts and fan set screws Visually inspect the equipment for oil stains leaks on interconnecting piping so
54. ith liquid refrigerant SUCTION LINE Reduced suction pressure due to excessive suction line pressure drop will reduce the density of the suction gas in a reciprocating fixed displacement compressor This means less weight of refrigerant pumped resulting in reduced compressor capacity It is a generally accepted practice to size suction lines for a pressure drop approximately equivalent to 2 F to obtain the optimum compromise between piping cost oil return and friction loss GAS BYPASS CONTROL On many air conditioning and refrigeration systems it is desirable to limit the minimum evaporator pressure during low load conditions This may be necessary for a number of reasons some of which are A Capacity modulation beyond maximum steps of control offered by compressor design Prevent compressor short cycling Freeze protection Humidity control E OE Oil Return at low load One method of controlling minimum evaporator pressure is by metering a portion of the discharge gas into the low side of the system thereby increasing the suction pressure STANDARD HOT GAS BYPASS Hot gas bypass into the inlet side of evaporator This arrangement requires piping the hot gas bypass line into a point between the expansion valve and evaporator inlet The hot gas regulator valve is equalized to the suction line and will meter hot gas into the evaporator maintaining the suction pressure preset on the regulator The expansion val
55. l the dial setting before the compressor s is staged on again WARNING Always consult equipment submittals for the proper design conditions before adjusting temperature control FREEZE PROTECTION CONTROL Water Chillers Control is a pressure sensing manual reset safety control It responds to suction pressure and prevents circuit operation should suction pressure fall below control set point for a period in excess of 120 seconds For straight water systems the control is factory set at 32 F The fixed time delay 120 seconds allows circuit to stabilize on start up and normal pump down operation For systems other than straight water systems refer to electrical diagram for freeze control settings THERMOSTATIC EXPANSION VALVE Adjust superheat setting to job requirements To determine superheat correctly 1 Measure the temperature of the suction line at the point the bulb is clamped 2 Obtain the suction pressure that exists in the suction line at the bulb location by either of the following methods a If the valve is externally equalized a gauge in the external equalizer line will indicate the desired pressure directly and accurately OR b Read the gauge pressure at the suction valve of the compressor To the pressure add the estimated pressure drop through the suction line between bulb location and compressor suction valve The sum of the gauge reading and the estimated pressure drop will eq
56. lder joints condenser and evaporator coil finned area Check and tighten all flare connections Check hand valve packing for leaks and tighten if needed Check condenser coil surface and clean if needed Visually check liquid line sight glass for flash gas Glass must be clear with no bubbles If glass is not clear check system for leaks Check the liquid line sight glass moisture indicator and replace the liquid line drier if there is any indication of moisture Compressor Oil Level The compressor oil level should be checked periodically If oil is needed allow equipment to pump down to approximately 5 psig crankcase pressure Place disconnect in off position and close suction and discharge service valves Add clean dry oil then open discharge and suction service valves Restart compressor and check oil level after two hours of operation Loss of oil would suggest that a leak may be in system Carefully inspect entire system for evidence of oil and repair as necessary Check for unusual noise and look for compressor pulsation or line vibration MAINTENANCE ENTIRE UNIT It is recommended that the unit be inspected occasionally for dirt accumulation on coil inlet Grease and soil should be removed from the fan and guard Check all safety and operating controls for proper settings and operation Settings are listed on wiring diagram Check evaporator coil surface and clean if needed Check that all defrost c
57. le 2 The user may also view edit the setpoints by pressing the knob and holding it down for 5 seconds The user is then prompted for a password to verify his credentials The knob should be rotated up to 111 for the password If the password is cor rect the user may change the setpoints to the value he desires in order to obtain optimum system performance The menu text and meanings for setpoint values are described in Table 3 Setpoints are saved to the controller when the user leaves the Setpoint menu by pressing the knob when ESC is shown The setpoint menu has a timeout of 60 seconds for inactiv ity When this timeout is reached the controller goes back to showing the process values and does not save any setpoints that might have been changed If the user is in the Manual Valve Position setpoint then this timeout length is 60 minutes As long as the controller does not time out the 60 minutes Setpoints are saved to the controller when the user leaves the Setpoint menu by pressing the knob when ESC is shown AII process values and setpoints are accessible through the local and remote displays Table 2 Process Value Menus Displayed Menu Item Description Range SuPH Superheat 0 to 165 F 0 to 91 6 C SucP Suction Pressure 0 150 PSI 0 to 10 34 Bar tSAt Saturation Temperature 60 to 150 F 51 1 to 65 6 C tout Suction Temperature 60 to 150 F 51 1 to 65 6 C CtP System Temperatu
58. lity with low hysteresis Feedback loops are not required simplifying controller design and circuitry step motor used in the SEI and valves is 12 volt DC two phase bi polar permanent magnet rotor type Motor rota tion is converted to linear motion by the use of a lead screw and threaded drive coupling Forward motion of the motor extends the drive coupling and pin which moves the valve to the closed position Backward rotation of the motor retracts the drive coupling and pin modulating the valve in the opening direction Full forward or backward travel while the valve is assembled is limited by the valve seat in the closed position or an upper Stop in the open direction slight clicking sound may be heard at either of these two positions and does no harm to the valve or drive mechanism The valve will operate only when connected to a properly designed controller The controller must supply the necessary square wave step signal at 12 volts DC and 200 PPS for the valve to control properly Various Sporlan and third party controllers are available for use with the valve Questions of suitability of a specific controller should be directed to Sporlan Division of Parker Attn Product Manager Mechatronics Products Control algorithms for the valve include a initializa tion sequence that will first over drive the valve in the closing direction This is to assure that the valve is completely shut SEI SEH IN
59. lve Page 3 4 Push the open close toggle in either direction at the 1 step rate will alternate the phases energized 5 Observe the terminal indicator lights At rates other than 1 indicator lights will flash quickly Pushing the open close toggle in either direction at the 1 step rate will alternate the phases energized The following sequence of indicator lights will light Black amp Red Red amp White Red amp White Red amp Black White amp Green Black amp Green Green amp Black Green amp White 6 Check that the power indicator light is lit if not replace the batteries 7 If the terminal indicator lights do not light one or both motor phases are open and the motor must be replaced 8 If the motor can be powered smoothly in both directions the motor assembly is functional and the controller must be tested or replaced SPECIFICATIONS _ Power input Two 9 volt Alkaline batteries Power output 10 Watts intermittent Step rate Selectable 1 50 100 200 steps per second Drive type Bipolar Connector Binding post with banana plug socket 12 Volt DC Bipolar Step Motor An accessory pigtail item number 958112 is available at extra charge to allow the SMA 12 to be directly connected to all Sporlan Packard Weather Pack equipped valves Table 1 Valve Model Motor Kit Gasket Number of Steps SEI 5 to 11 Not available 0621 016 75 x 1
60. n exception response The Kelvin II will allow a full and partial block read of the Input and Holding registers and Coils 4 1 Scaling In order to preserve precision scaling was implemented when using Bar or Celsius for units PSI and Fahrenheit units are both in whole numbers and have no scaling The tables of the MODBUS memory map below reflect this implementation The Celsius values that are transferred via MODBUS are 10X For example if Celsius is chosen for the temperature units then 45 C is transferred for the Superheat The actual Super heat is 4 5 C If the user desired to change a setpoint they should keep this in mind when they enter a value The Bar values that are transferred via MODBUS are 100X For example if Bar is chosen for the pressure units then 1034 Bar is transferred for the Maximum Operating Pressure The actual Maximum Operating Pressure is 10 34 Bar If the user desired to change a setpoint they should keep this in mind when they enter a value 4 2 MODBUS Memory Map Table 4 Memory Map MODBUS Function Data Code Bit Manual Valve Read Coils Milan Enabled Flag 0 Disabled 0x01 alve Bit Manual Valve 1 Enabled Control Duration Enabled Flag 0 Superheat 0 to 45 0 to 250 C Setpoint 0 0 to 25 0 0 22 1 134 2 402 3 404A 4 407 5 407 I 1 Refrigerant 6 410 7 417 Read Holding 8 422 9 422d Register Setpoints 10 507 1
61. n the new motor adap tor Carefully seat the adaptor on the valve body or engage and tighten the lock nut if used Lock nuts should be torqued to approximately 45 ft Ibs One eighth turn more than hand tight is sufficient to achieve a leak proof seal on knife edge joints Locktite 242 should be applied to the threads on the SEI 0 5 through SEI 30 The motor kit should be attached to the valve then tightened using a strap wrench ensuring the o ring is fully compressed 3 Pressurize the system and check for leaks 4 Reapply power to the controller Each controller manufac turer has a slightly different initialization scheme and the proper procedure must be followed Since during service valve position as calculated by the controller will be lost the controller should be initialized at least twice In some instances cycling power to the controller will accomplish this However the controller literature or the manufacturer should be consulted SMA 12 VDC BIPOLAR STEP MOTOR ACTUATOR e 1 Connect any Sporlan step motor valve to the SMA 12 by matching wire color to terminal color Any 12 VDC bipo lar step motor may be tested with the SMA 12 Phase one leads should be connected to the black and white terminals Phase two leads should be connected to the red and green terminals 2 Select a step rate with the selector knob 3 Push the open close toggle switch in the CLOSE direction to extend the driver or close the va
62. nkcase heater by measuring amp draw Verify proper compressor oil levels Inspect the liquid line sight glass for a dry and good quality refrigerant Inspect refrigerant piping for signs of leaks like oil stains QUARTERLY Check condenser performance Ambient Temperature vs Condensing Temperature Check evaporator performance Saturated Suction Temperature vs Leaving Fluid Temperature Check liquid temp entering metering device and evaporator superheat YEARLY e Leak check refrigerant circuits 20 APPENDIX A PRESSURE CHARTS Vecuum Inches of Mercury Italic Figures TEMPERATURE Hi E TEMPERATURE PRESSURE CHART at sea level REFRIGERANT SPORLAN CODE 410 2 8 407 CUN 1 W 220v sszsa888 21 1 20 0 18 9 17 8 17 2 16 7 16 1 15 6 15 0 14 4 13 9 13 3 12 8 12 2 11 7 DON ONENONDS 33 8 0 9 N S ON DN N 16 0 13 7 11 1 0 010900109 5 e iiou nii Lo aot NN N32 ND INL ao oe amp 28 0 0 0 0 5 5 o OcOOobnoOohu oonouunouooNde QutN oos 2 N TEMPERATURE REFRIGERANT SPORLAN T C
63. nt set point Use PB2 to decrement set point Press and hold PB1 and PB2 simultaneously for 5 seconds to lock in set point and return to actual superheat 5 To manually change valve position Scroll to valve position reading with PB2 Press and hold and PB2 simultaneously for 8 seconds Green LED will flash rapidly Increment valve open percentage by pressing 1 for 1 second Decrement valve open percentage by pressing PB2 for 1 second Valve will maintain manual open position for 1 hour or until 1 and PB2 are pressed simultaneously and held for 5 seconds REMOTE PANEL DISPLAY A remote panel display is available that will allow access to all the parame ters of the controller The Remote Panel Display can be used as a set point tool in production a diagnostic tool in the field or as a permanent readout device for the controller A five foot cable is included Plug the remote display into the telephone jack 79 on the controller The fol lowing is a list of readings available SUPH POSN Superheat read by controller for AC circuit 1 Number of steps valve is open 0 6386 for AC circuit 1 PRES Pressure read by the transducer 0 153 psi gauge for AC cir cuit 1 TEMP Temperature read by the temperature sensor 50 to 103 F for AC circuit 1 TSAT Saturated temperature for AC circuit 1 ACON PMDN ACON when in normal operation PMDN when in pumpdown R22 134A 407C 404A 507 R22 for refrigerant
64. o function at set points determine cause and correct WARNING Jumpering any safety control other than for tesing purposes is dangerous to personnel and equipment and nullifies equipment warranty CAUTION Energize crankcase heaters and allow a minimum of 24 hours operation before a compressor start A HIGH PRESSURE CONTROL Connect a gauge to the compressor discharge service valve Stop condenser air flow by stopping fans on air cooled equipment or restricting water flow on water cooled equipment Control should open immediately when discharge pressure reaches control set point WARNING Stop operation if cut out exceeds set point B LOW PRESSURE PUMP DOWN CONTROL Connect a gauge to the compressor suction service valve Throttle receiver outlet valve to lower suction pressure at compressor Compressor should pump down and be de energized when suction pressure reaches cut out setting of control Open receiver outlet valve and observe rise in pressure at compressor suction connection Compressor should be energized when pressure reaches cut in setting of control C Approved Oil Types see Appendix D TEMPERATURE CONTROL Water Chillers This control is the main unit operating thermostat As standard the control cycles both the compressor and the unloader s in response to return fluid temperature The sensing bulb is located in a well on the return fluid nozzle This control has be
65. ock shown Controllers are configured for pressure temperature superheat control Connect temperature sensor to TS2 The sensor is not polarized For suction lines 7 8 or less the sensor should be mounted to the copper suction line after the evaporator using the furnished clamps For larger lines or steel piping a well sensor P N 952795 available from Sporlan should be installed 5 The pressure transducer should be mounted on the top of the suction line near the temperature sensor location Transducer connections to the board are as follows The power wire is red and is connected to the 1 terminal PWN The signal wire is green and is connected to the 1S terminal The ground wire is black and is connected the 1 terminal SD 257 March 2005 Holders for Optional Fail Safe Batteries 24 Volt AC 50 60 Hz 40 VA Input One 5 ampere 240 VAC NC NO relay One Digital Input One Pressure Input Ponts One Valve Input a Two Temperature gt Inputs E Two Set Point Pushbuttons Two Digit Display Green Status LED Figure 1 6 The valve leads are connected to the terminals labeled Valve 1 The black lead is connected to terminal labeled B of Valve 1 The white lead is connected to terminal labeled W of Valve 1 The green lead is connected to terminal labeled G of Valve 1 The red lead is connected to terminal labeled R of Valve 1 7 is a digital input used as a pumpdown te
66. ontrols and defrost heaters are functioning properly check amperage Clean the drain pan with warm soapy water or mild acid and check for proper drainage Check drain line heater if equipped for proper operation The heater power should be on continuously The drain line should be insulated to prevent heat loss Check the evaporator for proper defrosting The frost amount and pattern can vary greatly depending on the temperature of the room the type of product being stored how often new product is brought in and the percentage of time the door to the room is open It may be necessary to periodically change the number of defrost cycles or adjust the duration of defrost and fan delay Check the refrigeration cycle take suction discharge and new oil pressure readings Check pressure drop across filters and driers replace as required Verify that superheat conforms to specifications In addition to quarterly maintenance checks the following should be examined annually 1 Take an oil sample and check for high concentrations of acid or moisture Change oil and driers if test results are not normal A test kit may be purchased at most wholesalers Take amperage readings on compressors motors and defrost circuits Amperage is listed on the wiring diagram MAINTENANCE SCHEDULE MONTHLY Visually inspect for physical damage of the unit Check for adequate free area for service and operation Inspect the condense
67. ow suction pressure trips of the compressor If the suction pressure goes below CTSP and the superheat is above the superheat set point the valve will keep opening until the suction pressure is above CTSP or the superheat is below its set point The controller will start controlling superheat from this new valve position If the superheat is below its set point and the suction pressure is below this set point the controller will change CTSP to 12 PSI below current suction pressure If power is lost the original saved set point is used again When in CALP or CALT the numeric display shows the PSI or degrees to be either added or subtracted from that particular sensor depending if the reading is negative or positive Press and hold the UP button and ENTER button for 5 seconds to enable the sensor to be calibrated The CAL number is displayed and the 10 s digit will blink Pressing the UP button will increase the CAL number by 10 PSI or degrees Pressing the DOWN button will decrease the CAL number by 10 PSI or degrees SD 257 Page 3 Pressing the ENTER button will change the flashing digit from 10 s digit to the 1 s digit Pressing the UP button will increase the CAL number by 1 PSI or degree Pressing the DOWN button will decrease the CAL number by 1 PSI or degree Pressing the ENTER button will change the flashing digit from 175 digit to the 0 173 digit Pressing the UP button will increase the CAL number by 0 2 PSI or degree Pr
68. own on the local or remote displays for 5 seconds when power is first applied If using a local display the display will show FrSt while the factory reset is being performed and then automatically connect to the local controller If using a remote display the display will show FrSt and switch to a menu that allows the selection of the controller to reset To perform a factory reset select the controller with the appropriate CAdr value The display should show while the reset is being performed When finished perform ing factory resets turn the knob counterclockwise until ESC is shown on the display Pressing the button while ESC is shown on the display exits the factory reset menu and should automatically connect to a controller on the display network Table 6 Replacement Parts Part Number Description 952560 Kelvin Il without display 952561 Kelvin Il with local display 952562 Kelvin Remote panel display 952662 Temperature Sensor Assembly 952795 Well Sensor Kit 953091 Pressure Transducer 150 psig with cable 952995 Pressure Transducer 150 psia with cable 952740 Pressure Transducer 300 psig with cable for R 410A applications only 952504 Pressure Transducer 500 psig with cable for R 477 applications only Sporlan Division Parker Hannifin Corporation 206 Lange Drive Washington MO 63090 USA 112009 SD 324 37 APPENDIX MAINTENANCE
69. placement of defective parts only and does not include labor RAE Corp at its sole discretion may preauthorize the inclusion of labor expense No claim for labor charges will be allowed without a written preauthorization from RAE Corp s service department Prior written approval from RAE Corp is required in the event RAE Corp has authorized the customer to purchase replacement parts for any warranted parts and such replacement parts must be obtained directly from a manufacturer s representative or RAE Corp Claims for replacement parts obtained locally will be disallowed unless accompanied by a RAE Corp purchase order for such replacement parts Orders for warranty replacement parts will be shipped ground transportation prepaid using the most appropriate transportation method Any premium transportation service will be at the cost of the requestor EXPORT EQUIPMENT Equipment exported outside the United States will be covered under the same parts only warranty as non exported equipment provided that all warranty transactions must take place within the territorial United States Parts covered under warranty must be paid for in advance of any parts shipment The customer will be reimbursed upon return of the warranty part and after the part has been inspected and determined defective All exporting paperwork and shipping costs including crating will be the responsibility of the party ordering the part INITIAL INSPECTION
70. r fans and motors for damage and proper operation Ensure that the condenser fans turn freely and have proper rotation Look for excessive or unusual vibration of fan blades or sheet metal panels when in operation take corrective action as required Check all fan blades for signs of stress or wear Check all fan set screws and tighten if needed nspect all motors check volts amps and if required rotation Inspect the condenser coil for cleanliness Check the air passages through the finned surface Look for signs of corrosion on fins cabinet copper tubing and solder joints Check drain pan to ensure that drain 1 clear of debris obstructions or ice buildup and is free draining Inspect electrical wiring and components Look for wear kinks bare areas and discoloration of wiring Replace any wiring found to be damaged Verify that all electrical and ground connections are secure and tighten if necessary Check operation and calibration of all timers relays pressure controls and safety controls Check and record use Appendix F suction and discharge pressures Check and record use Appendix F compressor superheat and condenser sub cooling Look for abnormal accumulation of ice patterns and adjust defrost cycles accordingly Compare actual defrost heater amp draw against unit data plate Check condensate drain line heat tape for proper operation Verify operation of cra
71. r the compressor to be covered by warranty The customer must provide RAE Corp service department with the Unit Model Number Unit Serial Number Compressor Model Number and Compressor Serial Number before any replacement will be provided RAE Corp reserves the right to determine the source of the replacement compressor The failed compressor body core must be returned to the re manufacturer or the wholesale house as determined by RAE Corp service department before the compressor will be replaced pursuant to this warranty If the core is not returned the customer will be invoiced for the compressor and the warranty will not be extended Although RAE Corp will replace the compressor RAE Corp is not responsible for any labor travel crane or tax expense Moreover RAE Corp assumes no responsibility for additional parts refrigerant or other expenses incurred in making the unit operational NOTICE TO RAE CORPORATION To contact and or notify RAE Corp service department the following contact information must be used Address P O Box 1206 Pryor OK 74362 Office Phone 918 825 7222 After Hours Emergency Cell Phone 918 633 2838 Fax 918 825 6366 Email customerservice rae corp com OIL CONTROL SYSTEM PARALLEL SERIES UNITS VIBRATION ABSORBER E OIL REG VIBRATION ABSORBER Figure 9A The Parallel Series condensing units and chillers are designed having multiple compressors on a common circui
72. re 60 to 150 F 51 1 to 65 6 C PoSn Valve Position 0 to 100 Open 3 Auxiliary Temperature 60 to 150 F 51 1 to 65 6 rELA Solenoid Status dEng Eng StAt System Cycle Status Current cycle and manual valve position state ALS Alarm Status noAL or all active alarms Table 3 Setpoint Menu Description Derai P Setting Setpoints ESC Escape and save _ A settings SHSP Superheat Setpoint 0 45 F 0102590 8 r22 134A 402A 2 404A 407A 407C rEFr Refrigerant 410A 417A r507 404A 422d r744 245F d On Delay 60 seconds 0 dOFF Delay Off 60 seconds 0 d St Delay Percent 100 percent 0 of Valve Cut out Suction 1509 PSI eer Pressure 0 to 10 39 Bar 0 Maximum Operating 0 to 1509 PSI H oP Pressure 010 10 39 Bar 150 a 60 to 125 F C in Cut in Temperature 51 1 to 51 6 59 60 to 124 F Cout Cut out Temperature 51 1 to 51 1 C 60 HiCP Max Valve Capacity 2010 100 100 SUPS Supermarket Setting OFF ON OFF Proportional es Coefficient 0161100 Integral Coefficient 0to 100 25 Derivative Coefficient 00100 2 1596 3192 2500 StEP Valve Type 6384 400 1596 Manual Valve 0 Present SPoS Position 010 100 Open Position Network Type nbUS MODBUS nEt MODBUS or or ProP Network nbUS Network Master Master MODBUS Network Aor Master Address 288 un P P
73. red by storing refrigerant charge in the receiver or condenser A Front seat the receiver outlet valve Set thermostat at a setting below system temperature to ensure that liquid line solenoid is energized Defeat the low pressure control and allow unit to pump down to a suction pressure of approximately 5 psig It may be necessary to repeat pump down as some refrigerant will remain in oil and will slowly boil off When suction pressure holds at 5 psig front seat suction service valve Lock disconnect in off position B units with water cooled condensers special precautions must be taken to completely drain the vessels to prevent freezing if ambient should be below 32 F C Inspect system for possible worn or faulty components and repair if required I SYSTEM RESTART AFTER SHUT DOWN A Thorough leak test should be performed B cCoil s should be checked for dirt accumulation or obstruction and cleaned if necessary CAUTION Energize crankcase heaters and allow a minimum of 24 hours operation before a compressor start C Install gauges start system and check for correct refrigerant charge and proper system operation and balance RAE CORPORATION EXPRESS LIMITED AND EXTENDED EXPRESS LIMITED WARRANTY The Express Limited Warranty and Extended Express Limited Warranty are only available to customers if the Start Up Warranty Checklist and Warranty Registration Card is completed and returned to RAE Corp
74. ressure Units PSI BAR PSI un T Temperature Units CELS FAHR Pressure Sensor PtYP Type AbSL gAUg gAUg Pressure Sensor 5to 5 PSI calibration value 0 34 to 0 34 Bar d Tout calibration 5 0 5 F 2 7 to 0 value 2 7 C CLt2 Ctp calibration value 10 59 F 2 7 to 0 2 7 C S 3 calibration value 310 95 2710 2 1796 2 0 1 CAdr Controller Display 4 gg for local Address 2 display 4 Kelvin II MODBUS The Kelvin II can communicate with a MODBUS master The Kelvin II will transfer process values and setpoints via MODBUS CD Setpoints can only be viewed and edited when the proper password is entered 2 The Auxiliary Temperature sensor input has a special Pumpdown feature If a short or switch closure is placed across these terminals the valve will shut for pumpdown The full details of this feature are described in Section 5 3 The Alarm Status process value is described in Section 6 The maximum value varies based on which refrigerant is selected R 410A is 300 PSI R 744 is 500 PSI and all others are 150 PSI The Kelvin II only supports the RTU transmission mode The serial settings are as follows m 9600 baud m 8 data bits m stop bit m Even parity The Kelvin II supports the Read Input Registers Read Holding Register Write Single Register Read Multiple Coils and Write Single Coil function codes Any other re quest will result in a
75. rminal A short or closed contact from an external relay will close the valve for pumpdown When the relay opens or the short is removed the valve will return to normal operation 8 Power is connected to the terminal marked 24VAC Power require ments are 24 volts AC at 40 VA For protection from electrical tran sients connect one MOV varistor between one leg of the input voltage of the 24 VAC transformer and earth ground Connect a second MOV varistor between the other leg of the input voltage of the 24 VAC trans former to earth ground Two MOV varistors are included with the con troller NOTE Sensor and valve wires may be extended for remote applications Waterproof butt connectors should be used and the cable should be at least 16 gauge Care must be taken to ensure a good splice and that the individual wires are correctly identified For remote installation where the sensors are located more than 25 ft from the controller contact Sporlan for guidance OPERATION 1 When first powered up the numeric display will show actual super heat 2 The small Green LED will be lit 30 Page 2 SD 257 3 PB2 will toggle the readings as follows and the small Green LED will be steady or flash Actual Superheat LED constant Valve percentage open LED slow flash 4 To change superheat set point Make sure the display shows the superheat Press and hold PB1 and PB2 for 8 seconds LED will flash rapidly Use to increme
76. rmostat closes This allows current to flow to the solenoid in the timer which is then energized and trips the timer switch back to the normal refrigeration cycle The fan delay portion of this thermostat is now open 2 The compressor starts its normal refrigeration cycle 3 The evaporator fan motor s remains off because fan delay thermostat is open This will prevent warm air and moisture from being blown into the refrigerated space 4 When evaporator coil temperature reaches approximately 30 the fan delay thermostat closes this allows current to flow to the fan motor s and the unit returns to its normal refrigeration cycle FAN DELAY CONTROL STANDARD ON amp FV SERIES UNITS This control is a single pole double throw switch The red lead wire is the common wire The black wire is wired in series with the fan motors The brown wire is wired in series with the defrost termination solenoid in the timer The brown and red contacts are closed when the temperature 1s above 55 F while the black and red contacts are open The black and red contacts are closed below 30 F and the brown and red contacts are open When the refrigeration system is first started up the room ambient and the coil temperature are normally above 55 F the fan delay thermostat 1 open and the fan remains off The fan motors will come on when the temperature is pulled below 30 F The number of times the fan will cycle is dependent on
77. t When using this method it is necessary that oil equalization between each compressor be maintained to prevent loss of oil from either compressor The method of crankcase equalization used by Century Refrigeration consists of an oil separator mounted in the common discharge line an oil reservoir and an oil regulating valve mounted on each compressor crankcase In addition a check valve having a 20 pound differential 1s installed in the vent line from the reservoir to the suction line With any or all compressors running the oil separator will collect the oil leaving the compressor s and return this oil to the reservoir The reservoir will be at a pressure approximately 20 pounds above the compressor crankcase pressure Oil from the reservoir is piped to the oil regulators which are mounted on the compressor crankcase As crankcase oil level drops the regulator will admit oil to the crankcase to maintain a proper operating level HOW IT WORKS A reserve of oil is necessary for the operation of the OIL CONTROL SYSTEM The OIL RESERVOIR is the holding vessel for this stand by oil It has two sight glass ports on the shell to observe the oil level inside the vessel Oil is fed into the OIL RESERVOIR by the OIL SEPARATOR Un COMPRESSOR CHECK VIBRATION VALVE MUFFLER ABSORBER OIL VALVE VIBRATION ABSORBER MUFFLER HV DISCHARGE T es Bil SUE CHECK VALVE OIL RESERVOIR STRAINER
78. the initial ambient temperature size of cabinet and the refrigeration equipment This type of fan delay control cannot be adjusted FAN DELAY CONTROL PENN TYPE A19ZBC STANDARD ON amp SERIES UNITS OPTIONAL ON amp SERIES UNITS This control is a single pole double throw switch refer to the sequence of operation This control has an adjustable defrost period It is obtained by turning the black knob clockwise to increase the temperature setting required to terminate defrost The defrost duration increases only as long as necessary to remove frost and ice from the refrigeration unit cooler coil DEFROST TERMINATION AND FAN DELAY DEFROST 4 DOES NOT CONTROL BOX TEMPERTURE Figure 18A SETTING DEFROST TERMINATION AND FAN DELAY A With a normal frost accumulation on the coil 1 Turn the knob clockwise to the end of the calibrated dial 2 Mowve the fan start differential adjustment pin 3 Trip the timer to defrost cycle 4 Observe when the coil has completely defrosted and the condensate has completely drained Then turn the knob counterclockwise until the refrigeration cycle resumes the fans will remain idle with fan delay hookup This is the final setting of the indicator knob B Fan start differential adjustment pin on thermostat 1 For fan delay adjustment observe when the coil begins to frost 2 Holding the indicator knob firmly in place move the d
79. the new cable to the old cable using the waterproof butt splices COLOR CODING ON THE INDIVIDUAL WIRES MUST BE MATCHED FAILURE TO DO SO WILL RENDER THE VALVE INOPERATIVE AND MAY DAMAGE EITHER THE VALVE OR CONTROLLER 4 Waterproof the splice with shrink tube or electrical tape suitable for use in cold and damp environments Care should be taken to prevent the splice from lying in the case pan or other wet location VALVE REPLACEMENT e The entire valve may be replaced if desired The old valve may be unbrazed or cut out of the piping If cut out use a tubing or pipe cutter and not a saw When installing the new valve any convenient brazing alloy and method may be used The valve need not be disassembled but the body and motor assembly should be wrapped with a wet cloth to prevent damage Extra care should be taken to prevent damage to the motor cable either directly from the torch or indirectly from contact with a hot surface Waterproof butt splices are not supplied with complete valves but must be used to prevent corrosion on the motor leads 27 Refer to the instruction for MOTOR REPLACEMENT above If the valve is disassembled for installation refer to REASSEMBLY instructions below REASSEMBLY e P 1 Use the SMA in the OPEN mode or valve controller to retract the white driver piston fully into the driver guide Remove power from the valve or controller 2 Lightly oil the gasket or knife edge o
80. tly located external equalizer 1 Low load a Not enough air b Dirty air filters c Air too cold d Coil icing 2 Poor air distribution 3 Poor refrigerant distribution 4 Improper compressor evaporator balance 5 Evaporator oil logged 6 Flow from one TEV affecting another s bulb 21 vp PRESSURE TEMPERATURE CHART PRESSURE TEMPERATURE CHART at SEA LEVEL continued at SEA LEVEL TEMPERATURE F LIGHT REDDISH SAND ORANGE BROWN PURPLE REFRIGERANT SPORLAN CODE REFRIGERANT SPORLAN CODE MP33 or HPS0or HP62 or FX 10 or 408A g Swaneunwotvee NN 170 174 178 135 inches mercury below one stmoschere amp ED e Bubble Point 1p m u amp w gt EM 4 ewok o moun GsGreos e end 30 5 BUBBLE POINT here reads 206 CAII OM 43 4062081911 rare wara wu BUBBLE POINT DEW POINT 25 525 5 SPORLAN VALVE COMPANY V 28 79 30 32 33 34 35 36 37 38 39 40 42 43 44 45 48 50 e a a BUBBLE POINT T gt 2 Form 24 O COPYRIGHT 2004 BY SPORLAN VALVE COMPANY WASHINGTON 500 PRINTED IN THE US OF A BUBBLE POINT Figure 22B gos lt lt BUBBLE POINT DEW POINT
81. tonal gt on retegerent pong cor sit ASMRAL s Relygeraton Nendboot or egucment mam actore Figure 23B 23 APPENDIX B APPROVED OIL TYPES BITZER RECIPROCATING Model Compressor Type Refrigerant Temperature Oil Type 2C R134a R407c R404a BSE32 R507a 4C 4B Semi hermetic R22 R12 R502 6B Ri24a 8C 410 4x2 Open Semi hermetic a a EM x T N P H G F NH3 R717 Clavus G68 2 2 R134a R407c R404a R507a S6 B5 2 Ito VII Open Slow Speed R134a R407c R404a BSE32 R507a BITZER OIL PART NUMBERS 1 gallon 3 78 liters inso r UT te saturated suction temperature BSE32 TT 24 REFRIGERANTS LUBRICANTS APPROVED FOR USE IN COPELAND COMPRESSORS Application Refrigerants Similar To CFC R 12 CFC R 502 HCFC R 22 Lubricant Choices Comments Phased out in MIN AB amp MIN 1996 Phased out in MIN AB amp MIN POE 32 1996 No new MIN AB amp MIN POE 32 equipment 2010 AB amp MIN POE32 amp MIN POE 32 Service only Suva MP3 OU amp MIN POE 32 amp MIN POE 32 Cice Suva MP66 y Service on Suva HP80 000 mem UT HCFC R409a HFC R507 R 502 L M HFC R407a HFC R407c HFC R410a Non Ozone Depleting HFC R438a R704 Helium R744 2 LEGEND MIN AB POE 32 POE PAG POE 32 amp MIN AB amp MIN L L M H HC
82. ts per shop wiring diagram All low pressure controls may require further adjustments per equip ment specifications Water and evaporative cooled high pressure switch R 22 R407c 315 psig CONROL R22 407C R134a R 404a 507 R 410a In In Out In Out High Pressure Manual Lm wer m Manual 400 Manual 585 Low Pressure Temp 5020 20 0 50 20 70 40 Step 1 220 200 120 270 200 340 320 Fan Cycle Step2 230 210 140 280 210 360 340 4 Steps Step3 240 230 140 290 220 380 360 Step 4 250 240 150 300 230 400 380 Step 1 220 200 120 270 200 340 320 9 Step2 230 210 130 280 210 360 340 Stp3 250 230 170 150 29 220 400 360 Fan Cycle Step 1 220 200 120 270 200 360 320 2Steps Step 2 250 230 120 290 220 400 360 Fan Cycle Step1 250 20 17 120 27 200 400 320 ind Eu Fan oso 200 120 270 200 400 320 Freeze Control Manual Manual Manual 20 Manual 97 407 48 Use adjustable switches Load limit pressure switch R 22 makes at 380psig opens at 350psig Freeze controls to be adjusted per conditions below freezing Un loaders to be adjusted per the application requirements High pressure cut out setting shall not be set above 9096 of the pressure relief valve setting A20 FLOOD CONTROL Utilizes a valve s mounted piped and adjusted to regulate condensing pressure by flooding the condenser with liquid refrigerant This option does require additional refrigerant in the system As
83. u from SHSP to POSN etc DOWN Will scroll through the menu the opposite way POSN MODE Press and hold the UP button and ENTER button simultaneously for 5 sec onds to put the controller in manual valve position The number of steps open will be displayed and the 1000 s digit will blink Pressing the UP button will open the valve 1000 steps Pressing the DOWN button will close the valve 1000 steps Pressing the ENTER button will change the flashing digit from 1000 s digit to the 100 s digit Pressing the UP button will open the valve 100 steps Pressing the DOWN button will close the valve 100 steps Pressing the ENTER button will change the flashing digit from 100 s digit to the 10 s digit Pressing the UP button will open the valve 10 steps Pressing the DOWN button will close the valve 10 steps Pressing the ENTER button will change the flashing digit from 10 s digit to the 175 digit Pressing the UP button will open the valve 1 step Pressing the DOWN button will close the valve 1 step Pressing the ENTER button will change the flashing digit from 175 digit to the 1000 s digit Press and hold the UP button and ENTER button simultaneously for 5 seconds to put the controller in normal control The digits will stop blinking SHSP MODE Press and hold the UP button and ENTER button simultaneously for 5 sec onds to enable the superheat set point to be changed The set point is dis played and the 100 s digit will blink
84. ual the approximate suction line pressure at the bulb 3 Convert the pressure obtained in 2a or 2b to saturated evaporator temperature by using a temperature pressure chart see Appendix A 4 Subtract the two temperatures obtained in and F3 the difference is superheat EXAMPLE REFRIGERANT 22 Temperature here reads OBTAIN SUCTION PRESSURE 69 esc M S40 at bulb 1 2 lt Figure 6A Figure 6A illustrates a typical example of superheat measurement on a refrigeration system using R 22 The temperature of the suction line at the bulb location is read at 52 F The suction pressure at the compressor is 69 psig and the estimated suction line pressure drop is 2 psig 69 psig 2 psig 71 psig at the bulb which is equivalent to a 40 F saturation temperature 40 subtracted from 52 F 12 F superheat See Appendix for Electronic Expansion Valve Appendix D for Superheat Controller and Appendix for Kelvin Control G HOTGAS BYPASS if supplied Connect gauge to compressor suction service valve Throttle receiver outlet valve to lower suction pressure at compressor Hot gas regulator should begin to open as suction pressure approaches design suction pressure This should be done before unit has pulled down to design conditions SHUT DOWN Equipment which will not be required to operate for a period of time should be secu
85. uld be taken to prevent air from other sources from entering condenser if this air is at an elevated temperature F Indoor design equipment must be installed in a protected enclosure SPRING MOUNTED COMPRESSOR Compressors are secured rigidly to make sure there is no transit damage Before operating the unit it is necessary to follow these steps 1 Loosen the upper nuts and washers until compressor floats on springs 2 Discard the shipping spacers 3 Allow 1 16 inch space between the mounting nut washer and rubber spacer Mounting spring must not be fully compressed when mounting nut is properly installed See Figures 1B and 1D Compressor Mounting Foot Shipping Spacer Mounting Nut Leave 1 18 inch space Upper after installation gt gt 77 Rubber Spacer Mounting Mounting Nut Spring Lower Mounting Base Figure 1C Mounting Stud Mounting Nut Upper Compressor Mounting Foot Rubber Spacer Mounting Rubber Spacer Spring O Lower EA Lockwasher Mounting Nut Lower Locking Device Mount is shown in properly adjusted position Figure 1D UNIT CLEARANCE DRAWINGS RECOMMENDED WALL OR FENCE 1 1 2 TIMES LONGEST UNIT WIDTH SMOOTH HARD LEVEL SURFACE SMOOTH HARD LEVEL SURFACE Figure 2A Figure 2B NOT RECOMMENDED WALL OR FENCE 1 1 2 TIMES LONGEST UNIT WIDTH
86. uperheat alarm LSAL Low Superheat alarm Normally on the process value screens the process value text alternates with its value When an alarm is activated the alarm status AL screen is added to the rotation to make the user aware that an alarm has been activated The Alarm Status menu display item ALS will show the active alarms shown in Table 5 7 Kelvin Il Display Networking The Kelvin II displays can be set up to access other Kelvin II controllers on the network The controller s current value can be determined by pressing down the button on the display while viewing a process value To enable the display network the CAdr setting MUST be set to a unique nonzero value with the RJ 45 connector on the side of the controller DISCONNECTED After CAdr has been set an End screen is added just be fore the SuPH process value Pressing the button on the display while viewing the End screen brings up a menu al lowing the selection of other Kelvin II controllers connected to the display network Turning the knob allows the selec tion of other Kelvin II controllers based on their appropriate CAdr address The local controller is listed as LocL by a local display Note the remote display always includes the End screen since it must be able to view any controller on the display network 8 Kelvin Factory Reset A factory reset can be performed by holding the button d
87. ve installed in the conventional manner will sense suction pressure and degree of superheat As hot gas is introduced into the evaporator the superheat will increase However this increase will be sensed by the expansion valve and additional liquid will be fed into the evaporator This will false load the evaporator to reduce the effective surface area and still maintain required evaporator pressure and superheat 13 VIBRATION VIBRATION ABSORBER AB R MUFFLER HV ly DISCHARGE e haje d kas HOT GAS REGULATOR HOT GAS LIQUIC RECEIVER D SUCTION FILTER REPLACEABLE CORE LIQUID DRIER LIQUID LINE GLASS EVAPORATOR SOLENOID REPLACEABLE CORE Hot Gas Bypass Control Figure 14A EFFECTS OF UNBALANCED VOLTAGE ON MOTOR PERFORMANCE Alternating current polyphase motors will operate successfully EXAMPLE under running conditions at rated load when the voltage 217 221 228 220 Volt Circuit unbalance at the motor terminals does not exceed 1 percent _ 222V Performance will not necessarily be the same as when the motor Phase 1 2 217V is operating with an unbalanced voltage at the motor terminals 228 222 6V 2 3 221V 3 1 228V A relatively small unbalance in voltage will cause a 100 6 _ 2 7 Voltage Unbalance considerable increase in temperature rise In the phase with 222 the highest current the percentage increase in temperature rise will be appro
88. ximately two times the square of the percentage Percent Percent Percent voltage unbalance The increase in losses and consequently Voltage Current Temperature the increase in average heating of the whole winding will be Unbalanced Rise Rise slightly lower than the winding with the highest current If nuisance trip outs or repeated trip outs of a motor are experienced and diagnosis of the motor shows no faults phase unbalance is a likely cause To illustrate the severity of this condition an approximate 3 5 percent voltage unbalance will cause an approximate 25 percent increase in temperature rise The percent of voltage unbalance is equal to 100 times the maximum voltage deviation from the average voltage divided by the average voltage NOTE WE RECOMMEND A SETTING OF NO MORE THAN 3 UNBALANCE 14 Compressor will not run Compressor noisy or vibrating High discharge pressure Low discharge pressure High suction pressure Low suction pressure TROUBLE SHOOTING CHART PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS Main switch open Fuse blown Thermal overloads tripped or fuses blown Defective contactor or coil System shut down No cooling required Liquid line solenoid will not open Motor electric trouble Loose wiring Flooding of refrigerant into crankcase Improper piping support on discharge or liquid line Worn compressor Condenser water insufficient or temperature too high Fouled condenser

Century Refrigeration IOM

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