Heatcraft Refrigeration Products Air-Cooled Condensers none User's Manual
Contents
1. The name behind the brands you trust HEATCRAFT Worldwide Refrigeration Commercial Refrigeration Parts CLIMATE Ci terLINIOD BOHN TROL te H IM 90 0808 CHANDLER2. POWER SUPPLY 18 FAN 1 HEADER FAN FAN 2 FAN 3 FAN 4 Diagram 3 Typical EC Condenser Wiring Diagram with External Signal FAN MOTOR IDENTIFICATION HEATCRAFT 3y 60Hz i lt lt USE COPPER CONDUCTORS ONLY FACTORY WIRING FIELD WIRING HEADEREND DISCONNECT SWITCH FAN SPEED CONTROL CIRCUIT Oto 10VDC TERMINAL BOARD 1 TERMINAL BOARD 2 MI 8 GND e 7 0 10V PWM 2 GND pe et 2 M2 LL 8 GND VY 7 0 10V PWM me 2 GND pe our __ tie 7 0 10V PWM 2 GND meor 2 g 5 M4 L 8 GND 7 me 2 GND oe out 2 5 Lf 8 GND ALL MOTORS TO BE PROGRAMMED AS FOLLOWS k 7 0 10V PWM OPERATION MODE Open Loop Pulse Width Modulation 6 2 GND 0 1 OUT PRIORITY Poti ANCONTA M FANMOTOR TB TERMINAL BOARD 1 UNIT MUST BE GROUNDED F FUSES CB CIRCUIT BREAKER 2 TO BE FIELD FUSED REFER TO UNIT DATAPLATE FOR VOLTAGE R RELAY R RELAY 3 ALL MOTORS ARE INHERENTLY PROTECTED FCC FAN CYCLE CONTROL MAY BE PRESSURE OR TEMPERATURE 4 USE 60 WIRE PM POWER MODULE USED ONLY W SYSTEM 350 COMPONENTS 5 REFER TO LABEL ADJACENT FUSE HOLDER FOR REPLACEMENT A319 THERMOSTAT FAN CYCLE CONTROL Diagram 4 Typical EC Condenser Wiring Diagram with Proportional Pressure Co
3. entrance Do not attach ductwork to the coil inlet or fan outlet Care should be taken to avoid air recirculation conditions that can be caused by sight screening walls etc Also keep unit fan discharge away from any building air intakes See page 4 for space and location requirements Sound Vibration Units should be installed away from occupied spaces and above or outside of utility areas corridors and auxiliary spaces to reduce the transmission of sound and vibration to occupied spaces The refrigerant piping should be flexible enough to prevent the transmission of noise and vibration from the unit into the building If the refrigerant lines are to be suspended from the structure of the building isolation hangers should be used to prevent the transmission of vibration Where piping passes through a wall it is advisable to pack fiberglass and sealing compound around the lines to minimize vibration and retain flexibility in the lines The unit needs to be secured in its final location Holes are provided in the base runner for this purpose Warning This equipment may contain a substance which harms the public health and environment by destroying ozone in the upper atmosphere Venting of certain refrigerants to the atmosphere is illegal Refrigerant recovery devices must be used when installing or servicing this product Consult your local codes for requirements in your location Warning There may be more than one source
4. rest rooms and other auxiliary areas where high levels of sound are not an important factor Sound and structural consultants should be retained for recommendations AIR FLOW MIN VA VANS em Py AIR FLOW Per AIR FLOW BY OTHERS AIR IF SUPPLIED FLOW 10 MAX Typical Arrangements Figure 1 illustrates a typical piping arrangement involving a remote condenser located at a higher elevation as commonly encountered when the condenser is on a roof and the compressor and receiver are on grade level or in a basement equipment room In this case the design of the discharge line is very critical If properly sized for full load condition the gas velocity might be too low at reduced loads to carry oil up through the discharge line and condenser coil Reducing the discharge line size would increase the gas velocity sufficiently at reduced load conditions however when operating at full load the line would be greatly undersized and thereby create an excessive refrigerant pressure drop This condition can be overcome in one of two following Ways 1 The discharge line may be properly sized for the desired pressure drop at full load conditions and an oil separator installed at the bottom of the trap in the discharge line from the compressor 2 A double riser discharge line may be used as shown in Figure 2 Line A should be
5. 15 Setpoint Potentiometer Or 19 Module Connector Minimum e PNA Potentiometer Throttling Range Potentiometer 11 S az CM gt Eso LED Indicalor Percent of Output J1 Jumper Positions BB Reverse Acling Integration DIP Switch A F Direct Acting Head Pressure Setpoint The head pressure setpoint potentiometer is adjustable from 90 250 psig A typical setpoints are from 170 200 psig Note Very low setpoints may cause the fan motors to run full speed continually if the condenser is not properly sized The fans will turn off if the system pressure falls below the desired setpoint Minimum Output The minimum output potentiometer controls the minimum signal sent to the motor It is adjustable from 0 60 If this is adjusted to 60 the motors will not start running until 6V is applied to the motor The motor will start running at 60 of full speed To maximize sound reduction and energy savings and to provide the most stable control it is recommended this setting be left at 0 Throttling range The throttling range potentiometer controls how far the system pressure must deviate from the control setpoint to generate a 100 output signal from the control It is adjustable from 10 100 psig The throttling range determines how quickly the motor will reach full speed when detecting a change in head pressure For example if the setpoint is
6. Johnson Controls Style 350 operation 5 differential set on all modules All modules set in the heating mode Table 6 Pressure Chart NumberofFans of Fans Control Settings Double T Pressure Switch Cut In Settings Rows Refrigerant Based on 20 TD For RA04A R507 set cutout 35 PSIG below cut in for R134A set cutout 25 PSIG below cut in Fan on header end to remain on whenever compressor is operating 11 Table 7 Refrigerant Charge for Fan Cycling plus Flooded Condenser Ibs R 22 Summer Model Charge E N NIJ N I N gt N N of gt 80 88 08 8 8 vp pe fa peppers UJ i REISE E wlo 6 N _ FEF 2 m AIN c Oo 1215 22 38 48 29 51 63 om En con o so 69 o 37 69 o o 2 31 36 39 spe pe 31 42 49 43 57 66 43 77 95 57 102 125 o 77 105 161577 o 74 137 o o 135 Refrigerant R 22 Additional Refrigerant R 22 Charge Required for Flooded Condenser Operation Lbs For Charge 20 F TD Minimum Ambient at Condenser for summer Operation Lbs See Model Cross Reference Table 10 Table 9 Flooded Charge Temperature Difference Factor Design T D Ambient F 30 25 20 15 10
7. at terminal KL2 even with the unit turned off Warning With a control voltage fed in or a set speed value being saved the motor will restart automatically after a power failure Speed Adjustment Characteristics The EC motor varies it s speed linearly based on a 0 10V input signal At 10 VDC the motor runs at full speed At 0 VDC the motor turns off A chart of the speed control curve is shown below Speed min N nom 1030 RPM 0 V 1 10 Control voltage The input control signal can be supplied from any controller that outputs a 0 10 VDC signal For units with a control signal supplied from a rack control or other external controller the unit is provided with a terminal board for control signal wiring Units with factory installed proportional pressure controls require no installation wiring External Control Signal Contact control manufacturer for setup of external controller to provide 0 10 VDC control signal Wire the control signal to terminal board in unit control box See Diagram 3 for typical external signal control wiring Proportional Pressure Control Units with factory installed proportional pressure controls use a PI controller to vary the motor speed in order to maintain a constant desired head pressure The PI controller has five user adjustable features e Head Pressure Setpoint Minimum Output e Throttling range Integration constant Reverse acting or direct acting mode of operation
8. should be in accordance with National Electrical leads from each motor terminate at the unit junction Electrical Code local codes and regulations Proper overcurrent box Field connections must be made from these leads in protection should be provided for the fan motors accordance with local state and national codes All standard motors have internal inherent overload protectors Three phase motors must be connected to three phase power of Therefore contactors can be used instead of starters requiring voltage to agree with motor and unit dataplate thermal protectors eliminating the problem of furnishing the proper heating elements The motors are wired into a common junction box Where ee fan cycling is furnished and factory installed the motors All air cooled condensers are furnished with either single phase completely wired through the control and to the contactors The or three phase fan motors which are identified by the unit motors must be checked for proper rotation Be sure to check that dataplate motor voltage and control connection agree with electric services furnished WARNING There may be more than one source of electrical current in this unit Do not service before disconnecting all power supplies Diagram 1 Typical Condenser Wiring Diagram with Fan Cycle Controls FAN MOTOR IDENTIFICATION USE COPPER CONDUCTORS ONLY FACTORY WIRING FIELD WIRING FAN CONTROL CIRCUIT 12 60Hz 15 AMPS MA
9. 200 psig and the throttling range is 50 psig when the system pressure is below 200 psig the fans will be off When the system pressure reaches 250 psig the fans will be at full speed see Chart 1 below To make the fans ramp more slowly the throttling range should be increased see Chart 2 below To maximize sound reduction and energy savings and to provide the most stable control it is recommended this setting be left at 100 psig 8 0 5 gt Motor RPM Motor RPM 0 0 0 200 psig 250 psig System Pressure 9 200 psig 300 psig System Pressure Chart 1 Ramp characteristics with 200 psig setpoint and 50 psig throttling range Chart 2 Ramp characteristics with 200 psig setpoint and 100 psig throttling range Integration constant The integration constant switch provides ability to change controller from a proportional only control to a proportional plus integral control To provide the most responsive system to maintain a stable head pressure it is recommended this setting be left on fast Reverse acting or direct acting mode of operation The reverse acting direct acting jumper is used to ensure the controller responds correctly to maintain desired head pressure In Direct Acting DA mode the motor speed increases as the pressure rises above desired setpoint For proper condenser operation this jumper MUST be in Direct Acting DA mode Failure to ensure J1 jumper is in direct acting mode
10. 9360 03 170 74 24 O os oos 0 wv j 16 Table 10 Model Cross Reference Model Reference NH NL NX NQ NE NL S01 A007 NE S01 A008 NE S01 A009 31 NH S02A011 NLSO2A010 NX S02 A010 NO SO2 A008 NE S02 A011 NE S02 A015 NE S02 A018 61 NH S03 A022 NL S03 A021 NX S03 A020 0 503 016 NE SO3 A023 NE S03 A027 8 NH S04 A030 NL 04 A028 NX 504 A026 0 504 021 NE SO4 A031 __ 9 NH S04 A034 NL S04 A032 NX 504 A030 NQ S04 A023 NE S04 A036 10 NH 05 A037 NL S05 A036 NX S05 A033 NQ SO5 A026 NE S05 A039 NE S05 A047 NE S06 A056 NE S07 A065 NE D04 A023 NE D04 A031 NE D04 A036 NE D06 A046 NE D06 A054 P19 NH D08 A058 NL DO8 A056 NX DO8 A053 NO DO8 A041 NE DO8 A062 NE D08 A073 NE D10 A079 NE D10 A093 NE D12 A112 First letter of model corresponds to a particular brand B is Bohn L is Larkin C is Climate Control H is Chandler Maintenance Air cooled condensing units require a minimum of maintenance the condenser fan motors have sealed ball bearings The only The unit coil will require a periodic cleaning and this can be acceptable service to these bearings is replacement accomplished by a brush vacuum cleaner pressurized air stream or a commercially available coil cleaning foam All of Cleaning Instructions Heatcraft recomme
11. Air Cooled Condenser HEAT CRAFT Installation amp Operation Worldwide Refrigeration Bulletin No H IM 90 August 2008 Part Number 25007301 Replaces H IM 90 March 2006 Table of Contents Inspection System Warranty Installation Unit Location Sound Vibration Rigging Instructions Space and Location Requirements Typical Arrangements Installation Refrigerant Piping Line Sizing Discharge Lines Electrical Wiring Typical Wiring Diagram Start Up Discharge Gas Pulsation Operation Winter Operation Head Pressure Control Fan Cycling Fan Cycling Head Pressure Controls Flooding Head Pressure Controls Refrigerant Charge Minimum Ambient for Fan Cycling Mechanical Fan Cycling Thermostat Settings Electronic Fan Cycling Thermostat Settings ir Cooled Pressure Chart A I r O O e Refrigerant Charge for Fan Cycling plus Flooded Condenser 12 Flooded Charge Temperature Difference Factor Co n d e n S e rs Additional Refrigerant Charges Model Cross Reference Maintenance Cleaning Instructions In Warranty Return Material Procedure InterLink Parts List E Series Motors with Integrated Variable Speed Speed Adjustment Characteristics External Control Signal Proportional Pressure Control Installation and Throttling Range 2 gt d Integration Constant e rat 1 0 n G u 1 Reverse Acting or Direct Acting Mode Master Slave Configuration Protective Features Applicable for Bohn Larkin Phase
12. Failure Climate Control and Chandler brands EC Motor Wiring Typical 1 x 4 EC Motor Wiring Diagram Typical EC Condenser Wiring with Ext Signal Typical EC Condenser Wiring with Proportional Pressure Control Installation Check List Inspection Responsibility should be assigned to a dependable individual at the job site to receive material Each shipment should be carefully checked against the bill of lading The shipping receipt should not be signed until all items listed on the bill of lading have been accounted for Check carefully for concealed damage Any shortage or damages should be reported to the delivering carrier Damaged material becomes the delivering carrier s responsibility and should not be returned to the manufacturer unless prior approval is given to do so When uncrating care should be taken to prevent damage Heavy equipment should be left on units shipping base until it has been moved to the final location System Warranty This equipment is designed to operate properly and produce rated capacity when installed in accordance with accepted industry standards Failure to meet the following conditions may result in voiding of the system warranty 1 System piping must be installed following industry standards for good piping practices 2 Inert gas must be charged into piping during welding 3 System must be thoroughly leak checked and evacuated before initial charging High vacuum gauge capable of reading mi
13. X BVERCURRENT PROTECTION TERMINAL BOARD 3 7 40 468 FCC 7 1 44 82 conte cB 11 15 48 18 16 F6 c3 15 19 52 16 20 i 4 19 23 siecle 56 3 20 24 23 60 24 LEGEND FAN CONTACTOR MOTOR TERMINAL BOARD FAN MOTOR TB TERMINAL BOARD FUSES CB CIRCUIT BREAKER RELAY R RELAY FAN CYCLE CONTROL MAY BE PRESSURE OR TEMPERATURE POWER MODULE CUSED ONLY W SYSTEM 350 COMPONENTS THERMOSTAT FAN CYCLE CONTROL TRANSFORMER 3 60 2 Li NOTE 1 UNIT MUST BE GROUNDED 2 TO BE FIELD FUSED REFER TO UNIT DATAPLATE FOR VOLTAGE 3 ALL MOTORS ARE INHERENTLY PROTECTED 4 USE 60 C WIRE 5 REFER TO LABEL ADJACENT FUSE HOLDER FOR REPLACEMENT TERMINAL BOARD o Start Up Check for proper fan rotation Air is drawn through the coil on all units Be sure the fans turn freely Rotation of the motors and blades should be in a CW direction looking at the unit from the blade side On three phase units it may be necessary to reverse two of the three power leads to the unit The manifold assembly is not designed to support field piping Any damages to the condenser due to excessive weight pressure or vibration will not be covered by our standard warranty Discharge Gas Pulsation Gas pulsations in a refrigeration system are mos
14. air flow and access all sides of the unit should be a minimum of W away from any wall or obstruction It is preferred that this distance be increased whenever possible Care should be taken to see that ample room is left for maintenance work through access doors and panels Overhead obstructions are not permitted When the unit is in an area where itis enclosed by three walls the unit must be installed as indicated for units in a pit Multiple Units For units placed side by side the minimum distance between units is the width of the largest unit If units are placed end to end the minimum distance between units is 4 feet Units in Pits The top of the unit should be level with the top of the pit and side distance increased to 2W If the top of the unit is not level with the top of pit discharge cones or stacks must be used to raise discharge air to the top of the pit This is a minimum requirement Decorative Fences Fences must have 5096 free area with 1 foot undercut a W minimum clearance and must not exceed the top of unit If these requirements are not met unit must be installed as indicated for Units in pits W Total width of the condenser Another consideration which must be taken is that the unit should be mounted away from noise sensitive spaces and must have adequate support to avoid vibration and noise transmission into the building Units should be mounted over corridors utility areas
15. ched After de blocking the motor WILL restart automatically Under voltage protection If power supply voltage falls below 150VAC 3 for 230V motors or 290VAC 3 for 460V motors for 5 seconds minimum the motor will be switched off electronically and the alarm relay is switched If power supply voltage returns to correct values the motor WILL restart automatically Phase failure If 1 phase fails for 5 seconds minimum the motor will be switched off electronically and the alarm relay is switched If all 3 phases return to correct values the motor WILL restart automatically within 10 40 seconds EC Motor Wiring All EC motor wiring is done at the factory If any motor wiring needs to be done in the field the diagram below indicates the terminal pin configurations inside the motor junction box Terminals in shaded area are not normally used Function Protection earth terminal screw Mains power supply Phase L3 Mains power supply Phase L2 Mains power supply Phase L1 arm relay brake for failure ad capacity 250 V AC A at cose 1 arm relay COMMON ad capacity 250 V AC at 1 arm relay make for failure ad capacity 250 V AC A at cos 1 1 OUT aster OUT for speed setting of _ 0 10V Slave Units max 10 mA E 2 GND GND 0 10 V analogue input PWM input resistance 100 kOhm PWM frequency 2 1 kHz 10 V 15 power supply for external potentiometer max 10 mA short ci
16. crons is mandatory Dial indicating pressure gauges are not acceptable 4 Power supply to system must meet the following conditions a Voltage for 208 230 motors not less than 195 volts or more than 253 volts b Allother voltages must not exceed 1096 of nameplate ratings c Phase imbalance not to exceed 2 5 All controls and safety switch circuits properly connected per wiring diagram 6 Factory installed wiring must not be changed without written factory approval Installation Installation and maintenance to be performed only by qualified personnel who are familiar with local codes and regulations and experienced with this type of equipment Caution Sharp edges and coil surfaces are a potential injury hazard Avoid contact with them Unit Location Units are designed for outdoor application and may be mounted on a roof or concrete slab ground level installation Roof mounted units should be installed level on steel channels or an l beam frame to support the unit above the roof Use of vibration pads or isolators is recommended The roof must be strong enough to support the weight of the unit Concrete slabs used for unit mounting should be installed level and be properly supported to prevent settling A one piece concrete slab with footings extending below the frost line is recommended The condenser should be located far enough away from any wall or other obstruction to provide sufficient clearance for air
17. d be maintained above a condensing temperature corresponding to 90 F This in effect corresponds to a normal lower limit of about 60 F ambient air Since air conditioning is not normally required at these lower ambient temperatures condenser head pressure control may not always be necessary However for those applications which are of such a nature that operation is required below 60 F ambient air temperature additional head pressure control will be required Fan Cycling A decrease in ambient air temperature results in a capacity increase in the air cooled condenser This capacity increase is directly proportional to the temperature difference between the condensing temperature and the temperature of the ambient air entering the condenser Since air cooled condensers are often required to operate over a wide range of ambient air temperatures and variable loading conditions provisions must be made to maintain the overall system balance Any air cooled condenser tends to run at a low head pressure when operating in alow ambient air temperature Low head pressures could result in poor expansion valve operation and poor system operation The cycling of condenser fans provides an automatic means of maintaining head pressure control within reasonable limits at lower ambient air temperatures A fan cycling control system allows fans to cycle in sequence by sensing either ambient temperature or condensing pressures However care must be u
18. de Do not cycle more than two fans at a time on double wide condensers and only one fan at a time on single wide condensers Fan Cycling Head Pressure Controls Condenser fans are cycled to maintain adequate head pressure Ambient and pressure fan cycling are available as optional equipment Ambient fan cycling cycles fans in response to the ambient air temperature This control is ideal for multi circuited condensers or for systems operating in mild ambient conditions See table 3 for minimum ambient temperatures for fan cycling Set points for thermostats will vary depending on the number of fans and condenser design T D See table 4 for recommended set points Pressure fan cycling cycles fans in response to condenser pressure This style of control is more appropriate where the load on the condenser will vary due to multiple compressor operation or stages of unloading or systems incorporating heat reclaim or hot gas defrost Variable Speed Condenser head pressure control is provided by varying the air flow through the condenser by changing the RPM of the condenser fan This control package is offered in combination with ambient fan cycling The fan motor next to the header end of the condenser is the variable speed fan The remainder of the fans are constant speed and are cycled separately using ambient sensing thermostats On condensers with two rows of fans two variable speed fans are provided one per unit and the remainder o
19. er means of head pressure control is to change the condenser capacity by filling the inside of the condenser with liquid refrigerant Flooding controls are ideal for condensers operating in low ambient conditions beyond the limits of fan cycling controls or under partial load conditions These controls require additional refrigerant charge to flood the condenser This additional refrigerant charge can often be reduced by incorporating the flooded control with one of the fan cycle controls previously described Several styles of flooding valves or combinations of valves are available Contact the valve manufacturer for specific recommendations Refrigerant Charge The refrigerant charge for summer operation can be found in table 8 This table also contains the additional charge required by flooding style controls Table 7 contains the recommended flooding charge required when combining fan cycling with flooding valves Table 3 Minimum Ambient for Fan Cycling Number of Fans Based on maintaining 90 F minimum condensing temperature Table 4 Mechanical Fan Cycling Thermostat Settings Single Double Design Rows T D 2 4 30 25 20 15 10 3 30 25 20 i Design T D Thermostat Setting Table 5 Electronic Fan Cycling Thermostat Settings NumberofFans_ of Fans 350 Temperature Stage Modules i Offset Settings N 1 oa n
20. f the fans are constant speed and are cycled in pairs Splitting Controls Additional head pressure can be provided by valving off a portion of the condenser circuit and removing that portion from the refrigeration circuit This is often referred to as splitting a condenser In addition to providing a means of head pressure control this control will reduce the amount of refrigerant required to operate the condenser with a flooded head pressure control Condenser splitting is recommended as a seasonal adjustment controlled by ambient temperature An initial setting of 50 to 55 F with a 20 F differential is recommended A pressure switch is also provided as a backup control to prevent high head pressures from occurring during heavy load conditions On condensers with a single row of fans the control package consists of an ambient sensing thermostat a pressure switch sensing condensing pressure and a splitting relay The splitting relay provides a set of dry contacts to control the valves required to split the condenser valves supplied by others On condensers with double rows of fans additional controls and contactors are provided to cycle all of the fans on the side of the condenser which has been split off Except as noted above the splitting packages do not control fan cycling It is recommended that fan cycling be controlled by combining the splitting package with pressure fan cycling Flooding Head Pressure Controls Anoth
21. nds that the finned surface of this unit be Calgon Corporation s CalClean 41352 or equal should be cleaned approximately every six months more frequent cleaning acceptable for cleaning this unit CalClean should be applied may be required if extreme conditions cause clogging or fouling liberally to entering air and leaving air surfaces of the finned area of air passages through the finned surface in accordance with the label directions CAUTION Under nocircumstances should this unit be cleaned with an acid based cleaner 13 In Warranty Return Material Procedure Material may not be returned except by permission of authorized factory service personnel of Heatcraft Refrigeration Products in Stone Mountain Georgia A Return Goods tag will be sent to be included with the returned material Enter the required information on the tag in order to expedite handling at our factories and prompt issuance of credits All parts shall be returned to the factory designated on the Return Goods tag transportation charges prepaid The return of a part does not constitute an order for replacement Therefore a purchase order must be entered through your nearest Heatcraft Refrigeration Products representative The order should include part number model number and serial number of the unit involved Following our careful inspection of the returned part and if itis determined that the failure is due to faulty material or workmanship credit will be is
22. ntrol FAN MOTOR IDENTIFICATION HEATCRAFT 3y 60Hz USE COPPER CONDUCTORS ONLY HEADEREND FACTORY WIRING FIELD WIRING DISCONNECT SWITCH P352PN Y350 SET P352PN J1 FOR DIRECT ACTING CONTROL SET P352PN MIN OUTPUT TO 0 SET P352PN THROTTLING RANGE TO 100 PSI SET P352PN INTEGRATION DIPSWITCH TO FAST TERMINAL BOARD 1 TRANSFORMER TERMINAL BOARD2 8 GND 7 0 10V PWM 2 GND 1 1 OUT i m Giu ALL MOTORS TO BE PROGRAMMED AS FOLLOWS OPERATION MODE Open Loop Pulse Width Modulation PRIORITY Poti LEGEND NOTE M FAN MOTOR TB TERMINAL BOARD 1 UNIT MUST BE GROUNDED F FUSES CB CIRCUIT BREAKER 2 TO BE FIELD FUSED REFER TO UNIT DATAPLATE FOR VOLTAGE R RELAY R RELAY 3 ALL MOTORS ARE INHERENTLY PROTECTED 4 USE 60 WIRE 5 REFER TO LABEL ADJACENT FUSE HOLDER FOR REPLACEMENT FCC FAN CYCLE CONTROL MAY BE PRESSURE OR TEMPERATURE PM POWER MODULE USED ONLY W SYSTEM 350 COMPONENTS A319 THERMOSTAT FAN CYCLE CONTROL Installation Check List Condenser Start Up Date Model Serial Electrical Voltage Amperage Installer Name amp Address Telephone Please retain this information with the condenser Since product improvement is a continuing effort we reserve the right to make changes in specifications without notice
23. of electrical current in this unit Do not service before disconnecting all power supplies O 2008 Heatcraft Refrigeration Products LLC Drawing 1 Rigging Instructions REMOVE FEET THAT ARE ATTACHED TO TOP OF LIFTING BRACKETS AND INSTALL ON BOTTOM OF LEGS AFTER UNIT HAS BEEN ROTATED TO UPRIGHT POSITION 516 HEX NUT TYPICAL 5 18 X 4 00 BOLT TYPICAL lL EXTEND LEGS TO OPERATING POSITION DO NOT REMOVE FEET THAT ARE ATTACHED NOTES TO BOTTOM OF LEGS Sarre REMOVE 4 00 BOLTS 2 PLACES AND SLIDE LEG amp FOOT 2 A AN TS FOR M TING Al CTRICA 0 BOLTS 2 Si E DARA TUTETE DOED LOR a MANC POK ASSEMBLY DOWN TO THE SHOWN POSITION THEN 4 IN NO CIRCUMSTANCE SHOULD COIL HEADERS RETURN BENDS OR ELECTRICAL REINSTALL 4 00 BOLTS BOX BE USED IN LIFTING OR MOVING THE CONDENSER Space and Location Requirements The most important consideration which must be taken into account when deciding upon the location of air cooled equipment is the provision for a supply of ambient air to the condenser and removal of heated air from the condenser area Where this essential requirement is not adhered to it will result in higher head pressures which cause poor operation and possible eventual failure of equipment Units must not be located in the vicinity of steam hot air or fume exhausts Walls or Obstructions The unit should be located so that air may circulate freely and not be recirculated For proper
24. rcuit protected 20 V 20 power supply for external sensors max 50 mA short circuit protected analogue input 4 20mA load 100 Ohm voltage drop 2 V at 20 mA analogue input input resistance 100 kOhm PWM frequency gt 1 kHz GND bus interface RS 485 ebmBUS Terminal RS B bus interface RS 485 ebmBUS Terminal RS A bus interface RS 485 ebmBUS Terminal RS B bus interface RS 485 ebmBUS Terminal RS A gt gt lt lt 10 V 20 V 4 20 mA 0 10 V PWM GND The following diagram shows typical motor wiring for a 1 x 4 EC condenser 17 Diagram 2 Typical 1 x 4 EC Motor Wiring with 0 10 DC Control Signal CONTROL WIRING m POWER WIRING 0 10V DC CONTROL SIGNAL L1 L2 L3 PE L1 L2 BLK L3 RED PE S o o m ES w M w M RSA RSB RSA RSB GND 0 10V PWM 4 20mA 20V 10V 0 10V PWM GND OUT NO COM NC L1 12 L3 PE L1 3 POWER SUPPLY 3 POWER SUPPLY 3 POWER SUPPLY 3
25. sed by the engineer or installing contractor in making adjustments to prevent short cycling of the fan motors Short cycling is normally caused by too close a differential in the control settings or set points If flooding valves are used with fan cycling they must be set to follow the fan cycling Recommended differential settings for ambient sensing thermostats are 5 F and a minimum of 35 PSIG differential for pressure switches However system or climate conditions vary and the controls may require further field adjustment to provide optimum system performance and prevent short cycling Any fan cycle that is less than three minutes is considered short cycling and could be detrimental to the system Adjust controls accordingly It is also recommended that the fan closest to the header end of the condenser be wired to run continuously whenever the compressor s is are operational Cycling all of the fans off usually results in rapid short cycling of the fans and erratic head pressure control If additional head pressure control is necessary beyond letting the lead fan run we recommend adding variable speed or flooding controls If cycling the header fan is necessary for adequate head pressure control we recommend cycling on pressure Ambient sensing thermostats should never be used to cycle the lead fan Fans must not cycle in multiples except on double wide single circuit condensers where they may cycle in pairs one motor on each si
26. sized to carry the oil at minimum load conditions and the line B should be sized so that at the full load conditions both lines would have sufficient flow velocity to carry the oil to the condenser For more complete information refer to the ASHRAE Handbook on Systems Figure 1 CHECK YALVE PREFERRED _ DISCHARGE LINE RELIEF VALVE COMPRESSOR RECELVER i CHECK VALVE Figure 2 PREFERRED CONDENSER BISCHARGE LINE 8 DISCHARGE LINE A RELIEF _ VALVE COMPRESSOR RECEIVER Notes 1 All oil traps are to be as short in radius as possible Common practice is to fabricate the trap using three 90 degrees ells 2 Pressure relief valves are recommended at the condenser for protection of the coil 3 A drain line check valve is recommended for applications where the condenser may be at a lower temperature than the receiver Installation Refrigerant Piping Install piping according to standard accepted refrigeration practice The following recommendations should be adhered to 1 SeeTables 1 and 2 for discharge and liquid drain line sizes for remote condenser connections 2 Useonlyrefrigeration grade copper tubing 3 Softsolder joints are not acceptable 4 Putdry nitrogen through lines while brazing 5 Donotleave dehydrated piping or components open to the atmosphere any longer than is absolutely necessary Discharge Lines The proper design of discharge lines involves two objec
27. sued on customer s purchase order Parts by InterLink When writing to the factory for service or replacement parts refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit If replacement parts are required mention the date of Inter LINK installation of the unit and date of failure along with an Commercial Refrigeration Parts explanation of the malfunctions and a description of the replacement parts required Table 9 InterLink Condenser Parts List 1140 H Models 1140 Var Speed Fan Motor Part Fan Blade Part Fan Guard No No Part No 25316401 22900401 23105701 25317101 2292625 23105701 1 5 75 1 5 1 0 5 25316601 22929501 23105701 25316201 22929301 23105701 Contact the InterLink Customer Service Department for parts to specific condenser models at 800 686 7278 interlinkparts heatcraftrpd com or www interlinkparts com 25316301 22929501 23105701 ESeries Motors with Integrated Variable Speed E Series units use an EC motor fan blade combination to provide variable speed condenser control All components required to run the motor at variable speeds are built into the motor Warning When connecting the unit to the supply power dangerous voltages occur Do not open the motor within the first 5 minutes after disconnection of all phases Be sure that the unit is isolated Warning Dangerous external voltages can be present
28. t commonly associated with the compressor and connecting discharge piping Variations in the system piping configuration line sizing operating pressures and compressor and component mounting all contribute to the presence and magnitude of these pulsations The vibration and movement of components caused by the pulsations may result in line breakage or damage to the condenser In order to eliminate discharge pulsations and the potential for related condenser damage it is recommended that a discharge muffler be installed in the refrigeration piping In all cases the recommendations of the compressor or muffler manufacturer must be followed when selecting these components Operation Winter Operation Head Pressure Control The capacity of an air cooled condenser varies with the difference between the entering air dry bulb temperature and the condensing temperature of the refrigerant Since air temperature in some regions varies as much as 100 from summer to winter some means must be employed to keep the condensing temperature sufficiently high to insure proper operation of the refrigerant expansion valve during low ambient operation and also allow sufficient capacity so that excessively high condensing temperatures do not result during high ambient conditions The low limit of the head pressure is dependent upon the required pressure drop across the thermostatic expansion valve For normal air conditioning applications head pressure shoul
29. tives 1 To minimize refrigerant pressure drop since high 2 To maintain sufficiently high gas velocity to carry oil pressure losses cause increased compressor through to the condenser coil and receiver at all loading horsepower per ton of refrigerant conditions Table 1 Tons of Refrigeration Line Size Discharge Line Drain Line Type op nt R 22 Sat Suction Temp F R 404A R 507 Sat Suction Temp F Velocity 100 FPM Refrigerant 40 0 40 40 0 40 12 os os os os om o 2 95 3s ow 9 poe 9 o3 23 eec 126 91 19 16 96 o oe 26 27 2 5 1 51 1 Source ASHRAE Refrigeration Handbook 1 Line sizes based on pressure drop equivalent to 1 F per 100 equivalent feet 2 Values in Table are based on 105 F condensing temperature Multiply Table capacities by the factors in Table 2 for other condensing temperatures 3 If subcooling is substantial or the line is short a smaller line size may be used Applications with very little subcooling or very long lines may require larger sizes Table 2 Condensing Temperature Correction Factor Condensing Discharge Line Temperature o 66 ao osm 698 oso o 67 oes 66 ose ue to vo vos 165 165 165 ue 18 me 169 168 ese Electrical Wiring The electrical installation
30. will cause the system to trip on high head pressure See Diagram 4 for typical proportional pressure control wiring Master Slave Configuration The EC motor control signals are wired in a Master Slave configuration This configuration allows for the maximum sound and energy reduction as well as the most stable head pressure control The control signal is delivered to the master motor located at the header end of the unit The master motor relays the control signal to the adjacent slave motor This relay is done until the last motor is reached As each slave relays the control signal it adjusts the signal so the next slave will run slightly slower than the upstream motor The end result of this is that when a motor receives a small enough signal it will turn off This provides built in fan cycling Protective Features The EC motors have many built in protective features The EC motors have functions within the motor to protect against e over temperature of electronics e over temperature of motor e incorrect rotor position detection With any of these failures the motor stops electronically and the alarm relay is switched With one of these failures the motor WILL NOT automatically restart To reset the power supply has to be switched off for a minimum 20 seconds once the motor is at standstill Locked rotor protection As soon as the rotor is blocked the motor gets switched off electronically and the alarm relay is swit
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