Installation & Service Manual PARALLEL
Contents
1. R 22 Refrigerant R404A Refrigerant 120 E r 120 1 R22 R404A 110 110 2 5 8 2 5 87 100 100 90 7 70 7 72 1 8 CAH 1 5 8 2 1 8 80 LL 80 1 5 8 amp 70 amp 70 gt 1 3 8 HHE 8 60 8 60 50 KS 50 1 3 8 40 40 30 30 1 1 8 20 20 F 7 8 7 8 CoO 10 5 8 10 E 5 8 40 30 20F 10F OF 106 206 30F 40 AOF 30F 20F 10F OF 10F 20F 30F 4OF SATURATED SUCTION TEMP SATURATED SUCTION TEMP 3 4 Using Line Sizing Charts June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Line Sizing Guidelines Minimum Horizontal Suction Velocity one half of Minimum Riser Velocity Maximum Pressure Drop Medium Temp Application Low Temp Application R 22 2 21 R404A 2 46 R 22 1 15 R404A 1 33 MINIMUM RISER VELOCITY MINIMUM HORIZONTAL SUCTION VELOCITY R22 MT R 22LT R404A MT RA404ALT R 22MT R 22 LT R404A R404A LT 1 5 1 5 6 5 7 7 7 8 PAO4A LT 60 1 2 950 70 se 80 118 50 8 950 40 8 8 90 8 rus 2 3 3 1 1 8 5 59 9 lt sw wo 4 _ zo 149 s _ s 130 98 144 75 1120 60 4 30 4 50 5 60 6 7 9 280 4235 315 475 em se _2. 1 LABEL NAMEPLATE ca 2 LABEL UL 3 LABEL 208 230V POWER 4 LABEL DEFROST CIRCUIT 1 0 14 WIDE eo ITEM DESCRIPTION Defrost Circuit Breaker Cooler Fan Fuses Defrost Cooler Fan Contactors Current Sensing Relay TG Defrost Time delay On Make Relay 1 Minute Termination Relay When Used Ground Lug Control Circuit Terminal Blocks Power Distribution Block O 5 G N GENERAL REFERENCE ONLY TG 1 CKT TC 2 CKT TS 1 CKT June 2007 Electrical Supply Locations 5 1 PARALLEL COMPRESSORS amp ENVIROGUARD ALES 19164 1 18 beg 94 m penny 1 1 F 0 9 1v1SL 5i e lllud E eee ETRAS 44 5 190 HOIOV LNOO S ualvaH 3s vo S3un LXId a 431009 UNN LY SNvJA 0z OL 222 995 Panel to Panel Field Wiring 3613 431009 UM SH3IV3HA 02201 120 1S0 HH SLOWSY 090 680 NO ILOANNOO H1937 TANVd 1S0u833d 31039 TANVd 1
3. SaHnlXH OL ESL 1wa want 35040 ja s s B 1 LO Id HOWE MOVY 1OH LINOO sayeoipuy LINGNOD IOHLNOO J June 2007 5 2 Electrical Supply Locations PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD SECTION 6 System Charging Requirements The heat of rejection must be known for the particular parallel system It is the figure required for sizing the remote air condenser If it is not known it can be estimated by following the formula Medium Temp Systems Heat of Rejection Total BTUH Load X 1 35 Example 200 000 BTUH X 1 35 270 000 use the 285 column Low Temp Systems Heat of Rejection Total BTUH Load X 1 60 NOTE REMOTE CONDENSERS WITH 1 2 TUBES ARE LESS SUITABLE for parallels with Heat of Rejections in the higher ranges especially with systems having gas defrost The bottom line of the Receiver Charging Charts on page 6 2 provides add on percentages which are to be used if the condenser has 1 2 tubes If adding this percentage to the top line equals more than 100 it has been marked and indicates that the internal volume of the condenser is too large for the application Heat of Rejection Table Use to select proper columns of receiver charge charts BTU LOAD MED TEMP LOW TEMP BTU LOAD MED TEMP LOW TEMP PER 1 00
4. 42 29 1 4 465 16 80 9 16 13434 W_ _ _ _ 8 5 8 1729 16 6 3 8 1 10 Planning for Mezzanine Machine Rooms 186 4 June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Setting Parallel Racks on Kinetic Absorption Pads The kinetic absorption pads should be placed in the locations shown The pads must be installed PRIOR to piping installation Installation Install the pads with the identification holes up NOTE PADS WILL NOT LAST IF THEY ARE NOT PROPERLY INSTALLED TOP IDENTIFICATION HOLE Optional Spring Mounting Pads for Parallel Racks The optional spring mounts should be placed in the locations shown The mounts must be installed PRIOR to piping installation Spring Installation Install the spring mounts with the long side of the mount parallel with the rail of the compressor rack To Level Equipment Adjust the height of the spring mountings by rotating the 1 2 adjusting bolt Check to see that the clearance between the upper amp lower spring assemblies is at least 1 4 bu not more than 1 2 V2 DIA POSITIONING PIN 1 2007 Planning for Mezzanine Machine Rooms 1 11 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Refrigeration Piping Successful Installation of a Refrigerati
5. 4 094 Planning Machine Rooms 1 3 June 2007 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER REFRIGERATION 4 P120X 50 P120X 40 P90X 40 P67X 30 P90X 30 P67X 20 138 134 ns J d 1 LP a P160X 60 P140X 60 P140X 50 163 188 r 169 165 88 1 4 Planning for Mezzanine Machine Rooms mu 81 2 2 4 54 _NORMAL WORST CASE FOR CARLYLE ADD 6 P180X 80 P180X 70 P160X 70 215 192 NOTE THAT THE ABOVE QUANTITIES OF COMPRESSORS PER RACK ARE THE MAX VERTICAL RECEIVER VERTICAL CONTROL PANEL OPT FRONT PIPING ACCESS STYLE PARALLEL RACKS FOR 3D COPELAND BODIES IF 4D 6D OR LARGER COPELAND BODIES OR ANY CARLYLE BODIES ARE USED THE NUMBER OF COMPRESSORS ALLOWED WILL DECREASE June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Parallel Compressor Rack ISOL Pad Mounting Drawings REF DWG ISOL PAD
6. 50 100150200250 300 T 50 1001 50200250 300 50 1001509200250 300 5 5 10 10 15 15 20 20 25 25 30 30 35 35 40 40 45 45 50 50 55 55 60 60 65 65 70 70 21 8 75 75 80 at 1 54 PD Total Run 80 at 1 5 PD Total Run 80 at 1 54 PD Total Run otal Run Step Sizing Step sizing is suggested for selections in the 1st half of a size range Pipe one size smaller can be used on the 50 closest to the cases when the entire rune is 100 or more Selections falling in the BLACK AREAS of the chart show that the gas velocity is below 750 fpm which is too slow to assure proper oil return Reducing one size will assure good oil return by increasing velocity Added pressure drop will require greater refrigeration capacity Be sure the compressor selection is adequate All horizontal suction lines should be sloped 1 2 per 10 toward the compressor See vertical riser charts for proper vertical suction line sizing June 2007 Using Line Sizing Charts 3 7 PARALLEL COMPRESSORS amp ENVIROGUARD R404A Suction Line Sizin 35 F SUCTION TEMPERATURE BUH ie 85 45 So Equivalent Feet n 50 100150 200 250 300 10005 U 8s 15 L roo 20 25 H1 5 8 35 28 40 45 HAS H 50 65 79 3 1 8 75 80 at 1 04 PD Total Run 10 F SUCTION TEMPERATURE 18 as dol 78 amp 90 Equiva
7. EIN ELS 8 9 8 0 2 17 20 24 i 33 42 46 46 eue pe Few TUBE E 30 sw 36 E 42 O D L DEVELOPED LENGTH OF EXPANSION OFFSETS paz z e e gt a ss e por ze os por ae wr er pee e poe os uz Law s r ee es ze sr pur oe e _ Few ur se ze we vor ae 2567 er ve as es oz we m 2 6 Refrigeration Piping June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Using Line Sizing Charts Basis These line sizing charts are based on a suction pressure drop equivalent to 2 F change in saturation pressure and liquid line pressure drop of 5 psi For R404A Low Temperature 1 psi for R404A and R 22 Medium Temperature 2 psi is used This is the maximum allowable pressure drop for the entire piping run regardless if it is 50 250 The advantage of the graphic representation of this information is to show just how close to full capacity a particular selection is This is true for both the condensing unit capacities on the individual specification sheets or the separate suction line sizing charts When the suction line graphs are arranged according to temperature the relationship of temperature and line size become readily apparent The lower
8. Open the 1 4 flare connection on the top of the reservoir QU Slowly open the low pressure isolation valve on the gauge manifold and use the oil pump to deliver oil to the system reservoir from the container It is important that some oil is left in the container so that the oil pump is always immersed If not air could be drawn into the system 8 Shut the low pressure isolation valve on the gauge manifold when oil transfer is complete 9 Open the flare valve at top of oil reservoir to receive oil from the separator NOTE Oil requirements vary by refrigerant used and compressor manufacturer The most widely used refrigerant oils are as follows Mineral Oil Applications e Copeland compressors use or 3GS with a viscosity rating of 150 SUS Carlyle compressors use Witco Sunisco 3GS Texaco Capella WFI 32 150 or Chevron Zerol 150 with a viscosity rating of 150 SUS Polyol Ester Oil Applications HFC s Copeland MT LT recommends Mobil EAL Artic 22 CC and ICU EMKARATE RL 2 Carlyle MT recommends Mobil ARTIC EAL 68 Castrol SW68 Castrol E68 ICI EMKARATE RL 68H Lubrizol 2916S and CPI SOLEST 68 Carlyle LT recommends Castrol SW68 Castrol E68 ICI EMKARATE RL 68H Lubrizol 2916S and CPI SOLEST 68 Carlyle Screw Compressor Applications Carlyle MT recommends Castrol SW100 CPI SOLEST 120 ICI EMKARATE RL 1008 and Castrol E100 Carlyle LT recommends
9. 36v38O030 SUOSSAUdNOD dO UIGANN FHL 0351 JAY 5310089 JAYO 531008 2l3 21V1 09 Ar 41 S3IGO8 JHL JAY JOYA 03 54 06593 dO 6 3H1 T3TIvtlvd TIALS SSADOV ONidid AVIY 15 INYA 1O8INOO TVINOZISIOCH 218 IVINOZIBIOH CIS 691 41 19 ASVO LSUOM TVIW2ION OS XOC Ld Ot XOc Ld Ob XO06d O XZ9d 02 9 2007 1 2 Planning Machine Rooms PARALLEL COMPRESSORS amp ENVIROGUARD Installation amp Service Manual 3SV3s O3Q TIM 54055344 1 dO 3H1 ASN JAY 51008 TMAVO SHOVE TaTT Ved TIALS SSADOV NIdId 4 CLS UO 5 J3 2lV1 09 Ar dl SAIGOd AF 304 TWLNOZRIOH CIS 9 9 90 TVOIRIdA dO JAV HOVE Ad SUOSSAUdNIOD dO 9 JHL ALON c egl 04 091 19 FAWVS 303 ISVO ISOM 2 yg t 2 4 9
10. Heat Rejected 1 000 s BTUH Heat Rejected mE EE 1 000 s BTUH Ambient 700 735 85 FOUR SOME with Electric Defrost Heat Rejected SE EE ES 1 000 s BTUH Ambient 700 735 FOUR SOME with Gas Defrost Indicates that a 1 2 Tube Condenser is not suitable 6 2 System Charging Requirements June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Horizontal Receiver Capacity Parallels Pounds or Refrigerant 90 F l i iii 1 gt 2 uc c UE MAX COMP 3 4 5 6 7 8 e me me ws e 9 ws 1 r 8s o 4 2 t 100 GAUGE 80 ACTUAL for safety R404A P67 P90 P120 P140 P160 P180 MAX COMP 3 4 5 6 7 8 woo w mi s i 42 sas se 99 sw 6 232 29 w 3 7 100 ON GAUGE 80 ACTUAL for safety NOTE Receiver sizing is not intended for total system pumpdown It is to allow for normal system variations It will usually allow for one or more circuits to be pumped out for servicing To obtain horizontal receiver capacities for different body sizes and or vertical receiver applications contact the Tyler Application Engineering department June 2007 System Charging Requirements 6 3 PARALLEL COMPRESSORS Installation amp Service Manual amp
11. 45 480 720 se 75 zu 1200 ver ve ze 9 2587 66 NOTE Use R404A information for 502 4 507 refrigerants R 22 amp R404A Liquid Line Sizing Chart R 22 R404A at 5 40 90 90 70 50 30 80 15 75 430 480 20 665 June 2007 Using Line Sizing Charts 3 5 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Using Suction Line Sizing Charts Correctly Suction Line Sizing Charts The Suction Line Sizing charts include R404A and R 22 suction temperatures and lengths to 300 equivalent feet These charts are based on DuPont data and extensive field experience The advantage of the graph presentation of information is to show just how close to full capacity a particular selection is The suction line graphs are arranged according to temperature and the relationship of temperature and line size becomes readily apparent The lower the temperature the larger the line for the same heat load 10 F SUCTION TEMP To determine the Equivalent Feet or Meters add the ETTTETRTS length of the pipe and the equivalent footage assigned for Equivalent Feet each particular fitting See chart below in soJioolsopooj sojaoo Find the Proper Chart Find the proper chart based on refrigerant and suction temperature Simply match BTUH load on the horizontal lines with equivalent feet on the vertical line The point formed by t
12. 1 5 per 100 feet of run medium temp Expansion loops are designed to provide a definate amount of travel Placing the loop in the middle of a piping run will allow for maximum pipe expansion with the minimal amount of stress on the loop Don t us 45 degree elbows for loop construction because they will not allow the lines to flex Refer to the charts on the next page for expansion loop lengths Suction and liquid lines cannot be joined together of be allowed to touch Pipe hangers must not restrict the expansion and contraction of piping Insulation on suction and liquid lines makes the whole system more efficient Insulate It Pays June 2007 Refrigeration Piping 2 5 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Expansion Loop Sizing Chart 1 is to be used for A B and C type loops Chart 2 gives the total length of the expansion joint L along the outside surface Example Given a 200 foot run of 1 3 8 medium temp piping there will be a linear expansion of 3 to compensate for medium temp 1 1 2 per 100 ft Pipe diameter has no affect on the amount of linear expansion but is needed for determining the size of the expansion loop Find the 3 column at the top of Chart 1 and go down until it crosses the 1 3 8 row The X dimension is 24 If using type A loop it will be 24 48 for type B and 72 for type C TUBE LENGTH in inches FOR LINEAR EXPANSION pe O D
13. CPI SOLEST 120 Castrol E100 and EMKARATE RL 1008 NOTE Castrol SW100 is not recommended for low temperature operations June 2007 Oil Control System 8 5 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Bitzer Copeland Screw Compressor Applications Bitzer Copeland model SHM L for MT LT HT HFC s recommends CPI Solest 170 Bitzer Copeland model SHM L MT LT R22 recommends CPI CP4214 150 Bitzer Copeland model SHM L for HT R22 recommends CPI CP4214 320 Removing Oil Occasionally problems in line sizing or system operation may cause oil to be trapped in an evaporator or suction line and large amounts of oil were added to compensate for this oil logging When the problem has been solved and corrected the excess oil will return to the compressor crankcase CAUTION If this excess oil is not removed from the system compressor damage will be the likely result To remove excess oil from the compressor via the oil fill plug 1 With the compressor OFF close the compressor suction valve and reduce the crankcase pressure to 1 to 2 psi 2 Shut the discharge service valve 3 Carefully loosen the fill plug allowing any pressure to bleed off before fully removing the plug 4 Remove the plug and insert a 1 4 O D copper tube into the plug hole Use a tube of sufficient length to reach the bottom of the crankcase and the external end can be bent down below the level of the cra
14. E E EN EN E June 2007 Using Line Sizing Charts 3 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A Sizing Liquid amp Suction Sub Feed Lines Properly Liquid amp suction line lengths over 300 equivalent feet are discouraged by TYLER Contact Applications Engineering for recommendations exceeding 300 Equivalent Feet Suction Line Sizing The line sizing charts on each specification sheet can be used to size the subfeed branch lines When the line serves one case select the size for that case length 6 8 or 12 This may be as small as 1 2 example service meat cases or as large as 1 3 8 example multi shelf ice cream cases Select each succeeding step on the basis of the number of feet of case being served by that portion of the suction line Liquid Line Sizing Use the Liquid Line size chart on page 3 5 to determine the appropriate size in the same man ner as for suction lines Exception In the case of gas defrost follow the special instructions on page 2 5 making and sizing a liquid line manifold at the case NOTE Low temp suction lines and all liquid lines must be insulated in all Nature s Cooling and Enviroguard applications Horizontal suction lines should slope 1 2 per 10 toward the compressor to aid in good oil return 3 2 Using Line Sizing Charts June 2007 PARALLEL COMPRESSORS Installation amp Service Manual Suction Line Riser Recommendations 1
15. ENVIROGUARD SECTION 7 Start Up Procedures The start up procedures consist of three steps leak testing evacuation and the charging start up procedures Follow these procedures to prevent any problems in the start up of the unit Leak Testing Procedure The success of all the subsequent evacuation charging and start up as well as successful operation of the system depends on a totally leak free system CAUTION Do not start any compressors before these procedures instruct you to do so BEFORE STARTING MAKE SURE THERE IS OIL IN THE COMPRESSOR Serious compressor damage may result if all the steps are not followed properly See page 8 5 for recommended oil usage 1 The pilot circuitry ON OFF switch on the store power distribution panel must be OFF 2 Check that the compressor primary ON OFF switches are all in the OFF position 3 All the following valves must be OPEN Discharge Service Valves on the compressors Suction Service Valves on the compressors Liquid Return Valve on the receiver from remote condenser Liquid Outlet Valve on the receiver All field supplied Hand Shut Off Valves All Liquid Line Manifold Valves All Suction Line Manifold Valves All Hot Gas Manifold Valves All Oil Equalization System Valves 4 Remove the black power wire from the multi circuit time clock motor in the defrost control panel This will prevent the clock from advancing until the start up procedures are complete 5 Tighten all e
16. 20 Replace black power wire to the motor of the multi circuit time clock or reactivate the defrost control 21 Check the ability of the compressor motors to start after shut down in effect simulating a power failure Use an ammeter to determine operation of a loaded start 22 Record the motor amperage at normal operating pressures and temperatures 23 Check the remote condenser and heat recovery coil for proper operation 24 Check oil reservoir level if oil level is below the bottom sightglass add oil until level can be seen or is above the sightglass Red beads should be visible in the center of the sightglass 25 On gas defrost systems check to ensure the system operates properly during defrost Description of operation is on pages 12 1 amp 12 2 26 Due to the use of refrigerants such as R404A and R 507 systems now require oil which is hydroscopic meaning it will very rapidly absorb moisture In addition the combination of the HFC refrigerants and the POE oils act as very good solvents This can break loose and circulate contaminants that before may not have been a problem In order to deliver a clean uncontaminated system proper start up procedures should be followed To help ensure a clean system filter changes should become part of the start up procedure Filters should be changed as needed Example Change filters at periodic intervals or 3 days 3 weeks and 3 months Watch the moisture indicator and observe the
17. J s o o4 20 e 6 10 o o 2 s 8 s o 38 48 2 1 38 sss 65 so 50 to 3 6 Using Line Sizing Charts June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD R 22 Suction Line Sizin 35 F SUCTION TEMPERATURE 25 F SUCTION TEMPERATURE 20 F SUCTION TEMPERATURE 15 F SUCTION TEMPERATURE B M LES abl E 18 la6 45 75 90 BIUH 45 60 75 Reamt 15 90 Feet Equivalent Feet Equivalent Feet In 50 1001 50 200 250 300 50 100150200 250 300 in 50 100150200250 300 10005 10005 5 7 8 5 10 1 8 4 10 18 1 3 8 20 20 25 25 Ad 1 5 8 30 35 gt 35 40 T 40 45 7 45 50 50 E 2 1 8 60 60 EA E 2 5 8 25 8 75 80 1 3 PD Total Run PD Tofal Run 80 at 1 3 PD Total Run 10 F SUCTION TEMPERATURE 15 F SUCTION TEMPERATURE 20 F SUCTION TEMPERATURE 936 451 60 75 90 BIUH 15 45 60 75 BUH 197 30 45 Equivalent Feet Reqm Equivalent Feet Reqm Equivalent Feet amit Equivalent Feet 50 100150 00250 300
18. adjustable pressure differential between its inlet and outlet pressures This is accomplished in its normal non energized state When the DDPR valve is energized the valve opens and equalizes the inlet and outlet pressures When all hot gas circuits in a system are in refrigeration mode the valve should be energized NOTE The minimum recommended differential pressure setting of the DDPR is 20 psi 9 2 Pressure Regulator Settings June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD OLDR Liquid Differential Regulator Valve The OLDR valve has a solenoid bypass feature so the valve can either remain fully open or operate to maintain a differential The OLDR valve fails to the open position In the differential mode the pilot differential valve controls the valve by varying the pressure on top of the main piston Inlet pressure enters the pilot assembly through an external tube connected to the inlet fitting The outlet of the pilot differential valve is connected to the outlet fitting with an external tube The valve will open only as far as necessary to maintain the pilot valve setting The pilot valve modulates the piston from partially open to partially closed to maintain its setting See Figure 1 on page 10 2 In the fully open mode the pilot port is closed This stops the flow to the chamber above the main piston The refrigerant above the main piston is bled to the outlet through an orifice in
19. return line is continually hot the oil float valve may be leaking or being held open by foreign matter In either case the oil separator and or the oil strainer should be cleaned Other problems may be indicated by a continually hot oil return line It may mean that a compressor is pumping excessive oil or the separator is too small for the compressors This can be checked visually by installing a sightglass in the oil return line If the oil return line is cold it means that there is condensation of liquid refrigerant in the oil separator Cil Reservoir Oil trapped in the oil separator is piped directly to the oil reservoir Oil movement from the oil separator to the reservoir is induced by having the reservoir at a lower pressure that the separator The pressure of the oil in the reservoir is reduced through a vent line to the suction header A 20 pound oil differential check valve is placed in this vent line to keep the pressure in the oil reservoir 20 pounds above the suction pressure This is to ensure oil flow to the compressor oil level controls from the reservoir The oil separator operates at the same pressure as the compressor discharge gas The reservoir will be at 20 pounds above the suction pressure and the compressor crankcase will operate at the suction pressure These differences in pressure ensure positive flow of lubricating oil throughout the oil equalization system June 2007 Oil Control System 8 1 PARALLEL COMPRESS
20. system is operating properly Oil should be added directly to the reservoir rather then individual compressors See Section 8 Oil Equalization System for more detail NOTE POE oils must be pumped into the system because of their high affinity to draw moisture Continue activation of the branch circuits one at a time Maintain no more that 50 psi charging pressure above the design suction pressure NOTE In order to cut charging time feed each circuit separately using refrigerant from a cylinder Keep service valve closed to the manifold until the circuit is charged Adjust the EPR and TEV valve settings for their individual applications Continue activation of the refrigeration circuits until they are all on the line Continue charging the circuits as necessary to maintain refrigerant level in the receiver Check liquid line sightglass during charging if bubbles are present it may indicate a low refrigerant charge However occasional bubbling may occur The liquid level indication is a better charging indicator On electric defrost systems check the defrost load amperage against the summary sheet Adjust the multi circuit time clock settings for proper time termination and sequence of defrosting Check starters and heaters contactor sizes and circuit breakers to ascertain correct selection and application 7 4 Start Up Procedures June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD
21. the temperature the larger the line required for the same heat load M E T Equivalent Feet 15 45 60175 Equivalent Feet 50 100150200250 Notice the phase Equivalent Feet applies to meters as well Fittings added to refrigerant line induce an added pressure drop in the line The added pressure drop is accounted for by adding extra length see chart on ga 3 8 page 3 6 to the piping run which will equal the same pressure drop produced by the fittings In order to determine the equivalent footage the actual length of the piping run and the equivalent footage assigned for each particular fitting Plot the intersection of the horizontal BTUH line with the vertical equivalent footage line The area in which the plotted point falls is the recommended line size Liquid Line Sizing Due to the lack of space the case specific specification sheets do not show liquid or suction line sizing charts They refer to a line sizing BUFF section in the back of the Specification Guide Within this section liquid and suction line sizing is explained Liquid line sizing is based on a 5 pound pressure drop for the entire piping run from 50 to 250 7 7 E E E Example A 25 000 BTUH load will require a 3 8 line for 100 equivalent feet Point A At 150 equivalent feet a 1 2 line would be required for the same load Point B See chart shown on this page B
22. 0 x 1 35 x 1 60 PER 1 000 x 1 35 x 1 60 Selecting and Using Refrigerant Charging Tables Use the percentage shown in the charts on page 6 2 to estimate the system charge shown in the charts on page 6 3 All charts are based on systems with Heat Recovery All commercial parallel refrigeration systems made by TYLER will make use of Nature s Cooling NC to a certain extent With NC systems the receiver will be near full in the summer as condensing temperatures drop so will the receiver level This drop in receiver level from lower ambient is caused by refrigerant backing up in the condenser These must also be an extra amount of refrigerant available to handle gas defrosting at the lower ambient condition Since the ambient temperature is the governing factor in how much refrigerant is required the charging tables give range of conditions June 2007 System Charging Requirements 6 1 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER REFRIGERATION R 22 amp R404A Receiver Charging Charts Heat Rejected 1 000 s BTUH Ambient Heat Rejected 1 000 s 3 7 asx sos sox oom 75 TWO SOME with Electric so ox 72 vom ser ere 7 eme or F F F o o Defrost Add for 1 2 Add for 1 2 Heat Rejected 1 000 s BTUH SOME with
23. MTG P180 186 858 42 291 4 30 REF 34 5 16 638 68 9 16 122 3 4 1 8 Planning for Mezzanine Machine Rooms June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD REF DWG SPRG ISOL MIG VRP VFP67 71 8 5 8 57 9 16 29 1 4 42 30 REF REF DWG SPRG ISOL MTG VRP VFP90 94 858 80 9 16 29 1 4 42 6 3 8 1 46516 REF DWG SPRG ISOL MTG VRP VFP120 30 REF 117 85 8 103 9 16 291 4 42 30 REF 6 3 8 F 46 516 80 9 16 2007 Planning Machine Rooms 1 9 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A REF DWG SPRG ISOL MIG VRP VFP140 M 140 85 8 126 9 16 1 42 29 1 4 30 REF 6 9 46 5 16 80 9 16 4 REF DWG SPRG ISOL VRP VFP160 30 REF 29 1 4 6 3 8 80 9 16 126 916 85 8 149 9 16 be 163 REF DWG SPR ISOL MIG VRP VFP180
24. MTG P67 2211 16 APPROX TYP FOUR PADS EQUALLY SPACED ACROSS THE BACK 30 REF FIVE PADS 7 SPACED ACROSS THE FRONT ee APPROX TYP REF DWG ISOL PAD MTG P90 94 30 5 16 APPROX FOUR PADS EQUALLY SPACED ACROSS THE BACK Z 30 SIX PADS ACROSS THE FRONT r 18 3 16 APPROX D1098 REF DWG ISOL P120 F 117 28 1 2 APPROX TYP FIVE PADS EQUALLY SPACED ACROSS THE BACK i 42 30 REF 3 1 4 16516 EIGHT PADS SPACED ACROSS THE FRONT APPROX June 2007 Planning for Mezzanine Machine Rooms 1 5 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION REF DWG ISOL PAD MTG P140 F 140 34 1 4 APPROX FIVE PADS ACROSS THE BACK Z 42 30 REF ZZ Y YA 1718 NINE PADS ACROSS THE FRONT APPROX REF DWG ISOL 160 163 32 APPROX SIX PADS EQUALLY SPACED ACROSS THE BACK 42 30 REF Z A Z TEN PADS EQUALLY SPACED ACROSS THE FRONT 17 3 4 AP
25. ORS TYLER amp ENVIROGUARD REFRIGERATION A Oil Level Controls Oil Float The oil level control will receive oil from the reservoir at 20 pounds above the suction pressure The control will meter oil flow to the compressor thus maintaining at least the minimum oil level required to operate safely As the level of the oil is lowered in the compressor crankcase through operation the float in the oil level control is lowered When the float drops to a certain point a needle valve will open allowing oil to flow back into the compressor crankcase TYLER s default oil level controller is Sporlan s OL 60XH The orifice in each is sized to maintain proper oil flow in the pressure differential range of 5 to 90 psi When a parallel system employs lower temperature satellite compressors which operate at a suction pressure more than 15 psi lower than the suction pressure of the main suction group a regulating valve Sporlan s ADRI 1 1 4 0 75 or Y 1236C are used to step down the oil pressure feeding the oil level control s of the satellite s The outlet of the regulating valve is adjusted to maintain the same differential across the satellite s oil level control as that which is maintained across the oil level control on the main suction group A minimum differential of 10 psi and a maximum of 30 psi are required Because the suction pressure on the main suction group will rise with an increase in load or the end of a defrost period it would be prude
26. OST OR GAS LOW MED DEFROST 195 PSIG 127 PSIG 175 PSIG 146 PSIG 230 PSIG 150 PSIG 189 PSIG 173 PSIG 235 PSIG 155 PSIG 192 PSIG 179 PSIG NOTE If the IPR valve has been replaced with an OLDR valve the OLDR should be adjusted to a differential pressure equal to the IPR setting minus the OPR setting IPR Inlet Pressure Regulator on Heat Recovery Coil NC FLOATING HEAD NC 2 NC 3 SYSTEMS PE OF DEFROST R TY GAS GAS ELECTRIC DEFROST ELECTRIC DEFROST 158 PSIG 158 PSIG 158 PSIG 158 PSIG 188 PSIG 188 PSIG 188 PSIG 188 PSIG 195 PSIG 195 PSIG 195 PSIG 195 PSIG The IPR valve is shipped loose for installation downstream of the Heat Recovery Coil This valve is used to raise system discharge pressure to get more heat out of the hot gases passing through the coil June 2007 Pressure Regulator Settings 9 1 PARALLEL COMPRESSORS TYLER 8 ENVIROGUARD REFRIGERATION OPR Outlet Downstream Pressure Regulator STANDARD NC FLOATING HEAD NC 2 NC 3 SYSTEMS TYPE OF ELECTRIC ELECTRIC GAS ELECTRIC GAS DEFROST OR GAS LOW MED DEFROST LOW MED DEFROST 170PSIG 102 PSIG 150 121PSIG 102 PSIG 150 121 PSIG 205 PSIG 125 PSIG 164 148PSIG 125 PSIG 164 148 PSIG 210 PSIG 130 PSIG 167 154PSIG 130 PSIG 167 154 PSIG The OPR valve supplies high side pressure to the receiver whenever the pressure falls below a set point DDPR Valve on Gas Defrost Systems Optional The DDPR is a valve that maintains an
27. OUT 390 395 PSIG Pressure Relief Valve 450 PSIG 140120 NND 2007 Parallel Pressure Control Settings 11 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Remote Condenser Fan Settings NOTE Chart for ambient control usage only OF FANS FAN 1 2 ores P ore f sro DROP LEG TEMPERATURE INLET TEMP Setting Suction Pressure Differential amp Time Delay The pressure differential is the suction pressure band that the compressor 5 will try to maintain This band can be set from 1 to 10 pounds TYLER recommends setting the differential at 4 pounds initially Time Delay Values Time delay is the time period that the compressor will operate or remain idle after a specific pressure set point has been reached This tends to minimize the amount of compressor cycling required to maintain a specific pressure differential Minimum ON time is the time the compressor runs after it reaches its target pressure Minimum OFF time is the time the com pressor waits to start TYLER recommends the following Minimum ON and Minimum OFF time settings Minimum ON time should be less than 15 seconds Minimum OFF time should be 2 minutes or less Of course these time and pressure differentials will vary depending on system characteristics of the loads being refrigerated and will have to be adjusted during the start up period NOTE Systems operating on electronic
28. PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD SECTION 1 Planning for Mezzanine Machine Rooms Many compressor rooms today are installed in mezzanine locations With conventional systems the units are typically spring mounted and spread over the expanse of the mezzanine area With parallels the total weight of the assembly may be as high as 7 900 all concentrated in 54 3 sq ft or less The industry typically uses solid mount compressor mountings for the purpose of simplifying piping to fixed manifolds This poses no problem with ground level concrete pads however mezzanine construction frequently doesn t consider this This can result in normal vibrations harmonics and pulsations being amplified NOTE It is imperative that the mezzanine floor design provides an adequate mass to keep vibrations harmonics and pulsations within normal ranges The floor surface must be smooth and level Following These Guidelines Maximum Weight of Racks 2 or 3 Compr 3 or 4 Compr 4 or 5 Compr 5 or 6 6 or 7 7 8 Compr 3 8007 4 4007 5 5004 6 100 7 000 7 900 Consult factory for all custom rack applications Machine Room Ventilation Requirements Remote Air 100CFM HP Water Cooled 100 CFM HP Air Cooled 1 000 CFM HP June 2007 Planning for Mezzanine Machine Rooms 1 1 PARALLEL COMPRESSORS TYLER REFRIGERATION A amp ENVIROGUARD Parallel Compressor Rack Dimensions
29. PROX REF DWG ISOL PAD MIG P180 186 30 1 2 APPROX PADS ACROSS THE BACK 30 REF ELEVEN PADS EQUALLY SPACED ACROSS THE FRONT 18 5 16 APPROX 1 6 Planning Mezzanine Machine Rooms June 2007 PARALLEL COMPRESSORS Installation amp Service Manual Parallel Compressor Rack ISOL Spring Mounting Drawings REF DWG SPRG 1501 P67 amp ENVIROGUARD 71 858 53 3 4 1 29 1 4 42 30 REF 6 3 8 1 REF DWG SPRG ISOL MTG P90 94 85 8 76 3 4 1 1 29 1 4 42 30 REF 6 3 8 i 34 5 16 REF DWG SPRG ISOL P120 112 85 8 99 3 4 2914 42 30 REF 63 8 34 5 16 k 68 910 June 2007 Planning for Mezzanine Machine Rooms 1 7 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION REF DRW SPRG ISOL MTG P140 pep M 85 8 122 3 4 34 5 16 68 9 16 REF DWG SPRG ISOL MTG P160 be 163 85 8 4 F 145 3 4 42 29 1 4 30 REF 6 3 8 m 34 516 68 9 16 1149 16 REF DWG SPRG ISOL
30. Riser which can be installed without a trap Suction line sizing is based on a design pressure drop which relates to the velocity of the gases moving through the line Acceptable velocities for horizontal suction lines with proper 1 2 slope per 10 run range from 500 to more than 1 500 per minute A properly sized line at the low range of its capacity will have a low velocity and one at full capacity will have velocities exceeding 1 500 fpm A specified minimum velocity is required to keep oil moving along with the gas when the pipe is vertical The charts on the next page show the size selection which will assure oil return ip a riser This size may be the same as the horizontal suction line selection or it may be one size smaller If the selection point on the chart is close to the dividing line between sizes use the smaller size The reducer fitting must be placed after the elbow Long elbows can be used to make the trap or a P trap can be used Do not use short elbows 2 Risers which require a P trap Low Temp systems must be designed knowing that oil is more difficult to move as the temperature is lowered The refrigerant gas also has a lower capacity to mix with the oil A trap will allow oil to accumulate reducing the cross section of the pipe and thereby increase the velocity of the gas This increased velocity picks up the oil The velocity chart is to be used to determine if the horizontal line size has sufficient velocity
31. UH TO RECEIVER 50 100 TO RECEIVER 50 100 4 2 High Side Field Piping June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD SECTION 5 Electrical Supply Locations Store Machine Room Parallel systems placed in a machine room have individual electrical knockouts on each unit 7 8 pilot knockouts are located so any necessary holes for the conduit can be punched out safely The TYLER Summary Sheet included with each parallel unit will give the load in amps for the unit Each power supply must be sized accordingly to accommodate the load Electrical specifications are also located on the name plate NOTE A single phase 208 volt power supply will be needed to power the compressor auxiliary circuit The circuit breaker to the power supply is located in the control panel Remote Electric Defrost Panels When Used The panel s required for Electric Defrost are separate from the Parallels Supply properly sized wire to the hookups in each panel If the defrost panel is to be located in a TYLER Mechanical Center the control wiring will be done in the factory Control wiring in a store machine room must be done on site to connect multi circuit time clock s or computer controller to the Electrical Defrost breaker panel Supply conductors must enter the panel via the electrical tap box knockouts Refer to drawing on the following page 208 230VAC
32. VIROGUARD High Side Field Piping Observe piping limits for best performance Maximum 50 equivalent piping feet to Remote Condenser Maximum 100 equivalent piping feet to Heat Recovery Coil Maximum 200 equivalent piping feet total for entire circuit Line size between Remote Condenser and Heat Recovery Coil must be the same size as the discharge line Installation Notice Remote condensers must be mounted high enough in relation to the parallel rack so that the liquid drain on the condenser is at least 3 feet higher than the liquid return inlet on the receiver Both applications ensure free draining This drawing shows which items need to be installed as field piping All items above the broken line are considered part of the field piping and are shipped loose A detailed description on pages 17 1 amp 17 2 gives a further explanation as to how the parts are employed All the components shown in the field piping diagram should be installed If a heat recovery HR coil is used 3 check valves A must be installed as shown in the diagram One is placed in the normal flow piping to the condenser and the other two at the inlet and outlet of the HR coil An optional IPR valve B for the HR coil will also be field installed on the coil for NC 2 only Isolation ball valves are recommended for the system and can be ordered as optional equipment Schematics Are Representative Only Optional Split Condenser Piping Typical Heat Reclai
33. and requirements NOTE The oil level control is factory set at 3 1 2 turns clockwise from the top stop 5 8 x BN k 9 1 OL60XH 10 PSI EN 1 2 Sight Glass b OL1 CH Center Line gt 3i 20 PSI lt 5 PSI 30 PSI 3 8 x i Es EM N 22 3 1 Bs EN N Top 1 2 3 4 5 6 7 8 9 10 Position NUMBER OF TURNS DOWN Adding Oil Oil may be added to the system in several ways However the following method is the preferred one You will need a piece of flared tubing attached to an oil pump Remember the oil and oil transfer equipment must be clean and dry The oil must be the proper viscosity for the compressor the refrigerant and the low side temperature 8 4 Oil Control System June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD The Preferred Method of Adding Oil 1 Attach tubing with oil pump to the middle opening of the gauge manifold 2 Attach the high pressure hose of the gauge manifold to the discharge service fitting and the low pressure hose to the 1 4 flare connection at the top of the oil reservoir Front seat the flare valve at the top of the oil reservoir to receive oil from the oil separator Purge the tubing using gas from the high pressure side After purging the tubing immerse the oil pump in a container filled with clean refrigerant oil
34. apacity Be sure the compressor selection is adequate All horizontal suction lines should be sloped 1 2 per 10 toward the compressor See vertical riser charts for proper vertical suction line sizing 3 8 Using Line Sizing Charts June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Pressure Concerns Avoiding Excessive Pressure Drop Pressure drop and resultant capacity losses are becoming more common with the increased use of EPR valves suction line filters accumulators and suction manifolds on parallel systems Each device stands on its own individual merit by contributing to case or system performance But when all the resultant pressure drops are added the end result is lower overall system performance The symptoms may lead one to believe that the system is undersized but a thorough check using a differential pressure gauge will very likely show where the real trouble lies Some Pressure Drop Built In In general most manufacturers rate their equipment by allowing for approximately two pounds pressure drop in the suction line between the evaporator to the compressor Pressure drop built into the evaporator is usually considered by the designer and can frequently be larger than two pounds This is to provide refrigerant velocities high enough to ensure good oil movement even in the coldest parts of the refrigeration system Avoiding Excessive Loss of Capacity 1 Size liquid and suction lin
35. color and transparency of the oil Another good indication is pressure drop across the filter and if it reaches 3 pounds or more it should be replaced However if proper evacuation procedures are followed and dry uncontaminated oil is installed in the system after the evacuation the 3 month filter change may not be needed NOTE The initial suction filters are shipped in place A replacement set of suction filters are also shipped loose These should be used to change the suction filters after initial startup approx 3 days Liquid drier cores are also shipped loose for installation prior to startup but after the system has been sealed Operational Check after Start Up When the system has been operating for at least 2 hours without any indication of problem check the following items allowing the system to continue operations on automatic controls 1 Check to see that all case fans are operating properly and rotating in the appropriate direction Check the setting of all thermostatic expansion valves for proper superheat Check the compressor operating parameters head pressure suction pressure line voltage and compressor amperage If any of the readings are not within the expected parameters as noted on the nameplate and in this manual determine the cause and correct 4 Check the compressor oil level to ensure that it meets manufacturer s specifications June 2007 Start Up Procedures 7 5 PARALLEL COMPRESSORS Installatio
36. es by accurately figuring the proper equivalent length EQUIVALENT LENGTH ACTUAL PIPING LENGTH LENGTH EQUIVALENCE FOR FITTINGS AND COMPONENTS Use the equivalent length chart located on page 3 6 to determine the appropriate length for these fittings 2 If possible avoid high pressure drop components such as various types of control valves manifolds tees accumulators and filters Of course these devices are often used hopefully after all the factors have been considered The disadvantages must outweighed by the advantages of combining systems paralleling compressors obtaining better case temperature control protecting the compressors and or safeguarding the system 3 If suction line filters are to be used size them properly Use a properly sized filter that is the same as main line size or one size over the suction service valve whichever is larger When Losses are Not Made Up When pressure drop losses are not properly compensated for an increase in case entering air temperature can be expected This will be particularly noticeable when the condensing unit is operating at its design ambient condition 90 F or 100 F The following approximations can be made Low Temp Case Each 10 increase 2 PD raises entering air temp about 3 F Medium Temp Case Each 10 increase raises entering air temp about 2 F June 2007 Using Line Sizing Charts 3 9 PARALLEL COMPRESSORS Installation amp Service Manual amp EN
37. from fixtures warms too much on its way to the compressor WITH GAS DEFROST INSULATION ON THE SUCTION LINE helps maintain the temperature of the hot gas flowing to the cases during defrost Insulation on suction and liquid lines helps make the whole system more efficient Insulate It pays The purpose of this section is to stress some of the more important aspects of piping and areas in which difficulties are most likely to occur This information is general and cannot allow for all possible factors in a given installation which can accumulate to make it less than acceptable Page 3 9 on pressure drop emphasizes the importance of properly designing the piping system June 2007 Refrigeration Piping 2 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Materials Use only clean dry sealed refrigeration grade copper tubing Make copper to copper joints with phos copper alloy or equal 1596 min silver content Make joints of dissimilar metals of 4596 silver solder To prevent contamination of the line internally limit the soldering paste or flux to the minimum required Flux only the male portion of the connection never the female CAUTION Piping should be purged with dry nitrogen or carbon dioxide during the brazing process This will prevent formation of copper oxide and scale inside the piping which can easily clog the small ports on pilot operated and other valves in the system Pressure regulators and flow
38. he intersection will indicate the proper size unless it is a dark area Selections falling in the dark areas of the charts show that the gas velocity is too slow to assure proper oil return even with properly sloped lines Reducing the line one size will increase velocity and pressure drop Added pressure drop will require greater refrigeration capacity Be sure the system can handle the added load See the vertical riser charts for proper sizing of vertical suction lines on page 3 5 Step Sizing Step sizing is suggested for the selections falling in the first half of a size R 22 range Pipe one size smaller than the indicated run can be used for 50 of the run closest to the cases when the entire run is 100 equivalent feet L or more To show this principle one size range on each suction chart has BEN been bisected by dotted line to indicate the 1st Half Step Size and the 2nd Half Full Size The purpose of step sizing is to assure better oil Dark Areas Gas return out of the evaporators Velocities less than 750 FPM Example Given a 50 000 BTUH load with R404A at 10 F Suction Temp and 150 Equivalent Feet of line a 1 5 8 line is required Since the selection point is in the 1st half of the range 50 equivalent feet may be sized 1 3 8 usually to the first 50 closet to the evaporators NOTE Any 1 3 8 vertical riser height should be subtracted from the 50 step sizing 2 o
39. in the vertical position to carry the oil along Generally the riser will have to be reduced one size 3 Riser requiring use of two traps amp ENVIROGUARD 1 2 SLOPE PER 10 _ MAX 6 gt REDUCER HERE WHEN REQUIRED Tug SLOPE PER 10 1 2 SLOPE PER 10 _ r 4 I MAX 16 REDUCER T LOCATION 1 2 SLOPE 10 6 1 2 SLOPE PER 10 MAX 16 MAX 16 1 2 SLOPE PER 10 The use of two traps is necessary on long risers for the collection of oil during an off cycle One trap would not be large enough to contain all of the oil coating a riser over 16 and could result in an oil slug delivered to the compressor system Supporting lines Properly supporting the lines suspended from a wall or ceiling is very important Line supports should isolate the line from contact with metal When gas defrost is used consideration should be given to rolling or sliding supports which allow free expansion and contraction These supports would be used in conjunction with expansion loops described on page 2 6 MAXIMUM RECOMMENDED SPACING BETWEEN SUPPORTS FOR COPPER TUBING Line Size O D In Max Span Ft 56 1 1 8 ms s 2 1 8 June 2007 Line Size O D In Using Line Sizing Charts 3 3 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Vertical Riser Suction Line Size Charts Proper line sizing i
40. iver liquid outlet valve Slowly open the refrigerant tank valve and charge liquid refrigerant into the system The vacuum should pull nearly all the refrigerant from a 145 pound tank June 2007 Start Up Procedures 1 3 PARALLEL COMPRESSORS TYLER 10 11 12 13 14 15 16 17 18 19 amp ENVIROGUARD REFRIGERATION 7 Close the following valves All liquid line manifold valves All suction manifold valves Choose a branch circuit and open both the suction and liquid service isolation valves 1 4 turn Turn ON the condenser fan circuit Start one of the compressors Check and record compressor amperage readings Open the receiver outlet Slowly open the suction and liquid isolation valves on the chosen circuit 1 4 turn at a time to activate the first branch circuit Monitor activation of the first branch circuit during the opening of the liquid and suction service valve until there is assurance that the expansion valve sensing bulbs are controlling refrigerant flow through the cases NOTE Refrigeration circuits must be monitored during activation to protect the compressor from liquid slugging Stop the compressor immediately if any abnormality is noted Monitor the oil level in the compressors Add oil as required to maintain oil level at 1 4 to 1 3 full in the sightglass If foaming occurs run compressors intermittently until foaming settles Before adding oil check to see that the oil equalization
41. lectrical connections in all panels prior to energizing the power 6 Turn ON the pilot circuit breaker 7 Turn ON the power at the store distribution panel and adjust the time clock modules so that all systems are ON REFRIGERATION Flip the system ON OFF toggle switches on the panel to ON This opens all the branch circuit liquid line solenoid valves NOTE All compressor switches must remain OFF See step 2 above 8 Connect the necessary charging lines to introduce refrigerant and dry nitrogen into the system use 3 8 or larger evacuating charging lines for proper system evacuation 9 Backseat the receiver liquid outlet valve and connect a charging line to the valve gauge port connection Pressurize the system with approximately 50 psi with refrigerant and then build with nitrogen to 162 psi CAUTION If pressure greater than 162 psi is used for testing disconnect the low pressure computer transducers control lines and seal the pressure port This is done to avoid damaging the control s bellows June 2007 Start Up Procedures 7 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A 9 Using an electronic leak detector carefully check the entire system for leaks Special care should be taken to inspect all joints Check the line pressure gauge at the nitrogen tank for pressure fluctuations A sharp drop in pressure indicates a leaky system 10 Allow the system to stand for 24 hours with the pressure on Nitrogen
42. lent Feet 50 1001 50200 250 300 45 50 55 60 E 170 75 80 1 5 PD Total Run Step Sizing 25 F SUCTION TEMPERATURE RIS 51 30 45 60 75 90 Equivalent Feet 50 100150200250 300 20 F SUCTION TEMPERATURE M E 5130 45 80 75 90 Equivalent Feet 50 100180200 2560300 TYLER REFRIGERATION 15 F SUCTION TEMPERATURE BUH f 30 45 75 90 Equivalent Feet 75 1 80 1 3 PD Total Run MI E 1 R 5 15 30 45 60 75 90 Equivalent Feet 50 100150200 250 300 80 1 5 PD Total Run MI E 1 E R s 15 30 45 60 75 90 Equivalent Feet 50 100150200 250 300 M E 1 E R s 15 30 45 60 75 90 Equivalent Feet 50 100150200 250 300 Step sizing is suggested for selections in the 1st half of a size range Pipe one size smaller can be used on the 50 closest to the cases when the entire rune is 100 or more Selections falling in the BLACK AREAS of the chart show that the gas velocity is below 500 fpm which is too slow to assure proper oil return Reducing one size will assure good oil return by increasing velocity Added pressure drop will require greater refrigeration c
43. m Piping Both discharge and liquid return must be piped symetrically relative to the condenser SPLIT ICONDENSER CURCUIT B CONDENSER CHECK VAIVESZ NOTE These check valves must be located 1 or less from the tee BALL VALVE 1 3 Og 2 SPACE RECLAIM 1 BALL VALVES OO o 66 COM A CHECK VALVE FIELD PIPING _ __ a FACTORY PIPING yore VALVE BALL VALVES O 50 SPLITER qe FIELD PIPING VALVE FACTORY PIPING CHECK DISCHARGE MANIFOLD 100 VALVE fo SEPARATOR mn MANIFOLD HEAT RECLAIM VALVE i 2 T HEAT RECLAIM VALVE Y OPR BALL VALVE SN OIL SEPARATOR ps BALL VALVE CHECK RELIEF VALVE CHECK VALVE RELIEF VALVE C RECEIVER D RECEIVER D Mor 4d BALL VALVE IPR BALL VALVE June 2007 High Side Field Piping 4 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Discharge to Remote Condenser amp Heat Recovery Line Sizin EE O Ea BSR CAPACITY EQUIVALENT LENGTH CAPACITY EE LENGTH BTUH 50 100 50 100 BTUH 100 50 100 Recommended Liquid Line Sizing Condenser to Receiver or Liquid Line Manifold RECEIVER TO RECEIVER TO CAPACITY CONDENSER EVAPORATOR CONDENSER EVAPORATOR BT
44. meter must be used with nitrogen or carbon dioxide Service Valves Field installed ball type service valves ARE RECOMMENDED TO FACILITATE SERVICING between the machine rack the remote condenser and the heat recovery coil NOTE Use long radius elbows rather than short radius elbows Less pressure drop and greater strength make the long elbows better for the system This is particularly important on discharge hot gas lines for strength and suction lines for reduced pressure drop Avoid using 45 degree elbows Vibration Isolation amp Piping Support Piping must be properly supported to minimize line vibration Vibration is transmitted to the piping by movement of the compressor and pressure pulsation s of the refrigerant as it is pushed through the piping NOTE Installer must follow applicable mechanical codes for pipe support and hanger installations Insufficient and improper supporting of tubing can cause excessive line vibration resulting in Excessive noise Noise transmission to other parts of the building e Vibration transmission of floors walls etc Vibration transmission back to compressor and other attached components Decreased life of all attached components Line breakage 2 2 Refrigeration Piping June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Guidelines for Good Piping NOT GOOD Tubing will vibrate or rotate about point C GOOD Long runs will
45. n amp Service Manual amp ENVIROGUARD Oil Control System The oil control system is made up of several devices working together to provide a constant supply of recirculated oil to the compressors Oil Separator As hot discharge gas leaves the compressors it must first travel through the oil separator The oil separator s duty is to make the refrigeration system more efficient and to save energy It does this by removing oil from the refrigerant vapors which would otherwise travel through out the system Because oil is a lubricant not a refrigerant its presence in the refrigeration circuits will reduce the efficiency of the system Oil Separator Operation An oil float located in the bottom of the oil separator opens or closes when a specific oil level is reached in the oil separator The float is attached to a needle valve which opens as the float rises to the upper limit of its travel The needle valve is located in the line between the separator and the oil reservoir When the valve opens oil is forced to travel to the reservoir which is at a lower pressure During normal operation the oil return line from the oil separator to the reservoir will be alternately hot and cool This is caused by the oil float valve alternately opening and closing while returning oil to the reservoir An oil return line at ambient temperature may suggest that the needle valve may be blocked by foreign matter or the oil strainer is plugged If the oil
46. nifold Settings are presented and include the pressure drops for the liquid line check valves and the defrost return solenoid valve Differential Pressure Settings for OLDR at Various Heights Chart ELEVATION PSD ELEVATION PSD NOTE The OLDR valve should be set at a minimum differential of 20 psi 10 2 OLDR Liquid Differential Regulator Valve June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Parallel Rack Pressure Control Settings PSIG These settings are average and will have to be adjusted to suit the particular store and case line ups Use an accurate gauge to make settings Use pressure settings as backup with electronic rack control CUT IN CUT OUT PRESSURE SETTINGS PSIG compressors e z e s s 2 R2210W 5 6 7 o 10 n 12 curour Jo o jo o 1 22 MED Low 9 10 14 12 13 14 15 16 CUTOUT JO 1 2 8 4 5 6 RAO4A MED also applies to R 507 Pressure Cycling Set Points for Condenser Fans REFRIGERANTS R404A 507 FANS OR DEFROST TYPES amp SETTINGS PAIRS OF HOT GAS ELECTRIC HOT GAS ELECTRIC FANS ON OFF ON OFF ON OFF ON OFF 200 180 210 190 170 150 230 210 190 170 200 180 160 140 220 200 180 160 190 170 150 130 200 180 160 140 170 150 130 110 190 170 150 130 160 140 120 100 High Pressure CUT
47. nkcase 5 Wrap clean rag tightly around the oil fill opening and crack the suction service valve to pressurize the crankcase to about 5 psi Oil will be forced out of the drain line and will continue to drain due to the siphon effect on the oil the residual refrigerant pressure will prevent any serious amount of moisture or foreign particles from entering the compressor 6 After the desired amount of oil has been drained remove the drain tube and reinstall the oil fill plug 7 Open the compressor suction and discharge service valves 8 6 Oil Control System June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD SECTION 9 Pressure Regulator Settings These settings are given as initial adjustment guidelines The settings required for each individual system may vary STANDARD settings are given as comparisons and can be used for single compressor remote condenser systems which may have the IPR and OPR A single compressor system cannot take advantage of reduced cool weather loads and increased system capacity NC systems feature two and up to eight compressors with solid state or conventional pressure controls to cycle off needed compressors NC 2 is the same with an additional liquid bypass for maximizing natural liquid subcooling NC 3 includes mechanical subcooling IPR Inlet Upstream Pressure Regulator STANDARD NO FLOATING HEAD TYPE OF ELECTRIC ELECTRIC GAS DEFR
48. nt to use a maximum pressure differential of 25 psi Refer to Figure 1 LOW TEMP EXTRA LOW TEMP SUCTION MANIFOLD LLL CHECK VALVE 20 PSID NOTES 1 REGULATING VALVE IS REQUIRED IF SUCTION PRESSURE DIFFERENTIAL BETWEEN LT amp XLT IS GREATER THAN 15 PSI OIL SEPARATOR DISCHARGE MANIFOLD FIGURE 1 8 2 Oil Control System June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD When a high temperature satellite is employed the reservoir is still vented to the main suction manifold but the check valve in the vent line must be sized to raise the oil feed pressure approximately 10 psi above the satellite suction pressure That pressure is then stepped down with the regulating valve to approximately 20 psi above the suction pressure of the main Refer to Figure 2 MED TEMP HIGH TEMP SUCTION MANIFOLD NOTES 1 CHECK VALVE PSID EQUAL TO HIGH TEMP SUCTION PRESSURE MINUS MAIN SUC TION PRESSURE PLUS 20 PSI 2 REGULATING VALVE OUTLET SETTING EQUAL TO MAIN SUCTION PRESSURE PLUS 20 PSI FIGURE 2 Q REGULATING VALVE SEE NOTE Ifan ORI 6 is used here instead of a check valve s adjust valve to maintain reservoir pressure at 20 psi higher than suction pressure of high temperature satellite The oil system for an internally compounded Carlyle system requires that the pressure differential across the
49. oil level float control be approximately 20 psi In addition the oil reservoir is vented to the interstage manifold See pages 22 4 amp 22 6 June 2007 Oil Control System 8 3 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION 7 Checking Oil Level Oil level may be checked with the system either operating or idle Some reservoirs are equipped with two sightglasses Oil level should be maintained between the two sightglasses Compressor oil level may be checked on the sightglass on each compressor crankcase The level may be viewed on the oil level control if it is equipped with a sightglass CAUTION The level indicated on the oil level control sightglass may give a false indication of actual crankcase level Use the sightglass on the compressor crankcase for an accurate oil level or to verify the oil level control sightglass reading Improper compressor oil levels could cause damage to the compressor Oil Level Control Adjustment The oil level control may be adjusted to vary the oil in the compressor crankcase To reset the oil level control remove the seal cap on the top of the control Turn the adjustment clockwise to lower and counterclockwise to raise the oil level See chart below for the number of turns required CAUTION When setting OL60XH 4 OL1 CH float controls DO NOT adjust beyond 9 turns down from the top stop or control may be damaged For all other float controls refer to O E M for setting instructions
50. on System is Dependent Upon 1 Good piping practices with properly sized and installed lines as directed in this section 2 Cleanliness of all refrigeration piping is of the utmost importance in the installation procedure CAUTION The use of gaseous nitrogen or carbon dioxide flowing at low pressure through the lines while they are being welded is necessary to assure relative freedom from oxides and scale which can clog the small ports on pilot operated valves and other valves in this system Some Possible Consequences of Poor Piping Increase oil requirements Decreased operating efficiency and loss of capacity ncreased changes of fouling vital components Failed compressors When NC 2 NC 3 or Enviroguard is employed ALL LIQUID LINES to and from the parallel rack all the way from the compressor rack to the fixtures MUST BE INSULATED Allowing subcooled liquid to warm in the lines cancels the energy saving advantage of subcooling the liquid and may even cause liquid to flash Flashing occurs when liquid converts to gas before reaching the expansion valve this will cause erratic valve feed and subsequent loss of refrigeration ALL SUCTION LINES MUST BE INSULATED in order to assure cool suction gas to the compressor Cool gas is necessary to aid in cooling the motor windings Head cooling fans help and sometimes are required by the compressor manufacturer Compressor motor failure can result if the suction gas
51. or computer controls will operate the compressors in such a way as to achieve the ideal suction pressures The systems still require setting pressure differentials and time delays as back ups 11 2 Parallel Pressure Control Settings June 2007
52. require additional supports between A and A GOOD Support at C may not be necessary for very short runs 1 A STRAIGHT RUN OF PIPING must be supported at each end Longer runs will require additional supports along the length usually these are not more than 8 internals depending on tubing size and situation Clamps should be properly anchored and rubber grommets installed between the piping and clamp Hydra zorbs or equivalent to prevent line chafing June 2007 Refrigeration Piping 2 3 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A NOT GOOD GOOD A 2 CORNERS MUST BE SUPPORTED and cannot be left free to pivot around the A B axis as shown above Don t Overdo It NOT GOOD Sed PIPE DIAMETERS 3 DON T OVER SUPPORT PIPING when it is attached to the compressor rack It must be free to float without stress 4 DON T USE SHORT RADIUS ELBOWS They can add excessive internal stress and pres sure drops which can lead to failure 5 CHECK ALL PIPING AFTER THE SYSTEM HAS BEEN PLACED IN OPERATION Excessive vibration must be corrected as soon as possible Extra supports are cheap when compared to the potential refrigerant loss caused from failed piping PROPER LINE SIZING IS THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR Application Department recommendations are listed on the System Summary Sheet furnished if required with the job Also refer to the line sizing charts in these instr
53. s very important When sizing for a suction line riser use the proper chart These charts are based on maintaining minimum velocities in the risers This will assure that the oil mixed with the refrigerant will return to the compressor Improper line sizing could cause less than optimum performance or pose the possibility of compressor damage due to oil failure NOTE The line sizing information shown on each case Specification Sheet applies to horizontal runs only DO NOT use this information for vertical runs The liquid line sizing charts shown in the BUFF section of the Specification Guide can be used for both horizontal and vertical runs When in doubt about oil return due to a point being near a line use the smaller size line Any sizing of riser or any other suction line or device must be considered in view of the total system The addition of any suction line pressure drop must not be ignored If suction P traps are used it is recommended that they be sized according to the horizontal line sizing chart CAUTION Do not arbitrarily reduce vertical risers without consulting these charts Unnecessary vertical suction line reduction can cause excessive pressure drop resulting in loss of system capacity
54. sure the following valves are OPEN Discharge Service Valves on compressors Suction Service Valves on the compressors Liquid Return Valve on the receiver from remote condenser Liquid Outlet Valve on the receiver All field supplied Hand Shut Off Valves All Liquid Line Manifold Valves All Suction Line Manifold Valves All Hot Gas Manifold Valves 3 Draw vacuum down to 500 microns with vacuum pump System must hold 500 microns NOTE 500 microns is the standard representing the absence of moisture in the system 7 2 Start Up Procedures June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD 4 The system is now ready for charging Remember that even the most careful evacuations and purging will not clean up a system that has been carelessly put together NOTE Moisture and air must be removed from the system in order to avoid any possibilities of compressor burnouts Complete evacuation draw vacuum down to 500 microns is one of the best ways to ensure the system is clean Parallel Charging amp Start Up Procedure Be sure to use the appropriate refrigerant designed for the system Low and Medium temperature systems typically use either R404A or R 22 refrigerant depending on the system design For charging of the TYLER Commercial Refrigeration system use the high side charging method FOR ENVIROGUARD SYSTEM CHARGING see pages 24 10 amp 24 11 Follow these precautions prior to and during
55. t is possible for this natural pressure drop to be higher than the differential valve s setting IMPORTANT To verify valve operation if no differential is occurring between the liquid header and the receiver during defrost take all cases out of defrost and then put the valve in its differential mode and check its setting If the valve is maintaining its set point with normal head pressures and no cases in defrost then the valve is opening correctly and some other system condition such as outlined previously may be causing the problem June 2007 OLDR Liquid Differential Regulator Valve 10 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION OLDR Valve on Gas Defrost Systems In order for the reverse flow to occur during gas defrost the pressure of the gas defrost mani fold must be greater than the pressure of the liquid header The OLDR valve is used to create the differential required when a circuit goes into defrost The valve is in the differential mode when energized It uses an MKC 2 coil and fails in the full open position OLDR Valve Illustrations Coil Energized Coil De Energized OLDR 20 Differential Operation OLDR 20 Full Open Operation MKC 2 Coil Pilot Differential Valve Figure 1 Figure 3 The following chart lists the differential pressure settings for the OLDR at various heights of liquid lifts from the lowest fixture liquid line elevation to the condenser inlet ma
56. tank off If no pressure changes are observed the system is tight If leaks are found isolate that particular portion of the system by closing off the hand valves Let the leak depressurize the system at that point and repair the leak immediately NOTE The use of nitrogen or carbon dioxide flowing at low pressure through the lines while they are being welded is necessary to assure relative freedom from the formation of oxides and scale These can easily clog the small ports on the pilot operated and other valves in the system Evacuation Procedure When the system is proven leak free evacuate it using an efficient vacuum pump with clean or fresh oil and sufficient time to do a thorough job Leave the system in a vacuum to aid in charging NOTE Due to recommended piping of heat recovery coils it is necessary to field supply a temporary by pass between the line downstream of the inlet check valve on the heat recovery coil and the discharge line downstream of the IPR hold back valve Failure to by pass the IPR will result in the inability to evacuate the reclaim coil The by pass line must be removed after evacuation to assure proper operation of the system See piping schematics on page 4 1 Evacuation Method 1 Attach vacuum pump to the system to be evacuated NOTE TYLER provides large servicing ports at Discharge line after the Oil Separator Liquid line prior to the Filter Suction Manifold Return Manifold 2 Make
57. the charging procedure 1 Make sure all system filters are properly installed and clean before charging the system 2 All charging lines must be cleaned and purged to ensure they are free of air and moisture 3 The system must be tested for leaks and evacuated properly prior to charging it with refrigerant 4 Remember to wear safety goggles when transferring and charging refrigerants NEVER allow liquid refrigerant to reach the compressors The liquid is not compressible and will damage the compressors 6 Be sure all temperature controls are set to the anticipated temperatures in each of the circuits Connect high and low side pressure gauges to common connection point or headers Make sure all fixtures are supplied with false loads prior to start up INSURE PROPER OIL CHARGE BEFORE STARTING THE COMPRESSORS Use oil recommended by the manufacturer NOTE The manufacturer s information is tagged to the compressor Charging amp Start Up 1 Use the charging tables on pages 6 1 amp 6 2 to determine the proper amount of refrigerant to charge into the system 2 Attach a refrigerant tank with gauge and dehydrator to the 3 8 Schrader Valve next to the downstream regulator Fill the receiver with as much refrigerant as it will take usually one tank 4 Attach a refrigerant tank with gauge and dehydrator to the receiver outlet valve service port 16 cubic inch drier should be used on a 145 pound cylinder Close the rece
58. the pilot differential piston The inlet pressure then moves the piston up and the valve opens See Figure 3 on page 10 2 Setting Procedure The OLDR is set by turning the adjusting stem located under the cap on the pilot differential valve Turning the stem clockwise increases the setting counterclockwise decreases the setting Adjustments must be made with the valve in its differential mode and no refrigerated cases in defrost so that the head pressure is normal Artificial low head pressure at the initiation of defrost can prevent a differential from occurring thereby making it impossible to set the valve ALWAYS set the OLDR when no cases are in defrost Once the pilot valve is set it will modulate to maintain this differential setting during defrost However there are several system conditions that can cause the differential to change beyond the valve s control and still be acceptable 1 When a defrost is initiated the head pressure may fall It can take several minutes for the differential to be created while the head pressure returns to normal 2 If there is a very low requirement for refrigeration and therefore low demand for liquid refrigerant the differential may never build up enough to reach the valve setting 3 As a gas defrost cycle progresses condensing occurs in the evaporator in defrost at a slower rate Therefore there is more gas present in the evaporators which results in a higher natural pressure drop I
59. uctions Horizontal suction lines should slope 1 2 per 10 foot of run toward the compressor to aid in good oil return 2 4 Refrigeration Piping June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Gas Defrost Liquid Lines Branch Lines LINES INTO CASES ARE ALWAYS 1 2 MAIN LIQUID LINE MUST 5 8 MINIMUM NOTE TEES POINT DOWN EVEN WITH JUST 1 CASE et 2 FOR as DEFROST Liquid lines to the cases should be branched off the bottom of the header This ensures a full column of liquid to the expansion valve A branch line from the header to an individual case should not be over 3 long and must have 3 expansion loop incorporated Don t Cross Pipe Systems Do not run suction or liquid lines through cases that are part of a separate system especially if either has gas defrost NOTE If there is no way to avoid this insulate the piping for the portion that runs through the other cases Allow for Expansion The temperature variations of refrigeration and defrost cycles cause piping to expand and contract The expansion of piping must be taken into consideration otherwise a piping failure will result The following are typical expansion rates for copper tubing 40 F to 100 F 2 5 per 100 feet of run ultra low temp O F to 40 F 2 per 100 feet of run low temp O F to 40 F 30 F to 50 F 1 per 100 feet of run high temp
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