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Installation & Service Manual

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1. INIV1O3H 1V3H 20 45 ONidid 21413 1SOHJ3d OIHLO3T3 HO 440 AINIL GINDI1Z ON ADVLS HHH T HHH T HHH T HLIM WALSAS 13TIVHVd 56 80 V uolVHOdVA3 59120 Parallel System w NC 2 amp Heat Recovery 17 3 June 2007 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A Parallel System with Heat Recovery amp Companion In the medium temperature range the typical refrigeration case load operates at 20 F suction temperature Lowering the pressure to accommodate a few meat or deli operating at 10 15 F would penalize the whole system Because the lower the suction pressure at which a compressor is operated the less efficient it is The entire system would have to operate at this lower suction pressure By adding a companion one or more compressors operate at this lower efficiency rate while the other compressor s run at peak efficiency A companion compressor s suction line runs directly to the meat or deli cases A 2 pound check valve connection to the suction manifold allows the adjacent parallels to help pull down the meat deli cases temperature immediately after defrost If there were sufficient meat
2. TYPE LOOP 3x INN Dues ewe ese s ew Lew n ewe 19 CAE ala R po 024 5 SINIS TYPE C LOOP TUBE P O D L DEVELOPED LENGTH OF EXPANSION OFFSETS Cm que poe ee pe or pm or Dew a oor pe pee por ve or os por Dae wr aor se per pee e ae por we ne Law sr ar ee es ze sr oe pur on _ Few ur se pe pur we var vor er ese er er vr es we noc oe 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 or 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
3. 24 11 Setting the SPR 24 11 Setting the SPR on Enviroguard 24 12 Example Condenser Fan Control Charts 24 13 Temperature Pressure Charts 24 13 Sample Worksheet for R 22 Low Temp System Application 24 14 Sample Worksheet for R 22 Medium Temp System Application 24 14 Blank Worksheet for System Start Up 24 15 Adjusting the SPR 212 24 16 SPR Bleed Pressure at Various Ambients at Condenser Design 24 17 Low Temp with R507 24 17 Low Temp with R404A Chart 24 18 Low Temp with R 22 Chart 24 19 Medium Temp with 507 24 20 Medium Temp with R404A Chart 24 21 Medium Temp with R 22 24 22 Setting the Normally Open Solenoid for Enviroguard 24 23 Adjusting the Branch Circuit Expansion Valve 24 23 Condenser Fan Settings 24 23 Enviroguard Settings 24 24 Differential Pressure Settings for DDPR at Various Riser Heights Chart 24 24 Setting the DDPR for Enviroguard 24 25 Mechanical Liquid Subco
4. 134 ns J 111 1 LP P160X 60 P140X 60 P140X 50 163 188 ______ r 169 165 88 1 4 Planning for Mezzanine Machine Rooms mu 25 81 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 OPT VERTICAL RECEIVER OPT 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 MTG P67 22 11 16 APPROX TYP FOUR PADS EQUALLY SPACED ACROSS THE BACK 30 REF FIVE PADS SPACED ACROSS THE FRONT 17 APPROX REF DWG ISOL PAD MTG P90 94 30 5 16 APPROX TYP FOUR PA
5. sosues di H3SN3GQNOO HOLVHOdV 3 Ht June 2007 26 10 Enviroguard III PARALLEL COMPRESSORS amp ENVIROGUARD Installation amp Service Manual Enviroguard III Piping Diagram for Electric or Time Off Defrost Winter Operation einsseid de ainsseig 3 V J _ ssej5 wis O N prousjos o pinbr seno E Josuags SHd3 ueiqui jueiquiy es ce P lea n Ric ri X AXL X 2 HO1VHOdVA3 L4 HO1VHOdVA3 Enviroguard III 26 11 June 2007 PARALLEL COMPRESSORS TYLER REFRIGERATION amp ENVIROGUARD Enviroguard Piping Diagram for Hot Gas Defrost Summer Operation einsseid T V gt 9 ko 10 1 495 9 2 sse 9 ale 4 J prouejos 14615 An Plousjos ON pinbr1 eunssejd aaa a 104INVIN 88819 34615 ma JE Ee somes G104INVW 5 Suda 3 xs WU
6. 95 91 90 HOlIVHOdV 3 HOlIVHOdV 3 HOlIVHOdV 3 3NN amp d June 2007 24 32 Enviroguard amp ENVIROGUARD PARALLEL COMPRESSORS Diagram for Enviroquard with Gas Defrost amp Space Heat Recover Installation amp Service Manual Pi Tva K IMYA H3NIVHIS Uds ANYA dION310S CRT 000 3unssaud QV3H IH 22 4410 1808430 amp 4 Galv1nsNI Gadd QNIGN L NOT 2 X QO JHLNO u3onasNvu L o m e m lt NOILONS 55 19 SVS Ssvio 8 5 GAYA 88400 dunssdud LV3H 3OVdS ONidid H3SN3ONOO 1904430 SVD LOH SNIdid NOISS3HdAOO 16 FIONIS INSLSAS TAT IVuvd 96 22 80 5 HOIVHOdVA3 ava E SNSudr ld SATVA dOIvHOdVA3 dHOIVHOdVA3 Enviroguard 24 33 June 2007 PARALLEL COMPRESSORS amp ENVIROGUARD Gas Defrost Control Settings 1 Defrost TYLER REFRIGERATION A Defrost frequency and duration should be set per fixture requirements recommended by manufacturer Normally no compensa
7. sss 65 3 50 3 6 Using Line Sizing Charts June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD R 22 Suction Line Sizing 35 F SUCTION TEMPERATURE 25 F SUCTION TEMPERATURE 20 F SUCTION TEMPERATURE 15 F SUCTION TEMPERATURE R M E T R M E T R Ee cone 50 250 300 10005 50 50 200 250 300 1500s 50 300 Ds 50 100150200 250 300 5 7 8 ee 5 7 8 5 7 8 5 7i 10 11 8 10 10 10 ires 15 15 15 15 20 20 20 20 3 8 25 25 25 25 30 30 30 30 ER 35 35 85 85 7 0 40 40 40 F 45 45 45 45 50 50 50 50 3 55 55 55 a AST 60 60 60 60 65 65 65 65 70 70 70
8. 2 1 Possible Consequences of Poor Piping 2 1 dc Mee apa de 2 2 Service Valves tsa Arse near OF eau oe GO we EEO idee 2 2 Vibration Isolation Piping 2 2 Guidelines for Good 2 3 Gas Defrost Liquid Lines 2 5 Expansion Loop SIZING a Y see e eee aes 2 6 3 Using Line Sizing Charts 3 1 Basis eve Oe Dn ROLE 3 1 Equivalent Feel ee 3 1 a veliesse Ges eam ees ERE DS KY IE 3 1 Sizing Liquid amp Suction Sub Feed Lines Properly 3 2 Suction Line Riser Recommendations 3 3 Vertical Riser Suction Line Size 3 4 Line Size Guidelines 3 5 R 22 amp R404A Liquid Line Sizing Chart 3 5 Using Suction Line Sizing Charts Correctly 3 6 22 Suction Line 51 3 7 R404A Suction Line Sizing 3 8 Pressure 5 3 9 4 High Side Field Piping
9. nia HOLOWLNOO NO HOLIMS qasn 39018 IVNIAH3 L SNOILO3NNOO 11 l1Sog3za Siena E E TT 4460 ASVYOUNVHO 440 NO SHOLONGNOD H3ddCO 009 ISN LSNW 5 Xlddns INaMdino3 y uoissiuuJed pesn Jo eq jou 6uueeurBue 10 eouepyuoo penssi 1 1 SIU pesojosip u swej uonejodioo Je AL FO LON R 22 Low Temperature Demand Cooling 21 5 June 2007 PARALLEL COMPRESSORS TYLER REFRIGERATION amp ENVIROGUARD le Unit Compressor Wiring TSK In ical Si T GION31OS NOILOGfNI JOHINOO MOTISA SLOVINOD HOLMS ALS AVS ALBAVE AGL 4 Hi uossaudWoo SLOVINOD SHOSNdS TJOHINOO 3unss3ud e 35NVHO aau AAOTI3A LSotidaq 1OHH1NOO ALVLS anos NI LNIOd TOHINOO ns y NI LNIOd 1CHINOO L 21 HOLOVINOO HO IOVINOO NO HOLMS X
10. NOILONS LINN 3ATVA TIV8 ANI SADYVHOSH 3ATVA INN LINN r 1 NOILONS be NOILV TOSI H3AI3O3H ainorr LINN GIO3INVIN NOILONS OLNI 3NI 103318 Oc SNILLI 3ATVA NOILLVTOSI H30VHHOS L L AATVA ONIDHVHO ANI LVSH SAENLOLAENL 6 SSVIDLHSIS SSVdAd 01 TIVE JNN LINN SNIT 335 All Enviroguard 24 9 Installation amp Service Manual Enviroquard Component Location SSVTOLHDIS S TVAMOSHO GATIVLSNI 07314 OL 5 0119201 IN3NOdNWOJ SIINA 599 LOH 62 NYSTHOIW SATIN NOILLUH3OIH 334 essor 2007 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Charging the System Refer to Figure 1 on page 24 9 for system component locations on the parallel compressor unit relative to Enviroguard system start up The following procedures should be used for charging Enviroguard systems 1 10 11 12 13 14 15 16 17 After evacuating the system leave charging hoses attached to the liquid charging port 2 on the main liquid line Close the 1 2 liquid line ball valve 1 located on the inlet side of the unit liquid
11. Enter Scroll down to 1 Add one Analog Sensor Enter F7 66 Enter Scroll down to 1 Add one Digital Combiner Enter F10 F9 Go to Home Screen Condenser Set Up Chart Key Entry F2 F8 B Got to condenser controls and choose Set up Scroll down three times to P Choose Control Type Pressure Scroll down twice to number of fan Enter the number of fan stages stages F2 Pressure Setpoint Tab to setpoints and set up Scroll down twice PRESS CTRL STPT Recommended minimum 0 00 00 Scroll down 0 00 00 Fan Min On 0 00 00 Fan Min Off 0 00 00 F2 board Scroll right point Tab to Inputs PRES CTRL IN Pressure board point board point F9 Return to Home Screen F2 board Scroll right point Tab to Fan Outs and set up output 26 24 Enviroguard III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Conversion Cell Set Up Chart Key Entry F5 F8 Go to Conversion Cell Status then choose Set up Del Sat Temp Delete default name Type in Sat Temp Scroll down to P Choose Press to Temp Scroll down to F7 choose ref Enter Choose proper refrigerant F8 Q Scroll down twice 0 00 01 Set Options to FULL Set Update Rate to 1 second F2 1
12. 1 6 Planning for Mezzanine Machine Rooms June 2007 Installation amp Service Manual Parallel Compressor Rack ISOL Spring Mounting Drawings REF DWG SPRG ISOL MTG P67 7 PARALLEL COMPRESSORS amp ENVIROGUARD 8 5 8 53 3 4 29 1 4 42 30 REF 6 3 8 REF DWG SPRG ISOL MTG P90 94 858 P 76 3 4 4 29 1 4 42 30 REF 6 3 8 T 1 34 5 16 REF DWG SPRG ISOL MTG P120 117 85 8 99 3 4 i 29 1 4 2 30 REF 6 3 8 34 5 16 68 9 16 June 2007 Planning for Mezzanine Machine Rooms 1 7 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION REF DRW SPRG ISOL MTG P140 140 858 122 3 4 V 42 29 1 4 30 REF 6 3 8 1 V 345 16 68 9 16 REF DWG SPRG ISOL MIG P160 163 85 8 145 3 4 42 29 1 4 30 REF 63 8 1 1 345 16 68 9 16 m 114 9 16 REF DWG SPRG ISOL MTG P180 186 858 P 168 3 4 T 42 291 4
13. 83119 NOILOnS AHOLOVJ TOJINVANGLONS 59 g JAVA AlddNs SVS 1N31V1 OF eS Q gg 2 Adang anon 59 D 2 AHOLOVJ ee H3HSN3ONOO 3 19NIS 7 1508438 570 LN31VT1 SNIadld NOILOAPNI ANYANA YASNAG N OO 69 ADVLS TIONIS x I O INSIESAS TaTIVuvd mies HOlVHOdVA3 HOlVHOdVA3 HOLVHOd WA ve Parallel System w NC 2 amp Heat Recovery 17 5 June 2007 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A Parallel System with Mechanical Subcooling Mechanical subcooling makes the entire system more efficient and allows closer sizing of compressor to cases in the sunbelt states It also provides a capacity reserve for hot weather protection The subcooler compressor operates at a high efficiency suction temperature of approximately 40 F Subcooler liquid supply is usually from a separate system The liquid line feed to the expansion side of the subcooler is controlled by two paralleled normally closed solenoid valves upstream of two expansion valves 1 The solenoid valves are sized at 75 and 25 of the total subcooling load The solenoid valves are thermostatically controlled 2 While the liquid inlet temperature is above 70 F the 75 solenoid is energized I
14. Carrier A United Technologies Company REFRIGERATION SYSTEMS Installation amp Service Manual E a i igs YAZ AD PARALLEL COMPRESSORS amp ENVIROGUARD PARALLEL COMPRESSOR SYSTEMS that Supply Specific Refrigeration Requirements for Case Line ups in Stores Save these Instructions for Future Reference These refrigerator systems conform to the Commercial Refrigeration Manufacturers Association Health and Sanitation standard CRS S1 86 PRINTED IN Specifications subject to REPLACES ISSUE PART IN U S A change without notice EDITION 3 99 6 07 NO 5806448 REV D Tyler Refrigeration Refrigerated Mechanical Systems Yuma Arizona 49120 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD TABLE OF CONTENTS Page 1 Planning for Mezzanine Machine Rooms 1 1 Machine Room Ventilation 5 1 1 Parallel Compressor Rack Dimensions 1 2 Parallel Compressor Rack ISOL Pad Drawings 1 5 Parallel Compressor Rack ISOL Spring Mounting Drawings 1 7 Setting Parallel Racks on Kenetic Absorption Pads 1 11 Optional Spring Mounting Pads for Parallel Racks 1 11 2 Refrigeration Piping 2 1 Successful Installation Practices
15. over itself on the sensor cable con Wiring a Harness Insert Plug To P2 connector UP b Insert the cable connector into the sensor or switch connector until it snap locks nector 40 x bis Cable Connector To P2 Connector c Roll the lip of the boot over the edge Figure 3 Sensor Switch Installation of the sensor housing E 23 2 Electronic Oil Pressure Control June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Setting the Anti Short Cycling Timer To change the anti short cycling delay timer from the factory set 100 second position move the jumper into the desired position See Figure 4 Insert B NOTE If the jumper is completely removed the control will operate at the default delay of 100 seconds R310AD or R10A Relay Connection To connect a Wide Range Current Sensing Relay cut and discard resistor R38 R39 Connect the relay to the two male blade terminals FT1 and FT2 See Figure 4 Insert A IMPORTANT The relay will not work when the control s anti short cycling delay timer is set at 0 seconds Set the timer to 35 65 or 100 seconds Wiring WARNING To avoid possible electrical shock or damage to equipment disconnect power supply before wiring any connections Make all wiring connections using copper conductors only All wiring must be installed to conform to the National Electric Code and local regulations Anti short
16. to energize the Sentronic If the Sentronic trips its contact L to in the LL1 LL2 control circuit opens to de energize the compressor contactor and stop the compres sor Sentronic contact L to A closes to energize an Alarm Relay Field Retrofit Considerations Sentronic can be used to replace conventional capillary tube style oil pressure controls in the field Before retrofitting determine if the existing oil pump is equipped with the plug fitting for mounting the sensor Order appropriate kit from TYLER Refrigeration NOTES Slight wiring differences exist from one manufacturer s unit to another If wiring modifications are unclear consult a certified electrician No wiring modifications are required with solid state motor protection Sentronic amp Sentronic Specifications Sentronic Sentronic CUT OUT 9 psid 2 psid 9 psid 2 psid CUT IN 12 14 psid 12 14 psid TIME DELAY 120 sec 15 sec 120 sec 15 sec MAX CONTROL 720 120 240 V 500 VA 120 240 V CIRCUIT VOLTS AMPS 120 Volt 6 0 Amps 120 Volt 4 2 Amps 230 Volt 3 8 Amps 230 Volt 2 2 Amps SENSOR TORQUE 60 65 ft lb 60 65 ft lb The sensor and module are provided as a set If a sensor or module is defective order the Sentronic kit from TYLER Refrigeration June 2007 Optional Electronic Pressure Control 19 7 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Electrica
17. 9510 30062 012 35 10 JATA NOISNVdIG SHOWIN IMYA 140d H310028n 13 31 JAWA NOISNYdX3 HO 01 9 530 01083105 39498311 OL 183A 15 10 amp X 440 ONIN WOW 01 011 110 4334 01 Q0H13W 3WOS NOISNYdX3 Compressor System Diagram June 2007 22 4 Carlyle Compound Cooling PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD R 22 Approximate Interstage Pressure psig 10 psi with a Subcooler SATURATED SUCTION 60 70 80 90 100 120 130 SUCTION PRESSURE SIG Mes 5 Indicates Vacuum NOTE If using alternate refrigerants such as 507 125 or R 404A use the given formula and appropriate PT charts to calculate the interstage pressures June 2007 Carlyle Compound Cooling 22 5 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER REFRIGERATION 5 Diagram for Parallel System with Two Stage Compressor Pi YASNAGNOO QIO3INVIN CIOAINVA ANOT OL NOLLO3NNOO G1OJINVIN 35vISH3INI Q IO3INVIA Alddns ONIdid AHOLOVH 91914 33r T38 4X T udAIHO3H 5 quii
18. Check termination and duration Check evaporator fans Clean evaporator Check and reset DDPR valve to proper value for elevation Check and reset duration of defrost Check and reset termination temperature higher Enviroguard 24 35 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD SECTION 25 Enviroguard II ENVIROGUARD II is a patented refrigerant control system in which the amount of liquid refrigerant being used in the system is controlled by an electronic I O board The algorithm receives input from the ambient temperature liquid dropleg temperature and pressure to control the condenser fans system head pressure and the solenoid valve operation Enviroguard Il systems have been superceded by Enviroguard systems Enviroguard system no longer being built Most Enviroguard systems have been retrofitted in the field into Enviroguard systems All questions concerning Enviroguard systems should be referred to the CARRIER TYLER Service Department Phone 800 992 3744 ext 428 or 747 June 2007 Enviroguard Il 25 1 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD SECTION 26 Enviroguard lll ENVIROGUARD III is a patented refrigerant control system that utilizes floating head technology Nature s Cooling The amount of liquid refrigerant being used in the system is controlled by a selection of various electronic contr
19. GTOdINVIA 02 INWA MO3HO NOLLONS ON I did AHOLOVA UE q ONIdid NOLLONS 55919 INYA Ihas Tiva 5 Kl m AHO LOVJ 91313 ONIdid 1804430 21419319 HO 330 3IALL SNIdld GUVYNDSOYIANA NOISS3HdINOO 15 3TONIS HUM WALSAS 1411 sizio 3 INNHLY ld Enviroguard 24 7 June 2007 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Installing the System A Installing System Piping 1 2 Install system components consistent with good refrigeration piping practices Ensure that the refrigeration piping is clean and free of debris and copper oxidation Purge copper lines with an inert gas such as nitrogen while brazing See Section 2 pages 2 1 through 2 6 Evacuate the system properly in preparation to charge the system with refrigerant See Section 7 page 7 1 amp 7 2 B Installing the Ambient Air Sensor 1 Install the ambient air sensor in a HORIZONTAL position under the air cooled con denser It should be mounted under the fan or set of fans These fans will always remain running This is typically located at the header end of the condenser NOTE DO NOT allow the ambient air sensor to contact the condenser fins or tubing The ambient air sensor should be mounted far enou
20. i NCJGCX NCJGECX form za ma DUAL TEMP 7 20 25 55 MENS E 7 29 259 5 NENX NFNGX NFBX NFBGX 14 2 3 25 30 55 NFEX NEGEX NFJGCX 14 2 3 20 25 55 NFJECX NFGECX NFMJCX NFMJGCX 15 22 2 3 20 25 55 DUAL TEMP 2 3 16 20 55 50 40 NFWX NFWGX 20 25 NFWEX 22 25 60 40 P5FG 20 25 25 10 14 50 EN HH me x 388 17 20 a 1820 28510 1820 20 2510 NFBGX 16 20 50 40 NFEX NFGEX NFJCX NFJGCX 20 pew NFWX NFWGX 16 20 50 40 E a 5 e fs m N2PSE 24 4 6 125 227 38 50 8 500 nso 3 s 5 so4o NG 3 50 6 t 50 Primary Fans Only 101 2 with HEAT NENX NENGX s June 2007 Defrost Control Strategies 12 5 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A CASE DATA HOT GAS DEFROST DISCHARGE EPR DEFROSTS FAILSAFE AIR TEMP SETTINGS TIME TEMP CYCLE MODEL F R 22 F veat 30 38 49 32 55 NEDNLIMIF ays 75 5040
21. 23 5 Operational Control Test 23 6 Troubleshooting Chart for Systems Not Using a R10A Sensing Relay 23 6 Troubleshooting Chart for Systems Using a R310AD Switch or R10A Sensing 23 8 24 ses cn crate e eats 24 1 Application Guidelines 24 2 Fixture Temperature Control 24 3 Condenser Locations 24 3 Condenser Piping Diagrams 24 4 Condenser Fan 24 5 Dropleg 24 5 Mechanical Liquid Subcooling 24 5 System 24 6 Piping amp Components Diagram Basic Enviroguard System 24 7 Installing the System 24 8 A Installing the System Piping 24 8 B Installing the Ambient Air 24 8 June 2007 Table of Contents V PARALLEL COMPRESSORS TYLER Table of Contents VI amp ENVIROGUARD REFRIGERATION Page Enviroguard Component Locations Diagram 24 9 Charging the System 24 10 Receiver Charge Guideline
22. 25 25 25 25 su 30 30 2 ri 30 30 85 85 35 35 40 40 7 40 40 FINE 45 45 45 45 50 50 T 50 50 i 8 55 55 55 55 60 DENT 60 2 5 8 60 60 7 65 65 65 65 it 70 3 1 8 Lut 3 1 8 70 70 2 5 8 75 75 75 75 H 80 at 1 0 PD Total Run 80 lat 1 04 PD Total Run 80 1 3 PD Total Run 80 rat 1 34 PD Total Run 10 F SUCTION TEMPERATURE 15 F SUCTION TEMPERATURE 20 F SUCTION TEMPERATURE 35 F SUCTION TEMPERATURE BTUH a5 5 55 BTUH a BTUH n fa D Es BTUH 45 fa Ream Equivalent Feet Reamt Equivalent Feet Equivalent Feet Equivalent Feet TEUS 50 100150200 250 300 cnc 100150 200 250 300 TN 60100150200 250 300 50 100150200 250 300 5 5 5 5 58 10 10 10 10 15 15 15 15 20 20 1 20 20 25 25 25 30 30 30 35 35 35 40 40 40 45 45 45 50 50 50 55 55 55 60 60 60 65 65 65 70 70 70 75 75 75 80 at 1 5 PD Total Run at 1 5 PD Total Run 80 1 54 PD Total Run 80 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 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 great
23. qu HOJVHOdV 3 3ATVA 181 ddlooo ans 219161 31009 ans YIOAYASAY dWAl MOT3IONIS SNIdid 31SNIS 15084880 21919919 HO 430 YATOOSENS M DNidid 88 39VIS OML 1 WALSAS T3TIVuVd X INHLONd June 2007 22 6 Carlyle Compound Cooling PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD SECTION 23 Optional Johnson Controls Electronic Oil Pressure Control P545 P445 and P345 Series Models The Electronic Lube Oil Control is designed for use on refrigerated compressors equipped with either a bearing head or oil pump that accepts a single point differential pressure transducer The control senses net lube pressure and de energizes the compressor if pressure falls below a setpoint The control has a front mount LED display to indicate the status of the lubrication system An anti short cycling delay is available as well as a choice of an accumulative or nonaccumulative timer as required by the compressor manufacturers NOTE These are general installation and service instructions Consult the Johnson Controls website for specific information on individual control models and sensors FEATURES AND BENEFITS Single Pole Double Throw Allows liquid line solenoid
24. 1 board Tab to Inputs Reformat to board point Scroll right point and assign the pressure board point Return to Home Screen Analog Sensor Control Set Up Chart Scroll down to 1 Use DF for units Scroll down to 6 Choose In1 In2 In3 for Comb Method Scroll down twice 0 00 02 Set Update Rate to 0 00 02 F2 1 2 Tab to Inputs Choose Controller Application Property format for Input 1 Scroll right to F7 Scroll to Sat Temp For Application Choose Sat Temp Enter Scroll right to F7 Scroll to Temp Out For Output Choose Temp Out Enter Scroll down board Scroll right point INPUT2 board point for the dropleg sensor F2 15 0 Scroll down 14 9 Tab to Setpoints and enter 15 0 for cut in and 14 9 for cut out June 2007 Enviroguard III 26 25 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Digital Combiner Set Up Chart Key Entry F5 P F8 B Go to Digital Combiners then choose Set up Scroll down F7 128 Enter F2 F3 1 2 Scroll right F7 Tab to Comb Ins Set Digital Input 1 Choose Subcool Enter Scroll format to Controller Application Output right F7 Choose Command Out Choose Subcool Command Out for Enter Digital Input 1 Scroll down F3 1 2 Scroll
25. 772 Table includes condenser TD 5 F safety 24 18 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Low Temp with R 22 Design Ambient F 90 95 100 105 110 Condenser TD F 15 15 15 15 15 SPR Offset psig 42 3 44 5 46 8 49 1 51 6 CF psig psig 140 382 389 1 135 361 368 1 130 339 348 3 125 327 329 5 120 3114 115 285 294 3 110 277 9 105 253 262 3 100 45 247 5 95 224 233 3 219 9 207 2 195 2 183 8 173 162 8 153 2 55 144 1 135 6 EC SET 685 nos na m53 qe 1201 377 8 82 845 868 893 A een Ee oas 132 555 577 6 63 648 Table includes condenser TD 5 F safety June 2007 Enviroguard 24 19 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Medium Temp with R 507 90 ss Io m F psig psig 135 3825 41 4545 4585 4625 4665 10 345 865 3905 395 3985 s aes so se 2745 345 305 3545 3585 ws 26 sms 32 i0 285 97 sos 3145 5 3225 95 gt 205 28 3 306 90 26 2745 e 28 26 29 80 17 265 29 253 27 261 60 1275 19 1995 2035 2075 2115 35 185 15 16 16 16 as
26. GLASS SUCTION BALL VALVE MANIFOLD Check Valve Symbol Check Valve Locations REFRIGERATION CIRCUITS A Refrigeration Branch Circuit is a lineup or group of cases and or coolers connected to a common liquid line solenoid and common suction line The suction line may or may not be equipped with an EPR valve Parallel systems employ a number of spring loaded check valves of various sizes They allow gases or liquid flow in only one direction Three different spring loadings are used Normal Check Valves The spring above the valve disc assures positive return and seating Applications 1 In cases around the expansion valves and liquid line solenoid valves to provide reverse flow of liquid during gas defrost 2 At the inlet and outlet of the heat recovery coil Three are provided with the unit for field installation June 2007 Component Description amp Definitions 18 1 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER REFRIGERATION OLDR Liquid Differential Regulator Valve Coil Energized OLDR 20 Differential Operation Figure 1 GAS BYPASS LINE 2 gt CHECK VALVE OLDR VALVE CHECK BALL VALVE VALVE Heat Recovery Valve SUCTION CONNECTION RECLAIM CONDENSER COMPRESSOR DISCHARGE NORMAL CONDENSER 18 2 Component Description amp Definitions BALL VALVE RECEIVER The OLDR Valve is used at the outlet of th
27. s 3 d 7 oor asx sox sox eo ev se 65 75 TWO SOME with Electric sox ox osx z vom ere 7 eme or F F F IN Defrost Add for 1 2 Cond Add for 1 2 Cond Heat Rejected 1 000 s BTUH SOME with Heat Rejected 1 000 s BTUH Heat Rejected EE 1 000 s BTUH Ambient 700 735 85 FOUR SOME with Electric Defrost Heat Rejected es ee 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 H 1 H 22 2 PR uc c UE MAX COMP 3 4 5 6 7 8 e me me ws e ws 8s ioe o 5 100 GAUGE 80 ACTUAL for safety R404A P67 P90 P120 P140 P160 P180 MAX COMP 3 4 5 6 7 8 woo s i 42 sss se sw s ws i 1 22 2 7 9 100 ON GAUGE 80 ACTUAL for safety NOTE Receiver sizing is not intended for total system pumpdown It is to
28. 20 2 Maintenance amp Troubleshooting June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD SYMPTOMS POSSIBLE CAUSES Se the condenser F Head pressure too low pP Headmaster temperature too high 5 Improperly adjusted expansion valve 6 Compressor malfunction See F 3 above June 2007 Maintenance amp Troubleshooting 20 3 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION SYMPTOMS POSSIBLE CAUSES 1 Loss of oil from compressor due to a Oil trapping in system b Compressor short cycling Insufficient oil system at too low of suction pressure the compressor 20 4 Maintenance amp Troubleshooting June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD R 22 Low Temperature Demand Cooling The Copeland Demand Cooling System Figure 1 uses electronics to counteract the occasionally high internal compressor discharge temperatures created by the R 22 refrigerant in low temperature applications Demand cooling diverts refrigerant to the compressor See Figure 2 on page 21 3 The demand cooling module uses the signal of a discharge head temperature sensor to monitor discharge gas temperature If a critical temperature is reached the module energizes an injection valve which meters a controlled amount of saturated refrigerant into the compressor suction cavity to cool the suction gas If the discharge
29. 4 1 Installation Notice 4 1 Discharge to Remote Condenser amp Heat Recovery Line Sizing Chart 4 2 Recommended Liquid Line Sizing Chart 4 2 5 Electrical Supply Locations 5 1 Store Machine Room 5 1 Remote Electrical Defrost Panels 5 1 Panel to Panel Field Wiring 5 2 6 System Charging Requirements 6 1 Heat of Rejection 6 1 Selecting amp Using Refrigerant Charging Tables 6 1 R 22 8 R404A Receiver Charging Charts 6 2 Horizontal Receiver Capacity Parallels 6 3 June 2007 Table of Contents PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Page 7 Start Up Procedure 7 1 Leak Testing Procedure 7 1 Evacuation Procedure 7 2 Evacuation Methods 7 2 Parallel Charging amp Start Up Procedure 7 3 Follow These Precautions 7 3 Charging amp Start Up sucesos EX px REX MERO ERGO EX ea xe 7 3 Operational Check After Start Up 7
30. June 2007 Enviroguard 24 27 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Evaporative Condenser Sensing Bulb LINE x 14 VALVE REFRIGERANT LEVEL AT MIDDLE OF SIGHTCLASS OVERFLOW STANDPIPE EVAPORATIVE CONDENSER 24 28 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Gas Defrost Application Hot Gas Defrost of a Branch Circuit Upon defrost initiation by the defrost time clock the following actions occur 1 suction stop solenoid valve or EPR closes The branch circuit gas solenoid valve opens The defrost differential pressure regulator DDPR is de energized into the differential pressure regulating mode 2 The discharge pressure drops as hot discharge gas begins to flow through the hot gas supply manifold to the evaporators 3 The frost on the evaporators absorbs heat energy from the hot gas which is increasing in pressure The liquid begins to flow backwards through the liquid line around the expansion valve It then goes through the bypass check valve and branch circuit liquid line return check valve to the hot gas return manifold The liquid continues to flow into the discharge line to the condenser increasing the available condenser liquid supply Another check valve on the branch circuit liquid line prevents the liquid from entering the main liquid supply manifold 4 Defrost pressure continues to rise until a differential pres
31. N C n Jumper Low Side Pressure Oil Pressure Switch 120V Dropping Resistor 7 Heater 240V P d j PODES T1 4D 6D 4R 6R Copeland Compressor Bodies have built in Time Delay Switches Current Relay Used on Copeland NR MR MD 2D 3D L1 L2 L3 Power Supply Connections T1 T2 T3 Compressor Motor Connections 18 6 Component Description amp Definitions June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Optional Sentronic Electronic Oil Pressure Control NOTE Information in this section is based on Copeland Application Engineering Bulletin AE 1275 R8 The optional Sentronics oil pressure safety control utilizes an electronic pressure sensor and module to precisely measure oil pump differential pressure The main advantage of the Sentronic control is to eliminate traditional capillary tubes to measure oil pressure A secondary advantage is the use of an electronic clock in the two minute time out circuit Because of these two advantages the Sentronic control will improve the overall reliability of the refrigeration system The Sentronic control has been specifically designed for the 3D however most Copeland compressors have oil pump designs that can utilize this control Sentronic can replace existing capillary tube controls in the field and retrofit older Copeland compressors with compatibl
32. R ADDED ALARM RELAY x st XeCONMECTION EXI ALARM LIGHT L 4 T Vee DIAGRAM 4A DIAGRAM 4B Diagrams 4A new Sentronic and 4B previous Sentronic use an added alarm circuit To contrast the 4 and 5 terminal Sentronic with the new Sentronic The new Sentronic does not require an extra relay or auxiliary contact for an alarm circuit Using Current Sensing Relay to Prevent Nuisance Tripping of Pressure Control On motor compressors equipped with internal inherent protection and oil pressure safety controls it is possible for a trip of the oil pressure safety control to occur if the protector should open due to motor overheating or a temporary overload on the motor In such an event the control and contactor would still be closed although the compressor motor would not be operating The two minute timing circuit would be activated due to a lack of oil pressure and after the 120 second time delay the oil pressure safety control could trip Even though the compressor motor had cooled sufficiently for the internal inherent protector to automatically reset the compressor could not be started until the oil pressure safety control was manually reset Normally this is not a problem since the compressor if properly applied will seldom ever trip due to an internal inherent protector If this does happen the fact that the protector trip has occurred indicates that the system operation should be reviewed Howe
33. Service Manual amp ENVIROGUARD Evaporative Condenser Settings SPR Settings 1 Determine the design ambient wet bulb temperature 2 Determine the design ambient wet bulb temperature to refrigerant condensing temperature difference Typical condensing temperatures for low temp systems are 90 to 95 F with a 20 TD Condensing temperatures for medium temp systems are 95 to 100 F with a 25 TD Refer to manufacturers recommended guidelines 3 The following examples are for low amp medium temp systems using R 22 refrigerant These example charts will determine the SPR differential setting Low Temp System Example Chart Design wet bulb temperature for area B Temperature difference TD for wet bulb to refrigerant C Saturated condensing temperature Corresponding saturation pressure at 182 psig condensing temperature G Corresponding saturation pressure at wet bulb 132 psig temperature Required SPR differential setting 50 psig Medium Temp System Example Chart Design wet bulb temperature for area Temperature difference TD for wet bulb to refrigerant Saturated condensing temperature 100 F Corresponding saturation pressure at 198 psig condensing temperature G Corresponding saturation pressure at wet bulb 132 psig temperature Required SPR differential setting 66 psig All Evaporative Condenser controls are set according to manufacturers guidelines i e two stage fan control damper controls etc
34. When EPRs are involved in controlling temperatures of the fixture evaporators condenser fans should be set to limit condensing pressure to 35 psig above the warmest evaporator pressure setting of the EPRs When Heat Recovery is used DO NOT apply an IPR on the outlet of the coil If an IPR is installed to a heat recovery coil it becomes a division point between the compressor discharge and the condenser liquid During colder ambients no liquid flow will take place to maintain refrigeration All liquid will stack in the cold condenser A Normally Open solenoid valve located downstream of the SPR is a low limit for the system head pressure This Normally Open solenoid valve must be configured to be energized closed at 10 psig higher than the lowest condenser fan setting To increase the amount of heat available for heat recovery raise the condenser fan pressure control setting to 75 F saturated condensing temperature and the Normally Open solenoid valve control at 30 psig above the fan pressure setting June 2007 Enviroguard 24 23 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Enviroguard Settings CONDENSER DESIGN 10 F 6 3 C TD Low Temp 15 F 8 C TD Med Temp CONDENSER FAN SETTINGS Low Temp 85 psig Med on Hot Hot Gas Defrost R507 507 102 125 130 The Normally Open solenoid valve must be programmed to be energized closed at 5 ps
35. field for DIG INPUT1 then press F4 for LOOKUP Scroll or page down to find the Anolog Sensor Ctrl that was set up prior named SUBCOOL ENV3 Press F1 for Select Scroll the cursor to the Output field for DIG INPUT1 then press for LOOKUP Scroll down to COMMAND OUT then press for Select Back at the SETUP screen scroll down to DIG INPUT2 line press F3 Edit then select Alternate I O Formats and Enter Enter the number that corresponds to Controller Application Property with the cursor in the Controller field for DIG INPUT2 press F4 for LOOKUP Scroll down to find this controller s name then press F1 Select Scroll the cursor to the Application field for DIG INPUT2 then press F4 for LOOKUP Scroll or page down to find the Condenser Control named Condenser Press F1 for Select Scroll the cursor to the Output field for DIG INPUT2 then press for LOOKUP Scroll down to the description of the last fan control used for this system EXAMPLE A condenser system with 4 stages of fan control you would scroll down to FAN OUT4 then press F1 Select A system with 1 point of fan control would use FAN OUT1 A quick way to determine this information is at the home screen as noted at the beginning of this procedure Press F2 NEXT for C4 Outputs to defi
36. temperature rises above a preset maximum level the module will turn the compressor off and activate its alarm contact This shut down will require a manual reset See Control Setting chart at the bottom of this page Temperature Sensor Injection Valve FIGURE 1 DEMAND COOLING SYSTEM COMPONENTS REPRINTED FROM COPELAND ENGINEERING BULLETIN AE 1287 CONTROL SETTINGS Cut In Temperature 292 F non adjustable Cut Out Temperature 282 F non adjustable Trip Temperature 310 F non adjustable June 2007 R 22 Low Temperature Demand Cooling 21 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION TYLER Part Number for Demand Cooling Kits 5931213 5980214 Demand Cooling Kits include Demand Cooling Module w 2 mounting screws Temperature Sensor w 3 ft of shielding cable Injection Valve and Solenoid w mounting hardware and an Installation Troubleshooting Guide TYLER Part Number Demand Cooling Components DESCRIPTION PART NO Electronic Control Module 5930500 Temperature Sensor 5930501 w 3 cable Temperature Sensor 5930502 w 10 cable 208 240V Injection Valve 5930503 Solenoid Coil 21 2 R 22 Low Temperature Demand Cooling June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD System Information The correct injection valve must be used for each compressor body style In order to provide th
37. 06 ono Tora 5 285 98 1015 155 30s a0 v 65 9 9 9 t 25 2 Table includes condenser TD 5 F safety 24 20 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Medium Temp with R404A Design Ambient F 90 95 100 105 Condenser TD F 20 20 20 20 SPR Offset psig 67 6 71 1 74 7 78 4 F psig psig 140 472 135 459 130 432 435 9 125 413 9 120 392 8 115 372 8 110 339 353 7 105 335 5 100 318 1 5 287 301 7 86 60 271 2 257 1 29 243 7 231 1 08 219 2 04 207 9 55 197 3 5 187 3 45 177 9 40 169 3 160 7 3 152 9 25 145 7 20 138 9 E 132 5 126 6 RET SESSA 5 77 753 788 84 38364 9 Table includes condenser TD 5 F safety June 2007 Enviroguard 24 21 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Medium Temp with R 22 579 609 64 6172 74 CF psig psig o 1683 2282 292 2323 2355 2887 80 166 2015 205 2076 208 24 6 1016 1595 165 1656 1688 172 32 967 999 10 Co ETE RR 20 101 7 05 35 26 os 635 656 73 Table includes condenser 5 F safety 24 22 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Ser
38. 1 Suction Pressure Range 22 1 Intermediate Pressure Range 22 2 Discharge Pressure Range 22 2 ECONOMIZE 255555 Sea ket LEA mes 22 2 Economizer Cycle Diagram 22 2 Desuperheating Expansion Valve 22 2 UD ER ERR a 22 3 Stes ccr IEEE 22 3 General ES EX ER aY A eet 22 3 Multiple Compressor Systems 22 3 Compressor System Diagram 22 4 R 22 Approximate Inter Stage Pressure PSIG w a Subcooler Chart 22 5 Piping Diagram for Parallel System with Two Stage Compressors 22 6 23 Optional Johnson Controls Electronic Oil Pressure Control P545 P445 amp P345 Series Models 23 1 Features Benefits 23 1 Installation wu Ca OAR Fo xU re Re me qe 23 2 Setting the Anti Short Cycling Timer 23 3 R310AD Relay Connection 23 3 WINO Sa Su eque etes betae hadas 23 3 Wiring Diagtrams Suai ates toe tne eee eed tet 23 4 Checkout Procedures LEDs Operating Status 23 4 Electrical Checkout Procedure
39. 14 Condenser Fan Group Set Up 26 15 Comtrol Analog Set Up Screen 26 16 Output Relay Set Up Screen 26 16 Alarm Setpoints Screen 26 17 Enviroguard Control Set Up for CPC s RMCC Controller 26 18 RMCC Controller 26 18 Sensor Set UD 26 18 Sensor Setpoints for Subcooling 26 18 Condenser Set Up 26 18 Condenser Pressure Inputs Set Up 26 19 Condenser Pressure Delays 26 19 Condenser Single Speed Fan Set Up 26 19 Condenser Setpoints 26 19 Input Output Board Point Definitions 26 20 Recommended Charging Procedure 26 20 SPR Solenoid Valve 26 20 Condenser Control w RO Board at Rack 26 21 Condenser Control w RO Board at Condenser 26 21 Enviroguard Control Set Up for CPC s Einstein 2 Controller 26 22 Anolog Input Set Up 26 22 Add the Control If They are Not Already Added 26 22 Condenser Control 26 22 Conversion Cell
40. 8 OD check valve must be installed near the tap in However a discharge line check valve must be installed within 4 upstream of the tap in This will ensure defrost return liquid will enter condenser and maintain liquid integrity to circuits in refrigeration This also prevents storage of defrost return liquid in excessive long discharge line during defrost Where systems utilize a heat recovery circuit the return line must be tapped in downstream of the main discharge line check valve The check valve needs to be installed within 2 of the tap in The hot gas return manifold outlet piping shall be piped into the horizontal discharge line leading to the condenser from the top side or side of the discharge line Piping into the bottom of the discharge line creates a holding well for oil and liquid refrigerant during the refrigeration cycle A vertical discharge line is no problem with the exception of the location of the discharge line check valve If using heat recovery the hot gas return manifold outlet piping should not be piped into the heat recovery coil This could cause a shortage of liquid refrigerant for fixtures in refrigeration while one branch circuit is being defrosted 24 30 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD 3 Check Valves for Gas Defrost Check valves installed in the discharge line and heat recovery return line should be located as close as possible to each o
41. 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 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 t
42. Compound Cooling June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Start Up Initial start up of the compressors should be done with the economizer and desuperheating valve OFF After a few minutes of run time the subcooler and desuperheating expansion valves should be allowed to operate After initial start up the economizer and desuperheating valve do not have to be valved OFF Oil Check for these proper oil levels at compressor sightglasses before start up and after 15 20 minutes of operation Small compressors 16 37 1 2 to 2 3 SG Large compressors are 50 99 CFM 1 8 to 3 8 SG Approved Oils R 22 Be 2 2 150 IGU Petroleum Ind Cryol 150 WITCOM Su wasps ete todas tite tine Suniso 3GS General Notes 1 Unloaders not allowed 2 All compound cooling compressors are equipped with a discharge temperature sensor open 295 F close 235 F for over temperature protection 3 The large body compressors 50 99 CFM require calibrated circuit breakers for over current protection same as O6E 4 Low pressure access ports are located on the low pressure side of the low stage cylinder heads Compressor crankcase is at interstage pressure 5 Do not run motor barrel equalizing tubing between compressors for oil level equalization Multiple Compressor Systems Multiple compressor systems
43. Copper Washer Compressor Mounted Control Bracket Oil protection Control Bracket and locarion lead termination may vary Oil purnp as mounted an compressor E m lt Plug Fitting fDifferantial Pressure Sensa To Install the Sensor 1 Remove the plug fitting from the oil pump housing 2 Discard the copper washer from under the head of the plug fitting 3 Install a new o ring into the groove on the sensor Use refrigeration oil to pre lube the o ring before installation NOTE Use care not to cut the o ring 4 Install anew copper washer under the hex flange of the sensor 5 Screw the sensor into the oil pump housing where the plug fitting was removed 6 Torque the sensor to 60 65 ft lb CAUTION Do not over torque the sensor during installation Over torquing could damage 19 2 Optional Electronic Oil Pressure Control June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD To Install the Module 1 When using the bracket above the oil pump use two 10 32 pan head screws with washers The maximum screw length is 265 plus bracket thickness CAUTION Do not use mounting screws that are too long Screws over 265 is length could damage the circuit board 2 Plug the cable from the module into the end of the sensor Care should be taken not to wrap the cable around a current carrying conductor 3 Hi Potting Copeland hi pots th
44. Cycle P545 P445 Delay Setting 1 a 0 2880 m Differential Oil Pressure Switch Connection R39 wil we un nir 0 seconds 35 seconds Inset B discard resistor R39 for R310AD or R10A installation Fe 100 seconds Inset 65 seconds Cut and discard R38 or R39 for relay installation Inset B Figure 4 Terminal Designations June 2007 Electronic Oil Pressure Control 23 3 PARALLEL COMPRESSORS TYLER ENVIROGUARD REFRIGERATION Wiring Diagrams 240 V 3 phase 240 V 3 phase 9 240 VAC Footnotes ra Footnotes 1 Circuit interrupts prohibited 1 Circuit interrupts prohibited 2 2 Power to control 2 Power to control Circuit interrupts can be inserted Moto Circuit interrupts can be inserted 3 Operating control 3 Operating control Figure 5 Typical 3 wire Application Figure 6 Control and an Alarm Circuit Powered by the Same Voltage Supply as the Compressor Motor Checkout Procedures LEDs Operating Status Green LED only The compressor contactor is energized and the system s net oil pressure is at or above the opening point of the P400 switch or the setpoint factory set of the P400 sensor Green and Yellow LEDs The green LED signals that the compressor contactor is energized while the yellow LED signals that the lube oil
45. Heat Reclaim Piping Both discharge and liquid return must be piped symetrically relative to the condenser Hp coros SER 4 H tee _ SPUI SPL P lt CONDENSER CONDENSER MEA CURCUIT A CURCUIT B NOTE These check valves must B IPR be located 1 or less from the tee BALL VALVE P i COIL CH x nnn m HECK VALVE SPACE HEAT RECLAIM 2 BALL VALVES DO 9 CON A CHECK VALVE FIELD PIPING _ _ LI FACTORY PIPING E X VALVE BALL VALVES 50 DISCHARGE CHEG SPLITTER Le FIELD PIPING VAL VALVE FACTORY PIPING CHECK DISCHARGE MANIFOLD 100 VALVE 1 1 DISCHARGE MANIFOLD SEPARATOR HEAT RECLAIM VALVE G E G HEAT RECLAIM VALVE OPR BALL VALVE XX OIL SEPARATOR OPR BALL VALVE CHECK VALVE RELIEF VALVE CHECK VALVE RELIEF VALVE RECEIVER RECEIVER D BALL VALVE IPR VALVE BR June 2007 High Side Field Piping 4 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Discharge to Remote Condenser amp Heat Recovery Line Sizin EE ee CAPACITY EQUIVALENT LENGTH CAPACITY EE LENGTH BTUH 50 100 50 100 BTUH 100 50 100 Recommended Liquid Line Sizing Condenser to Receive
46. Inputs Staces 0 2 2 AMBI Derivative Hold sepone Relay Output DUAE Steps 0 Ticks Stage 1 500 aP Aniko I Seperate Head ge 2 G 500 TMP 1 21 22 7 fe a pc vo THE mm Control Options Graphs 1 5 MIN _ nc EVO Pall ip dem Target Cond Temp 39 5 Ip Cond Temp E o Season Switch Temp 75 0 SPR Override Value Target Cond Pressure 85 0 Cond Temp Summer Target 10 0 Bleed Valve Delay Interstage Ditferentiol 70 Sensuviy J 5 Winter Target 15 0 SubCooling SubcoolDeadband LoSubCoolAlmLimt 50 High Safety Limit 300 0 Va Speed Min Cond Temp 450 Lo SubCool Alm Delay Hot Gas Offset 0 0 Spe Timeout TT Condenser Height 15 B Heat Reclaim Offset 00 DamperFullGpen 300 E EB 215120 3 ium June 2007 Enviroguard III 26 15 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Comtrol Analog Set Up Screen File Edit View Utilities Reports Help Go Sel Bg 2 I Bl 2 e ta 4 Comtrol Output Relay Set Up Screen i Ez Se
47. Keep adjusting until vaporizing liquid refrigerant is seen in the sightglass 10 in the outlet line downstream of the SPR Continue to observe the liquid line pressure It should decrease to the target SPR bypass pressure At this point the SPR 9 is set for proper operation To verify that the SPR 9 has been properly set turn all condenser fans ON again This will lower the condensing liquid line pressure The condensing fans were turned OFF to allow adjustment of the SPR After the condensing pressure has dropped well below the target SPR bypass pressure 30 psig turn OFF the condenser fans another time to raise the condensing pressure Again observe the sightglass 10 downstream of the SPR 9 while monitoring the liquid line pressure This determines the actual liquid line pressure at which the SPR 9 begins to bypass refrigerant into the receiver Again the actual bypass pressure will be indicated by seeing vaporizing refrigerant in the sightglass 10 If the SPR 9 is still not set at the correct bypass pressure repeat steps 5 through 8 until the correct SPR bypass pressure setting is obtained Turn the SPR square adjusting stem clockwise to raise the bypass pressure or counter clockwise to lower the bypass pressure Replace the seal cap on the SPR 9 and turn ON all the condenser fans to put then back into the automatic control circuit Leak test the seal cap on the SPR 9 to ensure that the cap has been in
48. Regulator Valve 10 1 Setting Procedure 10 1 Valve on Gas Defrost Systems 10 2 OLDR Valve Illustrations 10 2 Differential Pressure Settings for OLDR for Various Heights Chart 10 2 11 Parallel Pressure Control Settings PSIG 11 1 Compressor Cut In amp Cut Out Pressure Settings Chart 11 1 Pressure Cycling Set Points for Condenser Fans Chart 11 1 Remote Condenser Fan Settings Chart 11 2 Setting Suction Pressure Differential amp Time Delay 11 2 Time Delay Values 11 2 Table of Contents Il June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Page 12 Defrost Control Strategies 12 1 Electric Defrost os ie reste sequi fee P eens x 12 1 aas Defrost coa Rr DERE 12 1 Fan Control amp Defrost Termination Temperatures 12 2 Electric amp Time Off Defrost Requirements Chart 12 2 Hot Gas Defrost Requirements 12 5 19 Gas Defrosting 13 1 Gas Defrost Operating Principles 13 1 Gas Defrost Programming 13 2 14
49. Set Points for Condenser Fans REFRIGERANTS R404A R 507 FANS OR DEFROST TYPES amp SETTINGS PAIRS 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 OUT 390 395 PSIG Pressure Relief Valve 450 PSIG E June 2007 Parallel Pressure Control Settings 11 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A Remote Condenser Fan Settings NOTE Chart for ambient control usage only OF FANS FAN 1 ores P TEMPERATURE INLET TEMP Setting Suction Pressure Differential amp Time Delay The pressure differential is the suction pressure band that the compressor s 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
50. control adequate oil pressure and the contactor energized only the green LED is ON press and hold the TEST button down 2 On the P545 control the red LED lights up and the control de energizes locks out the compressor contactor On the P445 and P345 controls the yellow LED low pressure warning stage will be ON for approximately 8 seconds before the red LED lockout stage comes ON and the control de energizes locks out the compressor contactor If any of the systems are equipped with an alarm the relay circuit will energize close and the alarm will sound 3 Wait 100 seconds and press the RESET button to energize the contactor and restart the motor NOTE The control cannot be reset without power Troubleshooting Table 1 Troubleshooting Chart for Systems Not Using a R10A Sensing Relay LED Status Troubleshooting Procedure No LEDs ON Check the power source Red LED ON Use these steps to resolve the problem 1 Connect pressure gauges at the oil pump and at the crankcase 2 Press RESET on the control P545 A If the green amp yellow LEDs are ON but the compressor remains OFF inspect the wiring and check for an overheated motor If the compressor motor is overheated determine the cause and correct the problem An R310AD current sensing switch may be installed along with the control to provide a controlled shutdown caused by thermal overload B If both the green amp yellow LEDs are ON for the duration of th
51. it to step up its own voltage By making this voltage chack the transformer is being checked If the module successfully passes the above test sequence it is fully functional If the module fail s any of the above steps it is faulty and should be replaced 19 8 Optional Sentronic Electronic Oil Pressure Control June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Maintenance amp Troubleshooting Maintenance Compressors Lubrication Check oil level in the compressor crankcase sightglass on a regular interval after initial run check at least monthly If the level is low add according to instructions in this manual and the cause of oil migration corrected If the system has a suction filter check for pressure drop across the filter A plugged suction filter can lead to high oil levels Dirty or Discolored Oil Indicates One of the Following 1 Contaminants in the oil such as air moisture and acids 2 Operating the compressor in a vacuum This will cause a lack of suction cooling and in turn overheats and discolors the oil 3 Improper air flow on air cooled compressors can cause the oil to overheat 4 the oil appears contaminated the liquid line filter should be changed The first time the oil becomes discolored a new liquid line filter is usually enough to remedy the problem Any following oil discoloration will require the oil to be changed Mountings Check all compresso
52. line drier 3 to prepare for charging Close the 1 2 liquid line ball valve 7 to the inlet of the SPR 9 Close the 1 2 liquid line ball valve 13 bypassing the SPR 9 Remove the cap from the SPR 9 and turn the square adjusting stem at least 4 turns clockwise to increase the spring tension which increases the pressure setting of the SPR Open the liquid line and suction line ball valves on ONE branch refrigeration circuit Ensure that all condenser fans are turned ON and running Begin charging the refrigeration system with liquid refrigerant into the liquid line charging valve 2 downstream of the main liquid line ball valve 1 located on the inlet side of the unit liquid drier 3 Start one compressor Continue to open other branch circuit liquid line and suction line shutoff valves one branch circuit at a time while continuing to charge the system with refrigerant Turn ON additional compressors to balance the compressor capacity to the increasing refrigeration load Monitor discharge pressure at the discharge service valve on any running compressor Continue charging liquid refrigerant into the system while monitoring the discharge pressure When it begins to rise rapidly discontinue charging liquid refrigerant through the liquid line charging valve 2 Open the main liquid line ball valve 1 on the inlet side of the unit liquid drier 3 and check the condition of the sightglass 5 If bubbles
53. may also be controlled through the use of mechanical expansion valves Mechanical desuperheating expansion valves should be set to maintain approximately 220 F to 230 F discharge temperature with the bulb set 6 from the discharge service valve of each compressor The bulb must be well insulated See Compressor System Diagram on page 22 4 The use of floating head pressures in systems controlled by a mechanical TXV will result in varying liquid temperatures leaving the economizer due to varying interstage pressures A solenoid valve located before the economizer and desuperheating expansion valves is required except on application using electronic valves that have a positive shutoff The economizer solenoid must be interlocked with the rack to close anytime all compressors are OFF The desuperheating solenoids must be interlocked with each individual compressor to close when the compressor is OFF June 2007 Carlyle Compound Cooling 22 3 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER REFRIGERATION AX 831002805 QION 310S 831002805 OR 831002805 83 1303 1 Wud 803 831002805 Jdid 31002805 H 340338 boc 39402 010017 6 3051 01 35 30 09 Q303INYW 39VISu31NI 30 0333 831832 GNINWOI3Y SNIdld Q103INVIN 39VISU31NI U0SS3UdW02 9811002 QNn0JWO02 3AWA 323H2 Sv9 3OvISUJINI 39
54. 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 drier filters at periodic intervals or 3 days 3 weeks and 3 months Watch the moisture indicator and observe the 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 para
55. module will result if the terminal of the Sentronic is connected to ground or directly to line voltage NOTE When changing components or making any kind of electrical alterations to any installation existing or new all ground connections must be specifically checked to make sure they are secure If there is any doubt about component or system grounding the local electrical inspector should be consulted The electrical connection diagrams included in this section are intended to represent the most common Sentronic application control circuits The system manufacturer should be consulted when more complex circuits are encountered June 2007 Optional Sentronic 4 Electronic Oil Pressure Control 19 3 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Standard Control Circuits Current Sentronic Previous Sentranic DIAGRAM 3A DIAGRAM 3B Both Diagrams 3A new Sentronic and 3B previous Sentronic show typical wiring connections and the similarity of Sentronic and Sentronic oil pressure switches used on three phase motor compressors Sentronics are energized when they are connected to a voltage source In both diagrams 3A and 3B if the compressor controlling and overload devices are closed the compressor starts and at the same time a circuit is made from one side of the power to incoming lines to the terminal The terminal is one side of the L M N C contact of the Sentronic module The M sid
56. ms 70 ETT 75 75 75 75 80 al 1 3 PD Total Run 80 at 1 34 PD Total Run 80 at 1 34 PD Total Run 80 1 3 PD Total Run 10 F SUCTION TEMPERATURE 15 F SUCTION TEMPERATURE 20 F SUCTION TEMPERATURE 35 F SUCTION TEMPERATURE BUH 186 45 40 75 90 BUH i2 136 45 75 oe Em BTUH Ream Equivalent Feet Equivalent Feet Equivalent Feet Equivalent Feet S008 50 100150200 250 300 TE 29 100150200 250 300 50 100150200250 300 1000 28 100150200250 300 5 9e z 5 8 z 5 8 5 9e 10 7 8 10 7 8 10 10 15 1 1 8 15 15 15 20 20 11 8 20 20 25 25 25 25 30 T 30 30 30 35 35 am 35 35 40 4 40 a 40 40 45 7 rg 45 12 45 45 50 50 TU wg 50 50 55 55 55 55 60 60 60 60 65 zm 65 DS 65 65 70 70 70 70 75 75 75 75 80 at 1 54 PD Total Run 80 fat 1 54 Total Run T 80 rat 1 5 PD Total Run 80 3 1 5 PD Total 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 adequa
57. 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 Compr 3 or 4 Compr 4 or 5 Compr 5 or 6 Compr or 7 7 8 Compr 3 800 4 400 5 500 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 amp ENVIROGUARD Parallel Compressor Rack Dimensions 36v38O030 SUOSSAUdNOD dO UIGANN 0351 JAY 5310089 JAYO 531008 2l3 21V1 AO 09 Ar 521008 JHL JOYA 03 54 06593 dO 6 SION TATIVelvd TIALS SSADOV ONidi
58. 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 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 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Defrost Control Strategies Temperature termination for all hot gas and electric defrost equipment is recommended with a termination sensing device at each fixture or coil Frost build up on coils varies depending on loading traffic and ambient temperatures consequently the required defrost time will also vary If defrost termination is not sensed at each coil there is a risk of other coils in the line up not completely defrosting This could cause icing over defrosting and or product quality problems Electric Defrost On all TYLER cases except the N6F L multi shelf freezers electric defrost termination can be done with the current sensing relay in our defrost panel Therefore no control
59. 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 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 Oil 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 res
60. 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 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 a 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 add 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
61. 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 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
62. to be closed if the SPDT Relay Contacts for control shuts off the compressor due to low Liquid Line Solenoid and oil pressure minimizes refrigerant migration Alarm Applications provides alarm indication including circuits that use neon lights Relay Contact Output for Provides reliable long lasting operation Compressor Built In Test Circuit Verifies proper control operation quickly without additional tools or equipment Improved Noise Immunity Exceeds immunity requirements of UL 991 for transient overvoltage IEC 61000 4 3 for radi ated Radio Frequency RF and IEC 61000 4 6 for RF induced conducted disturbances Selection of Anti short Cycle Allows choice of anti short cycle strategy for Time Delay a wide range of equipment requirements possible elimination of external short cycle timer User Friendly Display Panel Displays the status of the compressor lubrication system continuously Backwards Compatibility Allows easy replacement of existing electronic lube oil controls June 2007 Electronic Oil Pressure Control 23 1 PARALLEL COMPRESSORS TYLER ENVIROGUARD REFRIGERATION Installation IMPORTANT WARNING These Johnson Controls are designed for use only as operating controls Where an operating control failure would result in personal injury or loss of property it is the responsibility of the installer to add devices safety or limit controls or systems alarm or supervisory systems that protect ag
63. wires are required between these cases and the compressor systems helping reduce installation costs Each case is independently terminated from the electric heat source by an inline klixon thermostat which opens on rise When the last heater shuts off the lack of current deactivates the current relay and initiates refrigeration This time tested method assures each case gets defrosted but prevents over defrosting by getting the refrigeration back on quickly The N6F L multi shelf freezer cases have defrost contactors located at the case and these have an auxiliary contact that closes when the termination thermostat de energizes the contactor These contacts are wired in series if more than one case and when all are closed the clock solenoid is reset again allowing each case to independently terminate based on its own needs When using an electronic controller with electric defrost the controller will still initiate the defrost based on time The sensors should still be placed in each case at the same location as our standard defrost termination thermostat Multiple sensors on the same defrost circuit should be used so that all cases are satisfied before terminating heat and restarting refrigeration The compromise is some danger of over defrosting if some cases have less frost loads than other on the same circuit The standard klixons must be kept in the circuit for U L requirements but changed to 70 F termination to act as a safety and preven
64. 170 PSIG DEPTH DEPTH DEPTH DEPTH wer ine ae mee se wer Changes per turn ORIT 10 17 psig IPR 10 14psig IPR 6 24 psig 8 N A See Section 9 1 Adjusting IPR and OPR Valves The factory setting must be adjusted to recommended settings soon after starting the system The valve can be adjusted by installing a pressure gauge on the Schrader valve and turning the adjusting screw IN to raise the pressure An allen wrench is required for the adjustment screw Remember The system must be in defrost to provide flow through the valve Outlet Pressure Regulator OPR REMOVE ADJUST ADJUSTING SPRING This valve is designed to be sensitive only to its outlet pressure The inlet pressure is exerted on the underside of the bellows NES and on the top of the seat disc Since the EE effective area of the bellows is equal to the area of the port the inlet pressure cancels out and does not affect valve operation The valve outlet pressure acting on the bottom of the disc exerts a force in the closing direction This force is opposed by the adjustable spring force Thus by increasing the spring force the valve VALVE setting pressure at which the valve will y close is increased As long as the valve outlet pressure is greater than the valve pressure setting the valve will remain closed As the outlet pressure is reduced the valve will open and pass refr
65. 30 REF 1 F I gt 34 8 16 6 3 8 68 9 16 122 3 4 4 1 8 Planning for Mezzanine Machine Rooms June 2007 Installation amp Service Manual PARALLEL COMPRESSORS REF DWG SPRG ISOL MIG amp ENVIROGUARD VRP VFP67 71 8 5 8 57 9 16 i 29 1 4 42 30 REF 6 3 8 1 l REF DWG SPRG ISOL MIG VRP VFP90 94 85 8 80 9 16 1 29 1 4 42 30 REF 6 3 8 46 5 16 REF DWG SPRG ISOL MIG VRP VFP 120 117 85 8 103 9 16 2914 42 30 REF 4 6 3 8 46 5 16 80 9 16 June 2007 Planning for Mezzanine Machine Rooms 1 9 PARALLEL COMPRESSORS TYLER ENVIROGUARD REFRIGERATION REF DWG SPRG ISOL MIG VRP VFP140 140 85 8 ig 126 9 16 i 42 29 1 4 30 REF Ly 63 8 i 46 5 16 80 9 16 REF DWG SPRG ISOL MTG VRP VFP160 30 6 3 8 1 46 5 16 80 9 16 bee 126 9 16 x 85 8 149 9 16 m 163 REF DWG SPR ISOL MIG V
66. 445 goes Off replace the sensor Figure 7 Troubleshooting Using the Cable Terminals Table 2 Troubleshooting Chart for Systems Using a R310AD Switch or R10A Sensing Relay Possible Solution Control does not respond to R301AD Switch or R10A Relay Control de energizes locks out compressor after compressor shut down Red LED is ON Control does not respond to R310AD Switch or R10A Relay The Green LED is ON for approx 4 seconds followed by the Yellow LED turning ON for the duration of the selected anti short cycle time delay This process repeats indefinitely Contactor energizes for 3 or 4 seconds It remains OFF for the duration of the anti short cycle time delay and then repeats Compressor is unable to start during the 3 to 4 second period 23 8 Electronic Oil Pressure Control Make sure that the anti short cycle delay is not at seconds 1 Check that resistor R39 has been cut and discarded 2 Check the R310AD switch or R10A relay replace the switch or relay if necessary Insufficient current to the R310AD switch or R10A current sensing relay is the most likely cause of this problem Normal control operation for when there is no current Check compressor for internal overloads Check the compressor wiring Check the compressor s contactors Check the compressor for general failure June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Envirog
67. 5 8 Oil Control System 8 1 Oil SepaldiDI e Ear tem eee 8 1 Oil Separator Operation 8 1 Oil Reservoir 8 1 Oil Level Controls Oil Float 8 2 Oil Level Control Diagram 1 8 2 Oil Level Control Diagram 2 8 3 Check Oil Level 8 4 Oil Level Control Adjustment 8 4 Adding Qil acces i dores RO HE dre 8 4 The Preferred Method of Adding 8 5 Mineral Oil Applications 8 5 Polyol Ester Oil Applications 8 5 Carlyle Screw Compressor Applications 8 5 Bitzer Copeland Screw Compressor Applications 8 6 Removing Oil 8 6 9 Pressure Regulator Settings 9 1 IPR Inlet Pressure 9 1 IPR Inlet Pressure Regulator on Heat Recovery Coil 9 1 Outer Pressure 9 2 DDPR Valve on Gas Defrost Systems 9 2 10 OLDR Liquid Differential
68. 6 2 50 T s gt gt ss 6 3 59 3 ms 4 lt EAT E IU SEROPTZ 28 35 46 RISER OPT 1 m as fase 6 Nue s a 8 1 5 L5 NSHMHENSHMGHE 49 amp s 2 ELIT SSE EE PREM NMG 325 38 50 6 3 ICM me Te 2 36 37 Em O CHEESE p p pue Umm m NSMGHP SCELERE AN SENT Da 2 2007 Defrost Control Strategies 12 3 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION CASE DATA ELECTRIC DEFROST OFF DISCH EPR FAILSAFE TERM FAILSAFE AIR TEMP SETTINGS DEF TIME TEMP CYCLE DEF TIME MODEL F R 22 R404A 2 TEMPS TLD TLD 2 4 6 ub esee feta m ps pap RS sz z Pee r 52 5 pr
69. 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 es E EN EN June 2007 Using Line Sizing Charts 3 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION 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 an
70. 8 4 Pressure Settings 18 5 PENN Oil Prossure Safety 18 5 Mechanical Oil Pressure Safety Switch P45 Chart 18 6 Oil Pressure Failure Switch Wiring Diagram 18 6 19 Opt Sentronic amp Sentronic Electronic Oil Pressure Control 19 1 Basic Operation 52 19 1 Installing Sentronic 19 2 Sentronic Illustration 19 2 To Install the Sensor 19 2 To Install the 19 3 Electrostatic Painting 19 3 Sentronic Troubleshooting 19 3 Electrical Connection Instructions 19 3 Standard Control Circuits Wiring Diagrams 19 4 Control with Alarm Wiring 5 19 5 Using Current Sensing Relay to Prevent Nuisance Tripping of Pressure Control Wiring Diagrams 19 5 Using a Separate Control Voltage with the New Sentronic amp Wiring 19 6 Field Retrofit Considerations 19 7 Sentronic amp Sentronic Specifications 19 7 Electrical C
71. 9 Determine the corresponding saturated refrigerant pressure equal to the actual ambient air temperature at the time of setting the SPR 10 List the target SPR differential pressure as determined in step 7 June 2007 Enviroguard 24 11 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION 11 Determine the target SPR bypass pressure by adding the corresponding saturated refrigerant pressure equal to the actual ambient air temperature and the target SPR differential pressure This pressure is the actual pressure at which refrigerant should be observed in the sightglass on the outlet line after the SPR during SPR adjustment This procedure can be used with other refrigerant types to determine the differential pressure setting required for proper system operation Differential settings will vary depending on the type of refrigerant being used Setting the SPR on Enviroguard 1 Determine the offset setting Refer to charts on pages 24 17 thru 24 22 Example Low temp R404A 100 F Design 55 psig 2 Measure the ambient air entering the condenser Example 60 F 3 Determine what pressure the refrigerant would be at that temperature Example R404A at 60 F 125 psig 4 Add the offset setting to the ambient converted to the pressure Example 55 psig 125 psig 180 psig 5 At 60 F ambient refrigerant should bypass through the SPR at 180 psig 6 Set the condenser fans on the controller to cycle OFF at 175 p
72. C 2 amp Heat Recovery 17 3 Parallel System with Heat Recovery amp Companion 17 4 Companion Compressor Protection 17 4 Piping Diagram for Parallel System w Heat Recovery amp Companion 17 5 Parallel System with Mechanical 17 6 Piping Diagram for Parallel System w NC 1 amp Mechanical Subcooling 17 7 Hot Water Piping Methods Diagrams 17 8 18 Component Description amp Definitions 18 1 Refrigeration Branch Circuit 18 1 CHECK eae aed fea 18 1 Check Valve Locations 18 1 OLDR Liquid Differential Regulator Valve 18 2 June 2007 Table of Contents III PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Page Heat Recovery Valve 18 2 Suction Stop Valve 18 3 Liquid Line Solenoid 18 3 Inlet Pressure Regulator 18 3 ORIT amp IPR or 8 Pressure Settings Chart 18 4 Adjusting IPR and Valves 18 4 Outlet Pressure Regulator 18 4 Piping Diagram for Valve 1
73. Close off the SPR line 3 Add charge until the subcooling sensor control point achieves an average of 30 F of subcooling NOTE Southern climates may use 25 F for low temperature systems 4 When checking your subcooling value you must deduct one half of the condenser elevation from the pressure reading Example If you have a 20 foot condenser elevation you would deduct 10 pounds from the pressure reading The condenser elevation deducts the static pressure of the column of liquid 1 2 pound per foot of rise The calculated pressure is the pressure at the outlet of the condenser Enviroguard III Piping Diagrams Evaporator 2 Defrosting The following four typical piping diagrams for Enviroguard III systems with Electric or Time Off Defrost and Hot Gas Defrost for Summer and Winter Operation are shown on pages 26 10 through 26 13 NOTE Enviroguard piping can vary based on system options and or customer requirements June 2007 Enviroguard III 26 9 PARALLEL COMPRESSORS TYLER REFRIGERATION amp ENVIROGUARD Enviroguard Piping Diagram for Electric or Time Off Defrost Summer Operation 55 de 1 eansseJd 9 jo D N ON pinbr1 G103INVIW AlddNs jene
74. DS EQUALLY SPACED ACROSS THE BACK 1 30 f t SIX PADS EQUALLY SPACED ACROSS THE FRONT rm 183 16 APPROX TYP D1098 REF DWG ISOL PAD MTG P120 117 28 1 2 APPROX FIVE PADS EQUALLY SPACED ACROSS THE BACK 30 REF EIGHT PADS EQUALLY SPACED ACROSS THE FRONT 165 16 F APPROX TYP June 2007 Planning for Mezzanine Machine Rooms 1 5 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION REF DWG ISOL PAD MTG P140 Le 140 g 34 1 4 APPROX TYP FIVE PADS EQUALLY SPACED ACROSS THE BACK 2 42 30 REF 2 ZZ z YZ 2 L 171 8 NINE PADS EQUALLY SPACED ACROSS THE FRONT APPROX TYP REF DWG ISOL PAD MTG P160 163 32 APPROX SIX PADS EQUALLY SPACED ACROSS THE BACK 2 Zi 42 30 REF eZ 71 Z Z ZA Z 7 1734 TEN PADS EQUALLY SPACED ACROSS THE FRONT APPROX TYP REF DWG ISOL PAD MTG P180 186 30 1 2 APERO ME SEVEN PADS EQUALLY SPACED ACROSS THE BACK z Z A 42 30 REF 7 2 d Z 1 1 7 2 ELEVEN PADS EQUALLY SPACED ACROSS THE FRONT H 18 5 16 APPROX
75. Enter Scroll to How many input 1 then Enter A dialog box will ask if you wish to edit the new application press for Yes to enter the digital combiner SETUP screen Scroll to the Name line and press the Del key to remove any existing text Enter the name as lt SPR gt Scroll to Num Inputs line and enter the number 2 Scroll to Eng Units line and press F4 LOOKUP to access the list of available descriptions Scroll to or press the item number that corresponds to ON OFF line then Enter Scroll down to Comb Method line and press F4 for LOOKUP to access the list of avaialble descriptions Scroll to or press the item number that corresponds to And then Enter Following the same procedure scroll down to Alt Comb Method and set its value to AND Press F2 NEXT TAB to C2 Comb Ins You are now ready to define the combiner digital inputs June 2007 Enviroguard III 26 31 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Digital Input Setup At the DIG INPUT1 line press F3 Edit then select Alternate I O Formats and lt Enter gt Enter the number that corresponds to Controller Application Property with the cursor in the Controller field for DIG INPUT1 press for LOOKUP Scroll down to find this controllers name then press F1 Select Scroll the cursor to the Application
76. GURE 2 DEMAND COOLING SYSTEM DIAGRAM REPRINTED FROM COPELAND ENGINEERING BULLETIN AE 1287 June 2007 R 22 Low Temperature Demand Cooling 21 3 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Typical Parallel Wiring Application COMPRESSOR CONTROL CIRCUIT 208 250 VAC 60Hz CUSTOMER PWR SUPPLY USE MINIMUM 60 C 140 F COPPER TERMINAL BLocks crouno Luc SONDUCTORS ONLY OQ Oy CIRCUIT COMPRESSOR PILOT 2M BRKR Q CIRCUIT BREAKER Q BLU RED ON OFF A COMPRESSOR OIL FAIL ALARM RELAY 124 145 DEMAND ees EL o COMPRESSOR m W COMPRESSOR IND LIGHT INJECTION C 9 SOLENOID YEL FAN AUX2 CC COMPRESSOR HEAD L1 L2 21 4 R 22 Low Temperature Demand Cooling June 2007 amp ENVIROGUARD PARALLEL COMPRESSORS Installation amp Service Manual Single Unit Compressor Wiring TFC TED T IOS NOILO3PNI s n S NV3 ANOO 0565 Sd ho S EST MOTISA 12 SLOVLNO HOLIAAS A134 VS joHINOO uoswas 994 3unss3ud 9 91 z SINGO 3unssaud 35NVHO FNN MOTISA 1509490 31 15 ANOS NI INIOd zm Alvis anes F j yovga NIINIOd LE
77. Ice cream discharge air temperatures 28 25 amp 8 F Frozen food discharge air temperatures 20 15 10 5 amp 1 All other discharge air temperatures are for medium temp applications Most low temperature cases can be set up for dual temp application frozen food medium temp Only the NTJCX amp NTJGCX cases can be set up for split temp application ice cream frozen food Termination thermostat bulbs are mounted on the bypass check valves around the expansion valves Multiple cases on a circuit using open on rise termination should be connected in parallel so that all are satisfied before stopping the gas flow An additional 5 minutes of drain down time should be allowed for after the failsafe time or added to the failsafe time if not a separate function before the refrigeration comes on for electronic controllers only 12 6 Defrost Control Strategies June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD SECTION 13 Gas Defrosting Gas defrost is accomplished by diverting hot gas from the compressor discharge down the suction line and into an evaporator where it condenses to liquid refrigerant This provides a very rapid means of defrost Gas defrost is available for cases operated by a parallel system Gas defrost uses superheated compressor discharge gases to provide the heat source to melt the ice off of the evaporator coils About 25 of the cases can
78. LIGHT BRANCH LIQUID LINE SOLENOID SUCTION OR SUCTION EPR SOLENOID NC DEFROST LIGHT HOT GAS SOLENOID NC June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Troubleshooting Enviroguard Problems Check motor fuses and control High discharge pressure Receiver full of liquid Condensate liquid dropleg too warm Floodback to compressors Gas defrost not clearing fixtures June 2007 Receiver overcharged Dirty or plugged condenser System overcharge Misadjusted SPR valve SPR air sensor lost charge Condenser fan failed Condenser dirty amp plugged Bleed circuit restricted SPR valve leaking Refrigerant undercharged Condenser fan failure Dirty or plugged condenser Expansion valves not set for proper superheat Incomplete defrost Loss of evaporator fans Clogged evaporator fins DDPR valve not set to correct differential for elevation Defrost duration is too short Defrost termination temperature set too low Check SPR circuit for closed off valves Clean condenser Reduce refrigerant charge Check setting of SPR Recharge sensor Check and replace motor fuses control wires etc Clean debris out of condenser Check strainer amp solenoid valve Check for chips and debris in valve seat Add refrigerant to system Check motors fuses wires controls etc Clean condenser Check superheat and readjust TXVs
79. LVE 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 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 8 ENVIROGUARD REFRIGERATION 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 oi
80. Multi Circuit Time Clock Module 14 1 Operation caes et kN utc muse Kane eq e E i as 14 1 Setting the Multi Circuit Time 14 1 Multi Circuit Time Clock Module Replacement 14 2 Removal Installation amp Alignment of Individual Program Modules 14 2 Removal Installation of the Drive 14 2 Program Charts for Multi Circuit Timers 14 3 15 Refrigeration Circuits Electric Time or Gas Defrost 15 1 Refrigeration Circuits Piping Diagrams 15 1 Time or Electric Defrost Circuits 15 1 Gas Defrost Piping Arrangements 15 2 Refrigeration Circuits Piping Diagram 15 3 Gas Defrost Circuits 15 3 16 Receiver Gas Defrost 16 1 Control Strategy NC 1 Latent Heat Receiver Gas Defrost 16 1 Piping Diagram for Parallel System with Demand Cooling Mechanical Subcooling amp Latent Gas Defrost 16 2 Piping Diagram for Parallel System with Latent Gas Defrost 16 3 17 Parallel System with NC 2 amp Heat Recovery 17 1 Typical Piping amp Devices All Systems 17 1 NG chee ee ordo qn 17 2 Piping Diagram for Parallel System with N
81. NFWX NFWGX NFWEX 10 17 23 40 55 emm lw bw lawl ANTHONY 101 19 40 20 Peumnaaton e 2 9 42 5 ION 101 1 18 40 20 emmo if fest v 50 mx Edd Ed Nd 50 255 02 EE LL lt 5 MIN 69 12 2 Defrost Control Strategies June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD CASE DATA ELECTRIC DEFROST TIMEOFF DISCH EPR FAILSAFE TERM FAILSAFE AIR TEMP SETTINGS DEF TIME TEMP CYCLE DEF TIME MODEL F R 22 R404A DAY an TEMPS a mE NFX NFSX NFSGX 22 50 1 36 NFNX NFNGX NFBX NFBGX NFEX NFGEX NFJCX NFJGCX 38 NFJECX NFJGECX NFWX NFWGX 38 50 NFWEX o LPFDT 5 PANG DEL s s 2 Fwrorpowg s 5 NOFL MENT 24 38 9 2 4 5 PNOPSE 4 24 3 4 6 39 s 5 gt PING 9 sj 2 27 6
82. NY casn H3lV3H 3SVOXNVUO VSL 53575 sa MOTHA ELZL 11 19 uoissiuued USM umoys BulyyAue e1njoejnueuu o pesn Jo peonpoidas eq jou pue ui penssi 511 BUIMEIP siy ui p so 5sIp 241 5 Al elidoid uogpeiodion 321 INASA SHOLONANOO H3ddOO 309 ISN 1 AlddNs 5 ANSINGPRS June 2007 21 6 R 22 Low Temperature Demand Cooling PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Carlyle Compound Cooling Why Compound Coolin In low temperature applications single stage compression of R 22 may cause overheating at high compression ratios Single stage compression also results in lower Energy Efficiency Ratios EERs than R 502 thus resulting in higher power usage To compensate for higher discharge temperatures in single stage R 22 the injection of liquid refrigerant must be used in many operating conditions Liquid injection may result in lower EERs and is a potential reliability risk to the compressor How Compound Cooling Works A variation of the two stage booster system the internally compounded SUCTION PORT compressor has both the high and low OASE MAINFOLD stages built into one compressor bo
83. 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 net liquid lifts from the lowest fixture liquid line elevation to the condenser inlet manifold 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 7 6 2 R2210W curn 5 7 10 n 12 curour Jo o jo 1 R 22 MED Raosa LOW CUTIN 9 10 11 12 13 14 fis 16 CUTOUT JO 1 2 8 4 5 RAO4A MED also applies to R 507 Pressure Cycling
84. ORS Installation amp Service Manual amp ENVIROGUARD Refrigeration Circuits Piping Diagram EVAPORATOR EVAPORATOR EVAPORATOR PARALLEL SYSTEM WITH HHfb SINGLE STAGE COMPRESSION ar NC 1 LIQUID PIPING a Y 6 nu LATENT GAS DEFROST SINGLE CONDENSER PIPING SPACE HEAT RECLAIM HHP CONDENSER BALL 5 SIGHT VALVE GLASS DRIER SUCTION FILTER DIFFERENTIAL PRESSURE R REGULATORY RELIEF VALVE 400 PSIG RECEIVER SHO S BALL VALVE BALL VALVE IPR Gas Defrost Circuits Hot gas from the receiver is used to defrost cases by reversing the flow through the evaporator coil This flow reversal must be done by devices added to the parallel rack piping including the hot gas manifold which is run parallel to the suction and liquid manifolds System pressure must be directed to the portion of the system that is in defrost This is accomplished using an electrically operated DDPR valve 6 in the discharge line The system pressure pushes hot gas through the suction line where it condenses into liquid in the frost laden evaporator coil Movement of the condensed hot gas liquid into the liquid manifold is induced by creating a 20 pound drop in the liquid pressure This is done with the normally open OLDR valve 7 When a part of the system goes into defrost the OLDR valve 7 is energized and modulates to a partially closed position creating the pressure drop required This va
85. OST LOW MED DEFROST 170PSIG 102 PSIG 150 121PSIG 102 PSIG 150 121 PSIG 205PSIG 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 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 va
86. RATION Screen 3 Low Subcooling Alarm Setup To get to this screen Select Alarm under Rack Configuration Define the Alarm condition as shown below File Edit View Simulator 09716704 Type Low Pressure Disabled High Pressure Disabled High dropleg temp Dropleg Temp A 01 2 Disabled Low Subcool below 26 36 Enviroguard III Name Address Disch Press A 01 1 Disch Press A 01 1 Dropleg Temp A 01 2 60min June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Screen 4 Condenser Status To get to this screen Select Condenser under Refrigeration This screen shows the Subcooling Value the SPR Status as well as the other condenser parameters File Edit View Simulator 09 16 04 Maintaining Capacity SPR Off Bleed Off Discharge 151 0psi Outside 65 0 F Target 101 6psi Drop Leg 69 0 F QUE 2999 Cond Al 4 H b B ec EE srca a dcm n June 2007 Enviroguard III 26 37
87. RP VFP180 Y NI T 42 29 1 4 30 REF 1 Y 48516 6 3 8 F 80 9 16 i 134 3 4 85 8 r 1729 16 186 2007 1 10 Planning for Mezzanine Machine Rooms 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 k 1 June 2007 Planning for Mezzanine Machine Rooms 1 11 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Refrigeration Piping Successful Installation of a Refrigeration System is Dependent Upon 1 Good piping practices with properly sized a
88. Rec Fan ON Delay 1 sec Fast Rec Fan OFF Delay 1 sec Equalize Runtimes NO Condenser Setpoints Condenser Setpoints Use the following table Medium Temp Low Temp Low Temp Refrigerant Time Off Hot Gas Electric Time Off Type 60 F 45 F 40 F Throttle Range 60 Fast Recovery Setpoint 300 Low Pressure Cutoff NONE June 2007 Enviroguard III 26 19 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Input Output Board Point Definitions Inputs Sensor 1 Condenser Output Temperature Sensor 2 Liquid Dropleg Pressure Outputs Sensor 2 SPR Valve Control ON to open Regular Condenser Fans Fan control Extra Condenser Fan Stage SPR valve control ON to enable NOTES This is only required when the condenser control RO board is located at the condenser See CASE 2 wiring on page 26 21 This extra condenser fan stage must be programmed at the last condenser fan and must not be forced either ON or OFF during normal operations The RO point for this extra fan stage is located at the rack while the RO points for the regular fans are located at the condenser Recommended Charging Procedure Ambient air temperature above 70 F Charge the system to a 20 receiver level Ambient air temperature below 70 F Make sure the condenser setpoint is set to a pressure whose saturated temperature is at least 35 F above the ambient air temperature Close off the SPR line Add charge unt
89. Refer to pages 24 11 through 24 15 to determine the actual differential pressure setting to be used for the system being installed Since the SPR pilot pressure is equivalent to the saturated refrigerant pressure at the ambient temperature the pressure at which the SPR begins to bypass refrigerant into the receiver on a R 22 low temperature system is the sum of the saturated refrigerant pressure corresponding to the actual ambient air temperature plus the approximate differential pressure setting of either 45 or 61 psig Whenever the ambient air temperature drops the pressure setting at which the SPR bypasses liquid refrigerant to the receiver also drops relative to the ambient air temperature Anytime the condensing pressure rises 45 or 61 psig above the corresponding ambient air sensor pressure the SPR begins to bypass refrigerant into the receiver Condensing pressure changes occur at the same time relative to changes in the ambient temperature so liquid feed is always constant If a condenser should become fouled or damaged an elevated condensing pressure will occur resulting in in refrigerant being bypassed into the receiver Eventually branch circuit evaporator temperatures will rise because refrigerant is being bypassed out of the working part of the system into the receiver simulating a refrigerant starved system June 2007 Enviroguard 24 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A Normally condenser fan
90. SSORS 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 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 reclai
91. Set Up 26 22 Analog Sensor Control 26 23 Digital Combiner Set Up 26 23 Analog Inputs Set Up Chart 26 23 Table of Contents VII PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Page Add Controls Chants cscs ERR tee hse C M E ERE 26 24 Condenser Set Up Chart 26 24 Conversion Cell Set Up Chart 26 25 Analog Sensor Control Set Up Chart 26 25 Digital Combiner Set Up 26 26 Recommended Charging Procedure 26 26 Condenser Setpoints Chart 26 27 Enviroguard III Control Set Up for Danfoss AKC 55 Controller 26 27 Screen 1 Condenser Configuration 26 27 Screen 2 Enviroguard Configuration 26 28 Screen 3 Low Subcooling Alarm 26 29 Screen 4 Condenser Status 26 30 Table of Contents VIII June 2007 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
92. TYLER amp ENVIROGUARD REFRIGERATION A Hot Water Piping Methods SPACE HEAT RECLAIM 3 WAY VALVE OPT lt gt COND METHOD 1 DIFFERENTIAL BYPASS VALVE d WATER COMPRESSORS FULL PARALLEL ON HOT WATER OR SPACE HEAT RECLAIM 3 WAY VALVE METHOD 2 COND OIL SEP OO E COMPRESSORS WATER FULL PARALLEL ON HOT WATER RECLAIM W 3 WAY VALVE COND METHOD 3 DIFFERENTIAL BYPASS VALVE OIL SEP OOOO WATER COMPRESSORS FULL PARALLEL ON HOT WATER RECLAIM W BYPASS VALVE DIFFERENTIAL BYPASS VALVE METHOD 4 SPACE HEAT RECLAIM HOT 3 WAY VALVE WATER 1 3 WAY VALVE COND OIL OIL EL I BSTR COMPR COMPRESSORS COMPR SATELLITE COMPRESSOR S gt 10 HP ON HOT WATER RECLAIM W MAIN PARALLEL ON SPACE HEAT RECLAIM 17 8 Parallel System w NC 2 amp Heat Recovery June 2007 Installation amp Service Manual PARALLEL COMPRESSORS amp ENVIROGUARD Component Description amp Definitions Refrigeration Branch Circuit FIELD PIPING RACK PIPING MANIFOLD SIGHT
93. Tab set at 45 minutes D Modules Red Tab set at 15 minutes E Modules Red Tab set at 105 minutes NOTICE RED TABS MUST BE ALIGNED TO ALLOW REMOVAL OR REPLACEMENT OF MODULES Removal and or Installation and Alignment of Individual Program Modules 1 To remove a program module rotate the black reduction gear on the motor module until the red tabs on all the 2 hour program dials come to the 12 o clock position Then pull out and up on the bottom of the module latching lever disengage and point module up from frame to remove 2 To re install a program module follow step 1 above and rotate the trailing modules by hand until all red tabs are at 12 o clock position Check to be sure that the black numbers on all the 24 hour dial are in the same position as those on the modules already in the frame Then fit the module cut out located above the switches into the slotted frame rod align the tongue groove on either side of the module and snap the module down over the non slotted frame rod Check to be sure all red tabs line up and all 24 hour dial numbers line up Removal and or Installation of the Drive Module 1 To remove the drive module rotate black reduction gear until tongue groove with program module number 1 is parallel to the mounting surface 2 Loosen hex nut fully 3 Slide complete motor module parallel to the mounting surface and toward the 24 hour dials until the three locator studs clear their
94. Type press lt F4 gt LOOKUP select the system refrigerant then lt Enter gt Scroll down to Use Abs Press this should be set to No If not press lt N gt Scroll down to Update Rate this should be set to 0 00 01 If not enter this value now Press F2 NEXT TAB to C2 Inputs Select the PRESSURE IN line and enter the board and point location to be converted This is the information for the condenser pressure input point Press the Home key house symbol then when asked to save changes Add Anolog Sensor Control for Enviroguard Access the MAIN MENU screen by pressing the menu key Scroll to or press the item number that corresponds to Add Delete Applications then Enter Scroll to or press the item number that corresponds to Add Application then Enter At the Add Application screen select the Type line and press F4 LOOKUP to access the list of available applications Scroll to or press the item nuber that corresponds to Analog Sensor Ctrl then Enter Scroll to How Many input 1 then Enter A dialog box will ask if you wish to edit the new application press lt Y gt for Yes to enter the conversion SETUP screen Scroll to the Name line and enter the name as lt Subcool Env3 gt then scroll to Num Inputs line and enter the number 2 Scroll to Eng Units line and press F4 LOOKUP t
95. ULATION 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 15 min silver content Make joints of dissimilar metals of 45 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 meter must be used with nitrogen or carbon dioxide Service Valves Field install
96. VIROGUARD Condenser Fan Control Normally condenser fans will be running most of the time but should be controlled by an electronic pressure controller for optimum performance The recommended control method would be to use a pressure transducer input to an electronic compressor controller having a condenser fan control feature Temperature control of condenser fans is not acceptable because it does not sense a sudden discharge pressure rise at low ambient This sudden pressure rise could create a starved liquid refrigerant condition to the system In this condition the liquid from the condenser would be dumped into the receiver through the SPR during the high pressure surge Upon reduction of the discharge pressure there would be insufficient liquid to maintain flow and discharge pressure at normal conditions until the refrigerant transferred back into the system The discharge pressure surge could be caused by compressor cycling defrost termination etc Dropleg Pressure Transducer The transducer is located on the condenser liquid dropleg The DDPR and condenser fan control settings are listed in the tables on page 24 24 Mechanical Liquid Subcooling Mechanical subcoolers may be used with Enviroguard in areas which have warmer climates to obtain subcooled liquid when actual condenser liquid temperatures are higher than 55 F Temperature control of the subcooler is achieved with two thermostats The thermostat sensing bulbs are locate
97. ainst and or warn of control failure NOTE The control is not position sensitive When direct mounting to a compressor is required a mounting bracket is available 1 If panel mounting use the mounting slots on the back of the control case If mounting the control on a compressor use the two threaded holes on the back of the control case Use only the mounting screws provided Damage to internal components may occur if other screws are used NOTE When modifying an existing refrigeration compressor to accept the sensor follow the procedures recommended by the original equipment manufacturer 2 Use the following procedure to install the sensor a Wipe and dry all mating surfaces before mounting the sensor b Fitthe fiber washer over the sensor nozzle See Figure 3 Wet the switch nozzle and gasket with oil c Install the sensor in the lube oil sensor port according to the compressor manufacturer s instructions d Hand tighten until surfaces of fiber washer and compressor housing meet e Tighten until sealed CAUTION Do not apply more than 25 ft lb of torque to the fiber washer Torque over 25 ft Ib may cause seal failure As a general guideline 1 8 turn equals approximately 40 ft Ib and 1 16 turn equals approximately 5 ft Ib 3 Use the following procedure to connect the cable to the sensor or switch See Figure 3 Sensor or switch may vary from illustrated types a Roll the lip of the rubber boot back
98. al capacity is being used to cool itself to the operating temperature of 25 F SST thereby leaving more for net refrigeration With this scenario less of the evaporator coil is actually being used with no ill effects to the product integrity June 2007 Enviroguard III 26 1 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Enviroguard and TXV Operation When a TXV has been applied to the evaporative load there are 4 variables that can affect it s operation in regards to the capacity 1 Evaporator Temperature 2 Head Pressure 3 Temperature of Liquid Refrigerant Entering the TXV 4 A Change in Evaporative Load IMPORTANT TXV operation is NOT compromised with Enviroguard because the lower operating head pressures are offset by the resulting drop in liquid temperature that is entering the valve Enhanced Nature s Cooling Concept With Nature s Cooling and Enviroguard we have the ability to keep condensing temperature within 4 F of ambient on a properly charged system In other words the condensing temperatures vary or float with the actual ambient operating temperatures Effects and Facts to Consider EFFECT CHART Increased Compressor Capacity For each 10 F drop in condensing temperature there is a 6 rise in compressor capacity Reduced Power Consumption For each 10 F drop in condensing BTU Watt Hr temperature there is an 8 drop in power consumption Lower Maintenance Cost Extended compressor
99. 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 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 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 re
100. amp 9 2 for proper pressure settings design raises system efficiency by maximizing the amount of natural liquid subcooling while allowing the compressors to operate at the lowest possible compression ratios Simplicity is attained by reducing the number of valves in the system NC 2 functions with a normally open solenoid valve located in the liquid return line between the condenser and the receiver With this valve open there is direct and unconstrained liquid flow from the condenser to the receiver head pressures are allowed to float The only time the solenoid valve will close is during NC 2 operation or for gas defrost if used During NC 2 operation when the temperature of the liquid returning from the condenser is less than 70 F flow will completely bypass the receiver NOTE Use of split condenser piping may reduce the effectiveness of NC 2 17 2 Parallel System w NC 2 amp Heat Recovery June 2007 amp ENVIROGUARD PARALLEL COMPRESSORS Diagram for Parallel System with NC 2 amp Heat Recover Installation amp Service Manual Pi JAVA TIVda ssaoov SANA TINE SAVA gt e gt 3unssaud 8 uolvuvdas AHO1OVJ diui 10 NOILONS gt AlddNs amori m IVNOILLdO Sud3 pas Sud 2 tn i AHOLOVJ eee ee
101. and suction lines 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 be 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 Ma
102. as Defrost Pi 55400 xib4 b HJAISO3H JAYA aunssaud eo a pue I ITI 5 ITI yard SNIdld 91315 ONIdid 31 NIS Lsoud3d SVO 1N31V1 ONidid AINON L ON NOISSSHdWOO 39 15 FTONIS HLIM WALSAS T3T VH Vd 96 72 180 HOlVHOdvA3 HOlVHOdVA3 HOlVHOdVA3 INN 1 8 Receiver Gas Defrost 16 3 June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Parallel System with NC 2 amp Heat Recovery TYLER Refrigeration manufactures multi compressor parallel systems with two or more compressors They can be of various size and capacity and operate at different suction temperatures All compressor units are electrically powered and use electro mechanical switches or electronics to control their operation The compressor control panel contains all the necessary controls to operate the compressors properly The systems are designed to be used with remote condensers and optional heat recovery coils The systems utilize either a horizontal or vertical receiver tank Compressor horsepower sizes may be mixed for flexibility in capacity control Each system is individually designed for the specific needs of a given application It is unlikely that any two parallel system assemblies will be exactly alike A typical installation will usually consist o
103. ation Circuits Electric Time Off or Gas Defrost TIME OFF OR ELECTRIC DEFROST CIRCUITS GAS DEFROST CIRCUITS EVAPORATOR EVAPORATOR EVAPORATOR EVAPORATOR EVAPORATOR EVAPORATOR uU x d Hub 4 yd EXEC E F FIELD PIPING FACTORY PIPING val vol LIQUID 40 SUPPLY MANIFOLD 1 2 3 d zi GAS DEFROST 30 59 SUPPLY MANIFOLD E 5 5 lt 5 lt 5 ii lt 6 SUCTION MANIFOLD m hu a X m Y a m Y 03 Time Off or Electric Defrost Circuits The following component arrangements are associated with cases or unit cooler coils equipped with electric defrost heaters air or timed off cycle defrost The purpose of these arrangements is to stop the flow of refrigerant through the evaporator while it is defrosting Termination with electric defrost is by TG sensing relays all cases except N6F amp N6FL or a termination pilot circuit All termination methods use the failsafe feature of the multi circuit time clock or a control relay in a computer controlled application A Liquid flow can be interrupted by a factory mounted normally closed liquid line solenoid valve 1 controlled by the multi circuit time clock or computer controller An evap orator pressure regulator EPR 2 valve is factory installed on the suction stub of the co
104. be defrosted at a time the other 75 of the cases are needed as a heat source for the defrosting cases Gas defrosts are initiated by a multi circuit time clock or a computer controller Both controls set the defrost initiation and duration times for all of the separate refrigeration circuits It is nec essary to program defrosts in the proper sequence Care must be taken not to schedule more than one defrost at a time No more than 25 of the rack system can be set to defrost at one time Gas Defrost Operating Principles In a gas defrost system hot refrigerant vapor is pumped directly through the evaporator tubing The system uses a series of valves to supply superheated vapor from the compressor or saturated vapor from the receiver through the suction line to the evaporator s to be defrosted This series of valves is explained in more detail on page 15 3 At a pre determined set time the time clock or computer controller will close a circuit s suction line valve to the compressor and open the hot gas supply valve to the circuit being defrosted The hot vapor rushes to the evaporator warming the coil The hot vapor is condensed into liquid in the evaporator and then the liquid is returned to the liquid manifold via a bypass around the expansion valve This liquid is in turn used as the refrigerant supply to other cases To make certain that the liquid flows from the evaporator of the defrosting fixture s a pressure differential is e
105. 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 1 000 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
106. ceiver 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 electrical 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 COMPRE
107. d AVIY 15 INYA TVINOZISIOCH 218 IVINOZIBIOH CIS 691 19 GAY JAVO ASVO LSUOM TVIW2ION OS XOC Ld Ot XOc Ld O XZ9d 02 9 June 2007 1 2 Planning for Mezzanine Machine Rooms PARALLEL COMPRESSORS amp ENVIROGUARD Installation amp Service Manual TIM GAMOTIV SUOSSAUdNIOD JO ASN 30 51008 TMAVO SHOVE TaTT Ved TIALS SSADOV NIdId CLS 5 QNVT3dOO 03201 09 Ar dl SAIGOd AF TWLNOZRIOH CIS 9 9 90 TVOLII3A dO 30 HOVE 2134 SUOSSAUdNIOD dO 9 JHL ALON c egl 04 091 FAWVS ISVO ISOM WNION 2 2 4 09 4 Ot XOcLd 0 X06d Planning for Mezzanine Machine Rooms 1 3 June 2007 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER REFRIGERATION 120 50 P120X 40 P90X 40 P67X 30 P90X 30 P67X 20 138
108. d 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 amp ENVIROGUARD Installation amp Service Manual Suction Line Riser Recommendations 1 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 fom 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 ora 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 lo
109. d on the main liquid line entering the subcooler and on the condenser liquid line dropleg The thermostats control the liquid solenoid valves feeding refrigerant to the subcooling expansion valves An optional EPR may be mounted in the suction line leaving the subcooler when the subcooler is supported by another rack system experiencing large suction pressure changes This enables the subcooler to maintain more stable liquid temperatures to the fixtures See pages 17 6 and 24 25 June 2007 Enviroguard 24 5 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION System Components Figure 1 shows the piping and components used in this system design See page 24 9 A System Pressure Regulator SPR The system pressure regulator SPR is the primary system component which needs adjusting compared to setting regulators on conventional refrigeration systems B Ambient Air Sensor The sensor consists of 12 inches of 1 3 8 O D tubing with a sightglass mounted on the side for charging the sensor The pilot line between the remote sensor and the SPR should be 1 8 or 1 4 O D copper tubing DO NOT USE COPPER TUBING LARGER THAN 1 4 O D The pilot line to the SPR valve MUST BE INSULATED when running through spaces where the temperature differs from the ambient air or water temperatures The ambient air sensor is mounted under the remote air cooled condenser in the entering air stream of the fans These fans will always
110. deli cases to warrant it the boosters could be on a separate parallel system Ice cream case companion compressors on low temp systems work similarly The normal low temp frozen food cases are at 20 to 25 F while the companion operates the ice cream cases at 35 F The parallel compressors on the frozen food system assist the booster in rapid temperature pulldown after defrost through the 2 pound check valve connection Companion Compressor Protection All companion compressors are equipped with a 2 minute delay to protect against short cycling When a companion compressor is applied to a gas defrost system an additional time delay relay is used to lock the compressor out after a defrost for a few additional minutes This allows the companion suction line to cool preventing possible liquid slugging and or thermal cutout because of high suction line temperature See page 17 5 for Piping Diagram for Parallel System with Heat Recovery amp Companion 17 4 Parallel System w NC 2 amp Heat Recovery June 2007 PARALLEL COMPRESSORS amp ENVIROGUARD Installation amp Service Manual Diagram for Parallel System with Heat Recovery amp Companion Pi 3ATVA TTvg AANIVA H3AI3O3H YOSHO 00t SAIVA dal 13H YOLWINOSY 3unissadud 60 BsvdAg svo TIVI LN3Ua 150433 ITI O A 5 lt
111. directing system high pressure to the top of lt the piston closing the valve HIGH PRESSURE Liquid Line Solenoid A normally closed valve in the de energized position must be energized to open during the refrigeration cycle It may be used for circuits on electric or timed off defrost or can be used with thermostats c SS ae W The heat recovery HR coil is optionally equipped with an inlet pressure regulator IPR on systems which employ Nature s Cooling NC 2 The IPR valve is standard on NC 2 systems The valve raises the system pressure during HR to get more heat out of the coil Inlet Pressure Regulator IPR IPR REMOVE a TO ADJUST OR A 8 DEPTH BELLOWS E 7 x ADJUSTING SPRING t HEAT RECOVERY As shown the outlet pressure from the heat SEAT recover coil is exerted on the underside of the bellows and the top of the seat disc at the same time Since the effective area of the bellows and the disc are the same the two pressures cancel out The force of the incoming pressure alone will work against the spring pressure to operate the valve ACCESS VALVE See page 9 1 for pressure setting requirements t June 2007 Component Description amp Definitions 18 3 PARALLEL COMPRESSORS TYLER 8 ENVIROGUARD REFRIGERATION ORIT amp IPR or A 8 Pressure Settings PRESSURE ORIT 10 IPR 10 IPR 10 IPR 6 SETTING SPOR X62 GR5172 GR5171 GR5
112. duce 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 crankcase 5 Wrap a 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 capacit
113. dy ECON LIQ INJ PORT In this arrangement compression is INTERSTAGE accomplished in two stages safely and economically All nine Compound Cooling models have six cylinders Four cylinders acting as the low stage boost the suction pressure from the refrigeration load to the intermediate pressure MIDSTAGE Y PRESSURE SWITCH PES The remaining two cylinders acting as the high stage complete the compression on to normal condensing temperatures The result is lower internal losses and a 06 COMPOUND COOLING COMPRESSOR compressor that delivers more capacity in the same displacement The lower losses also increase operating efficiencies DISCHARGE PORT Suction Pressure Range Compound Cooling Compressors C3 are specifically designed for today s low temperature R 22 applications These applications are designed for operation in the 40 F to 10 F SST Saturated Suction Temperature range June 2007 Carlyle Compound Cooling 22 1 PARALLEL COMPRESSORS TYLER 8 ENVIROGUARD REFRIGERATION Intermediate Pressure Range The intermediate pressure may be obtained from the table on page 22 5 The intermediate pressure of the C3 compressors will vary based on suction and discharge pressure The amount of interstage flow due to subcooling and desuperheating will also vary the inter mediate pressure When subcooling and desuperheating are employed the approximate intermediate pressure AIP may be ca
114. e ETRAS 44 5 190 HOIOV LNOO 9 ualvaH 3s vo 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 1Soudaad SSYNLXIS OL 1994 50 want 35040 ja B 1 LO Id HOWE MOVY LV TANVd sayeoipuy LINGNOD IOHLNOO 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
115. e O D Max Span Ft Line Size O D In 5 5 8 ris re s 4 f j Using Line Sizing Charts 3 3 June 2007 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A Vertical Riser Suction Line Size Charts Proper line sizing is 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 pressur
116. e receiver to provide a pressure difference between the gas manifold and liquid line manifold This assures liquid refrigerant movement from case coils while on defrost Any lack of liquid refrigerant for circuits not in defrost is made up using liquid in the receiver LATENT GAS SUPPLY RELIEF VALVE BALL LIQUID INLET VALVE This 3 way valve is used for heat reclaim thereby eliminating the need for an N O solenoid In the de energized position the discharge gas is routed through the outside condenser and the gas in the heat recovery coil is isolated using check valves The gas in the line between the diverting valve and the check valve upstream of the heat recovery coil is fed back through the valve and into the suction side of the system In the energized position discharge gas is fed through the valve and into the heat reclaim coil and then into the remote condenser The line to the suction side of the system is automatically closed through the valve June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Suction Stop Valve This normally open valve is operated from the multi circuit time clock or computer controller During the refrigeration cycle the valve is de energized and remains open The valve makes use of the system s low pressure to hold itself open by porting the top of the piston to suction manifold When defrost is initiated the solenoid valve is energized IN
117. e components that are referred to in these procedures 1 5 Open the ball valve 13 on the recharge line to allow the liquid refrigerant to flow from the receiver into the unit liquid manifold 6 Open the hand valve 15 on the bleed line assembly Continue to observe the system head pressure until it reaches the design condition or higher This is also indicated when no bubbles are observed in the unit liquid line sightglass 5 Close the ball valve 13 in the recharge line and open the main liquid line ball valve 1 on the inlet side of the unit liquid drier 8 The system is now ready for normal operation To service a separate branch circuit without shutting down the entire system follow this set of procedures 1 Close the branch circuit liquid line ball valve while monitoring the suction pressure in the branch circuit When the suction pressure in the branch circuit reaches the same suction pressure as the parallel compressor unit or 0 psig close the branch circuit suction line ball valve In servicing the branch circuit ensure that proper procedures are followed in recovering refrigerant After servicing the branch circuit ensure that the branch circuit has been proper evacuated before putting it back into service To place the branch circuit back into service open the branch circuit liquid line and suction line ball valve 24 26 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp
118. e drop resulting in loss of system capacity R 22 Refrigerant R404A Refrigerant Se BE 110 Ee 7 90 80 70 60 1000 s OF BTUH 1000 s OF BTUH 50 40 30 20 40F 30F 20F 10F OF 20F 40F 40F 30F 20F 10F OF 20F 40F 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 R404ALT ____ 22 MT R 22 LT 404 R404A LT 1 5 1 5 6 5 7 7 7 8 PAO4A LT 1 2 950 70 5 8 890 78 1 1 8 _ 50 8 950 40 8 8 90 8 rus 2 3 3 1 1 8 5 lt sw wo 4 zo s _ s 130 em rare 144 75 1120 60 4 30 4 50 5 60 6 7 9 280 425 315 45 se _ 45 480 720 se 75 ver ve 2587 66 NOTE Use R404A
119. e module as part of final processing If additional hi potting is required it is recommended it be limited to one time only CAUTION Excessive hi potting can cause damage to the Sentronic module Electrostatic Painting Static electricity discharges from electrostatic painting can damage the Sentronic module It is recommended that the module not be mounted until such painting is complete Sentronic Troubleshooting Checking the Sensor Unplug the sensor and start the compressor Simultaneously measure the oil pump differential pressure Monitor the two terminals at the back of the sensor with an ohmmeter or continuity measuring set If the differential pressure is below 7 9 psid the sensor circuit should be open infinite resistance or no continuity If the pressure is above 12 14 psid the sensor circuit should be closed Checking the Module Shut off the compressor Unplug the sensor Verify the module is powered 230 volts or 115 across the 230 volt terminal and L on the control Start the compressor with the sensor unplugged After 120 seconds plus an additional 15 seconds the contact between the L M terminals should open and shut off the compressor If not the timing circuit is defective and the module must be replaced With the module off on oil pressure press the reset If there is power to the module the contactor should close and start the compressor Electrical Connection Instructions CAUTION Damage to the Sentronic
120. e necessary cooling when required the orifices in the injection valve have been carefully matched to each body style These orifices are large enough to provide the cooling but will prevent large amounts of liquid from being injected This helps prevent excessive system pressure fluctuation during injection valve cycling Normally pressure fluctuations should not exceed 1 to 2 psi Demand cooling is designed to work on all Copeland Discuss compressors equipped with injection ports The system must be clean The refrigerant injection line feeding the injection solenoid valve must tie in after the liquid line filter drier The liquid refrigerant supply line must be a minimum of 3 8 and routed so it will not interfere with compressor maintenance The liquid refrigerant supply line to the injection valve must be supported so that it does not place stress on the injection valve and injection valve tubing or permit excessive vibration A head fan must be used to help lower compressor discharge temperatures Return gas temperatures must not exceed 65 F Suction lines should be well insulated to reduce suction line heat gain To DEMAND COOLING CONTROL CONTROL 220 CIRCUIT MODULE INJECTION M KM VALVE ELECTRICAL CONTROL LINE REFRIGERANT INJECTION LINE DEMAND COOLING SENSOR AND SENSOR LINES LIQUID LINE FILTER DRIER INJECTION SOLENOID VALVE SUCTION LINE FILTER FI
121. e of the N C contact is usually connected to the compressor contac tor coil The circuit for the electronic module power is completed by the connection of the 230 240 or 115 120 volt terminal to the other side of the incoming power line The electronic two minute timing circuit operates whenever voltage is applied to a Sentronic and it has not tripped The timing will be iterrupted when oil pressure rises above 12 14 psid and closes the Sentronic sensor Should oil pressure not build up suffi ciently for 120 seconds the electronic delay will time out open its L M contact break the control circuit and de energize the compressor contactor to stop compressor operation While the compressor is running if the compressor net oil pressure falls below the cut out setting of the sensor while operating and does not re establish sufficient pressure within an acceptable time the time delay circuit will open the L M contacts stopping compressor operation Once the oil pressure switch has tripped it must be manually reset to restore the system to operation IMPORTANT If a power interruption occurs after an oil pressure safety trip wait two minutes before resetting after power is restored 19 4 Optional Sentronic Electronic Oil Pressure Control June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Control with Alarm Current Sentronic Previous Sentronic m Li ALARM VOLTAGE PATH BETWEEN LAND Li
122. e oil pump designs As in the past all new and replacement Copelamatic motor compressors equipped with oil pumps require the use of an approved safety control Failure to use an oil pressure safety control will be considered a misuse of the compressor To meet Copeland specifications an oil pressure safety control must maintain its pressure setting and time delay calibration within close limits over the widest variation in operating conditions This control must successfully pass a life test with a minimum 200 000 cycles Controls must be of the nonadjustable manual reset type with a 120 second nominal time delay at rated voltage They must have a cut out pressure of 9 psid 2 psid witha maximum cut in pressure of 14 psid Basic Operation The Sentronic oil pressure sensor mounts directly into the oil pump The sensor measures oil pump differential pressure i e the difference between oil pump outlet pressure and crankcase pressure The oil control sensor will then send an operating signal to the oil control module Should the oil pressure fall below 9 psid 2 psid for a period of two minutes the module will open the control circuit and shut the compressor down The two minute time delay serves to avoid shutdown during short fluctuation in oil pressure on start up Oil pressure can be approximately measured in the field Oil pumps will still be furnished with a Schrader valve for the discharge high pressure port To measure oil pressure
123. e optimum temperature control This consists of floating the suction pressure higher by referencing the case temperature 24 2 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD 8 Existing system retrofits WILL NOT be sold or installed at this time until approved by TYLER 9 electronic air temperature sensor at SPR air sensor is beneficial for setting and checking the SPR valve 10 Evaporative condensers may be used with Enviroguard NOTE The same benefits will not be realized as those realized when using air cooled condensers especially in colder climates The primary benefit from using Enviroguard with an evaporative condenser may be some small additional refrigerant charge reduction over and above only using the evaporative condenser without Enviroguard An evaporative condenser does not rely on flooding the condenser in cool weather to reduce condenser surface as compared to an air cooled condenser Extremely low subcooled liquid temperatures would not be obtained unless an additional air cooled coil or subcooler is added This is because of the lower temperature limit of the water in the evaporative condenser sump Fixture Temperature Control Suction stop EPR s are recommended for fixture and or circuit temperature control NOTE Liquid line solenoids and pump down can be used on a LIMITED basis Condenser Locations The IDEAL location of the conde
124. e sensor cable from the control circuit board and press RESET if the system restarts correctly replace the sensor cable C If the green amp yellow LEDs are ON for the duration of the time delay and the system shuts down observe the crankcase and oil pump pressure gauges f the system does not reach sufficient oil pressure by the end of the time delay check the compressor and system for problems the system does reach sufficient oil pressure disconnect the sensor cable at the sensor connect a voltmeter to the left and center pins of the sensor cable via two short pieces of 22 gauge wire See Figure 7 Press the RESET button If the voltage between these terminals is not approximately 5V between 4 75 and 5 35 test the sensor cable for continuity Replace the cable and repeat this step if the cable is faulty If the cable is OK and the voltage is still insufficient replace the control the control cable are OK remove the voltmeter and use a single piece of 22 gauge wire between the center and right pins of the sensor cable See Figure 7 Press the RESET button If the green LED comes ON and the yellow LED goes OFF replace the sensor Otherwise replace the control Dim and 1 Check the power source flickering Yellow LED 2 Confirm that the compressor is operating at sufficient pressure without excessive pressure fluctuations 3 Check the wiring harness for loose connections 4 f the oil pre
125. e time delay and the system shuts down observe the crankcase and oil pump pressure gauges system does not reach sufficient oil pressure by the end of the time delay check the compressor and system for problems f the system does reach sufficient pressure Disconnect the wiring harness at the P400 switch Use a single piece of 22 gauge wire as a jumper between the common and signal terminals of the wiring harness WHA P400 xxx Press RESET Common Signal Wiring Harness Plug If the green LED come ON and the yellow LED turns OFF replace the P400 switch Otherwise replace the control 23 6 Electronic Oil Pressure Control June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD LED Status Troubleshooting Procedure Red LED ON P445 P345 cont A If the green amp yellow LEDs ON but the compressor remains OFF check the wiring B If the system immediately shuts down the compressor may be overheated or the pressure sensor or sensor cable may be bad Check compressor temperature if the compressor is overheated an R10A relay can be installed with the control to provide controlled shutdown based on thermal overload Determine the cause of overheating and correct Unplug the sensor cable from the sensor and press RESET if the system restarts correctly with the sensor unplugged replace the sensor the system does not restart with the sensor unplugged unplug th
126. ectrical Checkout Procedure Use the following procedure to test for correct operation during initial installation and maintenance operations WARNING To avoid possible electrical shock or damage to equipment disconnect power supply before wiring any connections 1 De energize the supply voltage to the control and the compressor circuit 2 Disconnect wire leads between the contactor and compressor motor T or W terminals to stop the compressor from running during this part of the test See wiring diagrams Figures 5 amp 6 NOTE On systems using a current sensing relay R310AD or R10A remove relay connections to control terminals W1 and W2 or FT1 and FT2 and connect a jumper between these two terminals 3 Re energize the supply voltage to the control Check that all the operating and limit con trols are closed This ensures that power is being supplied to the control 4 The compressor contactor circuit will immediately be energized and the yellow amp green LEDs will be ON The green LED indicates that the compressor contactor is energized The yellow LED indicates that the oil pressure differential is low and the timing circuit is energized 5 When the factory set low pressure time delay elapses the control de energizes locks out the contactor The red LED will illuminate while the yellow amp green LEDs will turn OFF If an alarm is installed the control s alarm contacts will close and the liquid li
127. ed 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 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 require additional supports between A and B A GOOD Support at C ma
128. eee NunissvoioH AT i A 49249 6 1 neg 2945 l H3SN3QNOO Buidid 4 7 a j Buidid pier i 9 Ht HOLVHOdVA3 cit HOLVHOdVA3 June 2007 26 12 Enviroguard III PARALLEL COMPRESSORS amp ENVIROGUARD Installation amp Service Manual Enviroguard Piping Diagram for Hot Gas Defrost Winter Operation ainssaid Jug Qm 86819 ed peog 1 SS pers o 1 G1O3INVW 14615 1ode 5 4 HdS eunssejd gt lt 5 pinbr T 4 4 G04INVW 55919 14615 Cy rx p 72 773 E T EIE L lo 1osu s Q103INVIA SV9 LOH 7 TIE Ni AS A 42949 5 Buidid 4 5 lt Buidid 1 5 oou cit HO1VHOdVA3 Hf HOLVHOdVA3 Enviroguard III 26 13 June 2007 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Enviroguard Control Set Ups Enviroguard systems are desig
129. el 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 amp ENVIROGUARD TYLER 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 X LENGTH in inches FOR LINEAR EXPANSION 1 2 2 1 2 512 2 0 915 e 1 1 8 1 3 8 1 5 8 2 1 8 2 5 8 3 1 4 1 5 1 6 1 22 2X 2X
130. er 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 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
131. ermining the setting of the SPR Example worksheets for R 22 low and medium temperature systems are shown on page 24 14 1 Determine the condenser outdoor design ambient air temperature 2 Determine the design condenser temperature difference TD TYLER generally recommends using a 10 F to 15 F TD for low temperature air cooled applications The design condenser TD can be determined from the TYLER Summary Sheet as the difference between the condensing temperature and the design ambient air temperature 3 List a 5 F TD safety to the design condenser TD to compensate for any condenser foul ing that may occur bent fins loss of condenser fans dust etc 4 Determine the adjusted condensing temperature by adding the condenser TD and the 5 F TD safety to the design ambient air temperature 5 Determine the corresponding saturated refrigerant pressure equal to the adjusted air temperature 6 Determine the corresponding saturated refrigerant pressure equal to the design ambient air temperature 7 Determine the SPR target differential pressure by subtracting the corresponding saturat ed refrigerant pressure equal to the design ambient air temperature from the corre sponding saturated refrigerant pressure equal to the adjusted condensing temperature 8 Determine the actual ambient air temperature at the time of system start up Ambient air temperature sensor as an input to electronic rack controller can be referenced
132. ervoir 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 COMPRESSORS TYLER ENVIROGUARD REFRIGERATION 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 pressure feeding the oil level control s of the satellite s The outlet of the re
133. essure Target Use the saturated pressure at the following temperatures 40 F Low temperature racks without gas defrost 55 F Low temperature racks with gas defrost 60 F Medium temperature racks File Edit View Simulator 16704 09 Condenser type Far Number of fans Maia 3 Fan stage monitoring None Control Sensor 0m P Pressure Monitor dropleg temp Yes Target Target control type Rate of change 101 6psi PG DN for more 26 34 Enviroguard III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Screen 2 Enviroguard Configuration To get to this screen Page Down from Screen 1 Select Yes to activate the Enviroguard Condenser Control Option Min condenser temp Use the same temperatures that were used in the previous screen Elevation Change it according to the actual installation File Edit View Simulator 09716704 Enviroguard Subcooling target x S p v PORIS RE Min condensing temp 2600 Min subcooling temp Muze OU Elevation rack to cond 30 ft Open SPR if discharge 80 0 psi Target June 2007 Enviroguard III 26 35 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGE
134. exist finish charging with vapor refrigerant through the suction charging valve 21 until the sightglass 5 clears and a solid column of liquid is observed in the sightglass An alternate method to charging the system with vapor refrigerant through the suction charging valve is to charge liquid refrigerant directly into the liquid line of a branch circuit Before charging isolate the circuit from the unit liquid manifold by closing the liquid line ball valve on that branch circuit Attach an accurate thermocouple to the unit liquid line near the main liquid line ball valve 1 located on the inlet side of the liquid drier 3 Attach a pressure gauge set to the Schrader access fitting on the unit liquid drier 3 24 10 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD 18 Continue charging until the liquid temperature measured with the thermocouple is within 2 to 3 F of the actual ambient air temperature and the liquid pressure reaches the corresponding pressure for actual ambient air temperatures up to 60 to 70 F Charging in ambient air temperatures above 60 to 70 F will require adding additional refrigerant after this condition is reached See chart below for approximate guidelines for receiver charges when ambient air temperatures are above 70 F Ambient Receiver Charge full charge Setting the SPR The following procedure should be followed in det
135. f more than one parallel system A typical installation may use R 22 or R404A refrigerants Separate loads will be connected to the parallel rack at the liquid and suction line manifolds Temperature control at each individual circuit will be provided by an evaporator pressure regulator EPR valve in the suction lines or by thermostats with liquid or suction line solenoid valves Typical Piping amp Devices All Systems See page 17 3 for Piping Diagram for Parallel System with NC 2 amp Heat Recovery All liquid refrigerant flowing out to the case and cooler circuits must pass through a replaceable core filter drier 1 This filter and the filters in the suction line of each compressor are important in keeping installation debris from damaging the components in the system The drier element absorbs and holds moisture acids sludge and varnish which may be in the system A moisture indicating sight glass 2 tells when the drier needs to be changed it also shows flow through the liquid line A liquid level gauge on the receiver determines the system charge Factory piping includes three ball shutoff valves 3 to aid in servicing There are also service valves at each station on the liquid manifold 4 and suction manifold 5 Additional ball valves 6 are recommended and optionally supplied for field installation at the points shown This makes the completed system fully serviceable at any point with a minimum of refrigerant l
136. f the temperature falls below 70 F the 25 solenoid is energized The settings for the 25 thermostat are 55 F ON and 40 F OFF The subcooler compressor is controlled and protected by its own pressure control When liquid return temperature is above 55 F the subcooler will cycle ON and OFF between 55 F and 40 F See page 17 7 for Piping Diagram for NC 1 amp Mechanical Subcooling 17 6 Parallel System w NC 2 amp Heat Recovery June 2007 amp ENVIROGUARD PARALLEL COMPRESSORS Installation amp Service Manual Diagram for Parallel System with NC 1 amp Mechanical Subcoolin Pi AAWA MO3HO IVNOLLdO ldid ONIdid 91915 H3SN3QNOO 3ATVA uaria NOILONS NOILONS 20 E 5 ONIdid AHO LOV 91914 3ATVA NOILONS LIVISL 431000 B ans YIOAYASSY aisd 3AIVA MO3HO ABLSAS 5 Ad yaya 5NIIOOoans ssv1o JAVA O 30945 ONIdid 1SOHJ3Q OIH1O313 HO 430 INIL 0 M GINO L ON NOISS3HdlIOO JOVLS HLIM WALSAS TH TIVHvd Y YNSHLOFd Parallel System w NC 2 amp Heat Recovery 17 7 June 2007 PARALLEL COMPRESSORS
137. fety factor Adjusted condensing temperature Corresponding saturated refrigerant pressure equal to the condensing temperature F Corresponding saturated refrigerant pressure equal to the ambient air temperature Target SPR differential Actual ambient air temperature at time of system start up Corresponding saturated refrigerant pressure equal to the ambient air temperature J Target SPR differential pressure Target SPR bypass pressure 95 F SF 163 psig In this low temperature example the actual pressure at which the SPR will be set to bypass refrigerant to the receiver is 163 psig with the ambient air temperature measured at 60 F 24 14 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Blank Worksheet for System Start U Design ambient air temperature Design condenser TD TD safety factor Adjusted condensing temperature E Corresponding saturated refrigerant pressure equal to the condensing temperature F Corresponding saturated refrigerant pressure equal to the ambient air temperature Actual ambient air temperature at time of system start up Corresponding saturated refrigerant pressure equal to the ambient air temperature J Target SPR differential pressure Target SPR bypass pressure After determining the actual SPR bypass pressure follow the procedures listed on the following pages to adjust the SPR IMPORTANT NOTE The pressure at which t
138. gh under the condenser so that sunlight does not shine directly on it Connect a 1 8 or 1 4 O D copper line from the ambient air sensor to the pressure pilot on the SPR The SPR is located on the compressor rack return liquid line NOTES Do not use copper tubing larger than 1 4 O D Do not run this line adjacent to a discharge line It is recommended to have a temperature sensor located at the SPR air sensor for the purpose of setting the SPR Evacuate and charge the ambient air sensor and copper capillary line assembly with the same refrigerant type being used in the refrigeration system It should be charged to approximately a 1 2 to 3 4 level This can be viewed in the sightglass located on the side of the ambient air sensor NOTE Evacuate and charge sensor only with new unused refrigerant DO NOT use refrigerant that may be contaminated with oil 24 8 Enviroguard June 2007 PARALLEL COMPRESSORS amp ENVIROGUARD 5 SL HOlVinodgdunssa3ud WALSAS 6 NYNLSY 599 LOH Se SSVISLHSIS O33 18 1 H3NIVHLS 8 SVD LOH GCION3IOS 03378 91 SSWdAd 4 SNOILIGNOS O33 18 St ANI LINN 9 8 N3dO ATIVINHON H3NIVH IS O33 18 vL SSVIOLHOIS LINN S
139. gulating 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 prudent to use a maximum pressure differential of 25 psi Refer to Figure 1 LOW TEMP EXTRA LOW TEMP _ SUCTION MANIFOLD VALVE 20 PSID NOTES 1 REGULATING VALVE IS REQUIRED IF SUCTION PRESSURE DIFFERENTIAL BETWEEN 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 VA
140. he SPR will be set to bypass refrigerant into the receiver depends on the actual measured ambient air temperature taken at the time the SPR adjustment is performed This is determined from the information on this worksheet Target SPR differential June 2007 Enviroguard 24 15 PARALLEL COMPRESSORS TYLER ENVIROGUARD REFRIGERATION Adjusting the SPR The following procedure must be followed for each installation at the time of system start up to properly adjust the SPR The item numbers in this procedure correspond with the Figure 1 drawing on page 24 9 1 2 10 11 12 Open the 1 2 ball valve 7 located on the 1 2 bypass inlet line to the SPR 9 Compare the liquid line pressure to the target SPR bypass pressure The liquid line pressure should be some value less than the target SPR bypass pressure See pages 24 14 amp 24 15 If the liquid line pressure is greater than the initial SPR bypass pressure and vaporizing liquid refrigerant is being observed in the sightglass on the outlet line of the SPR immediately turn the SPR square adjusting stem 4 turns clockwise This will raise the actual SPR pressure If the liquid line pressure is less than the initial SPR bypass pressure turn OFF condenser fans until the liquid line pressure rises equal to or 5 psig greater than the target SPR bypass pressure Turn the SPR 9 square adjusting stem counter clockwise to lower the actual SPR bypass pressure
141. he load With the voltmeter connected to terminals M and 120 the voltage should now read zero volts because the circuit between and has been opened through the action of the electronic circuit Reset the Sentronic then remove voltage from terminals 120 With a small piece of wire jumper the female sensor connections at the end of the black sensor cord attached to the module Reapply power to terminals 120 and wait two minutes The module should not time out after two minutes because jumpering the sensor connections makes the timing circuit see good oil pressure The jumper imitates the action of a small pressure switch located in the sensor This switch opens on low oil pressure and closes on good oil pressure Measure between the 120 terminal and the M terminal with the voltmeter The meter should read full line voltage showing that the circuit has not opened To check if the module will operate on 208 240 volts as well as on 120 volts change the scale of the voltmeter if necessary to read up to 250VAC Without removing power measure the voltage between the M terminal and the 240 terminal You should read nearly twice the voltag as that read between the M terminal and the 120 terminal This is because Sentronic has a small control transformer connected so that it can accept either 120V or 208 240V It s self transforming action actually enables
142. he 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 A 16 cubic inch drier should be used on a 145 pound cylinder Close the receiver 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 7 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 mo
143. heckout Procedure 19 8 20 Maintenance amp Troubleshooting 20 1 Maintenance e504 G6 ERSRESRRGCMRBRRRSSRRPRERRRRRS EEG 20 1 Electrical sce dud poems ees ee 20 1 Refrigerant Piping 20 1 Troubleshooting Chart Symptoms Possible Causes 20 2 21 R 22 Low Temperature Demand Cooling 21 1 Demand Cooling Components Illustration 21 1 Control Settings 21 1 Tyler Part Numbers for Demand Cooling Kits Chart 21 2 Tyler Part Numbers for Demand Cooling Components Chart 21 2 Tyler Part Numbers for Demand Cooling Injection Valves Less Solenoid 21 2 System Information 21 3 Demand Cooling System Diagram 21 3 Typical Parallel Wiring Application Diagram 21 4 Table of Contents IV June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Page Typical Single Unit Compressor Wiring TFC TFD Diagram 21 5 Typical Single Unit Compressor Wiring TSK Diagram 21 6 22 Carlyle Compound Cooling 22 1 Why Compound Cooling 22 1 How Compound Cooling Works 22
144. ig higher then the lowest setting of the condenser fans Differential Pressure Settings for DDPR at Various Riser Heights RISER HEIGHTS DDPR SETTINGS __ 23 __ The minimum allowable differential pressure setting of the DDPR is 20 psid 24 24 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Setting the DDPR for Enviroguard 1 2 3 4 Adjust DDPR to proper setting DDPR setting 20 psig plus 1 2 the riser height 5 6 7 Install gauges both upstream and downstream of the DDPR Close the hot gas hand valve to station 1 Initiate defrost station 1 Example If the riser height between the case level and the condenser inlet is 24 the setting for the DDPR would be 20 12 32psig Remove the gauges Cycle the defrost OFF Open the hot gas hand valve to station 1 Mechanical Liquid Subcooling 1 3 4 When subcoolers operated with two expansion valves one is rated at 25 of the load and the other at 75 of the load Two thermostats are necessary to control the respective valves The one designated thermostat in the 25 TXV solenoid circuit is set to operate at 55 F cut in and 50 F cut out This thermostat is wired to the close on rise temperature switch function The one designated thermostat in the 75 TXV solenoid circuit is set to operate at 80 F cut in and 75 F cut out This double throw switch is wired to the close o
145. igerant vapor into the receiver Further reduction in outlet pressure will allow the valve to open to its rated position where the rated pressure drop will exist across the valve port An increase in the outlet pressure will cause the valve to throttle until the pressure setting is reduced The valve supplied with R404A systems has a range from 80 to 200 psi See page 9 1 for pressure setting requirements GAS BYPASS LINE BALL VALVE CHECK VALVE 9 ae RELIEF VALVE RECEIVER SHOR CHECK BALL BALL VALVE VALVE VALVE 18 4 Component Description amp Definitions June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD CROT amp OPR Pressure Settings SETTING GR5168 GR5169 PSIG DEPTH DEPTH 9 16 a me m wu we gt 5 U Changes 6 72 OPR 6 OPR 6 A 9 per 27 psig 50 130 15 5 psig 80 200 24 psig See Section 9 1 PENN Oil Pressure Safety Switch All Copeland and Carlyle compressors 5 HP and above are equipped with Lubrication Protection a PENN term LUBRICATION The control is completely non adjustable and set to Copeland amp Carlyle specification available to circulate oil through the lubrication system Net oil pressure is the difference between the oil gauge pressure and the refrigerant pressure in the crankcase The P45 control mea
146. il during the OFF cycle and unnecessary shifts of refrigerant to the receiver 3 One ambient temperature sensor may be required for each Enviroguard system controller dependent Each sensor should be mounted under the header end of the condenser The mounting locations should be away from metal surfaces that could affect the temperature readings 4 Suction stop EPR s are recommended for circuit temperature control NOTE Liquid line solenoids and pump down can be used on a LIMITED basis 5 Prior to TXV adjustment set condensing temperature to 90 F Refrigerant type will dictate the corresponding pressure When valves are set use Enviroguard guidelines to set condensing pressure for normal operation See page 26 19 6 Prior to normal operation insure that the Enviroguard ball valves are in their proper positions See page 26 10 Example N O open and N C closed 26 8 Enviroguard III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Condenser Set Points CONDENSER SET POINTS Refrigerant Medium Temp Low Temp Hot Gas Low Temp Type 60 F 55 F 40 F Recommended Charging Procedure Ambient air temperature is above 70 F The system should be charged to 20 25 of the receiver level Ambient air temperature is below 70 F 1 Make sure the condenser set point is set to a pressure whose saturated temperature is at least 35 F above the ambient air temperature 2
147. il the Subcooling Sensor Control point achieves an average of 30 NOTE Southern climates may use 25 for low temp systems SPR Solenoid Valve Wiring Use the RO point for the last fan to break the circuit for the SPR control SPR valve will only open when all fans are running In the following cases RO board 5 is located at the rack and board 8 is located at the condenser In the case where there is a control board at the condenser RO points 5 7 are added as an extra condenser fan stage and must be programmed as the 5th last fan 26 20 Enviroguard III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD CASE 1 Condenser Control with RO Board at Rack RMCC FAN RMCC FAN BOARD CONTACTOR BOARD CONTACTOR POINT POINT CONTROL POWER 208 VAC CONTROL POWER 208 VAC 5 1 1 5 1 1 5 2 2 5 2 2 5 3 3 5 3 3 5 4 5 4 4 SPR SPR 5 8 VALVE 5 6 VALVE CASE 2 Condenser Control with RO Board at Condenser RMCC FAN RMCC FAN BOARD CONTACTOR BOARD CONTACTOR POINT POINT CONTROL POWER 208 VAC CONTROL POWER 208 VAC 8 1 1 8 1 1 CHANGE 8 2 2 TO 8 2 2 8 3 3 8 3 3 8 4 4 8 4 4 5 7 SPR SPR 5 8 VALVE 5 8 VALVE June 2007 Enviroguard III 26 21 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Enviroguard Control Set Up for CPC s Einstein 1 Controller Analog Input Set Up Make sure the board point for the pressure input is set to Type 500 Ib Eclipse Sensor Off
148. information for 502 4 R 507 refrigerants R 22 amp R404A Liquid Line Sizing Chart R 22 R404A at 5 PD 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 ETT ETRIS length of the pipe and the equivalent footage assigned for t 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 the intersection will indicate the proper size unless it is a dark area Selections falling in the dark areas of the chart
149. ion to Input 2 Setpoint Set CUTIN to 15 0 and CUTOUT to 14 9 Digital Combiner Set Up General Name it SPR Give it 2 Inputs Choose On Off for Engr Units Choose And for Comb Type Inputs Assign Subcool Command Out to Dig Input 1 Assign Condenser 01 the last Fan out on the condenser to Dig Input 2 Outputs Assign the board point location for OUTPUT to be the SPR Relay Analog Inputs Set Up Chart Key Entry F8 6 1 Go to the Input summary screen Scroll to the Pressure Sensor Choose the pressure sensor input and board point F7 select 1 if not already defined Scroll down Sensor Type Eclipse 500LB to Scroll down four times 1 2 the Sensor Offset 1 2 the condenser condenser elevation in feet elevation in feet F10 Scroll to the dropleg sensor Choose the dropleg sensor input and board point F7 select 1 if not already defined Scroll Sensor Type Temperature down to T F10 F9 Go to the Home Screen June 2007 Enviroguard III 26 23 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Add Controls Chart Key Entry F8 Z 1 Scroll down to 1 Add the Condenser Control Enter F7 97 Enter Scroll down to 1 Add one Conversion Cell Enter F7 96
150. key slots then remove the module 4 To reinstall reverse the above steps 14 2 Multi Circuit Time Clock Module June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Program Charts for Multi Circuit Timers Below are program charts for the multi circuit time clock These charts may be used to design a defrost program for an entire parallel system TIME OF DAY DIAL EVEN HOUR MODULE 2 EVEN HALF HOUR MODULE 3 ODD HOUR MODULE 4 ODD HALF HOUR MODULE 5 EVEN HOUR MODULE 6 EVEN HALF HOUR MODULE 7 ODD HOUR MODULE ODD HALF HOUR MODULE TIME OF DAY DIAL EA PA SAS CA DA wo 070l EA RA EA CASES COOLERS e ar EVEN HOUR MODULE 2 EVEN HALF HOUR MODULE 3 ODD HOUR MODULE 4 ODD HALF HOUR MODULE 5 EVEN HOUR MODULE 6 EVEN HALF HOUR MODULE 7 ODD HOUR MODULE 8 ODD HALF HOUR MODULE June 2007 Multi Circuit Time Clock Module 14 3 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD SECTION 15 Refriger
151. knockouts Refer to drawing on the following page 9 9 EH 1 LABEL NAMEPLATE E C 2 LABELUL LABEL 208 230V POWER 4 LABEL DEFROST CIRCUIT 14 WIDE ENCLOSURE 26 H x 8 D E E ORO RS ITEM DESCRIPTION nx err ere lol Tnm 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 ojojo ajon ce FES O Q gt Ground Lug 6 o 2 Control Circuit Terminal Blocks 6 Power Distribution Block He 8 e GENERAL REFERENCE ONLY TG i CKT TC 2 CKT TS 1 June 2007 Electrical Supply Locations 5 1 PARALLEL COMPRESSORS amp ENVIROGUARD AWUSLAYSL 1151 fe beg ge he one ae gt 94 n NIA adie nob penny e 1 F 0 1 9 1v1SL 5i e lllud E ee
152. l Bench Checkout Procedure The following instructions describes how the Sentronic may be easily bench checked using only a voltmeter and a 120VAC electrical extension cord CAUTIONS Damage to the Sentronic module may result if the M terminal of the Sentronic is connected to ground or directly to a voltage line This test is conducted with 120VAC A shock will result if the Sentronic terminals are touched when the Sentronic module is energized Use care whenever working with any voltage Make sure your electrical outlet is grounded the electrical extension cord used has a ground wire and the ground wire is connected to the grounding screw of the Sentronic Apply 120VAC power to the Sentronic module terminals marked 120 The Sentronic should have a jumper in place between terminals M and 2 Wait two minutes then push the Sentronic reset button to reset the module and start the timing circuit With a voltmeter measure line voltage 120VAC between the M terminal and the 120 terminal It should be the same as the electrical outlet voltage About 120VAC Since there is no connection made to the pressure sensor the module sees this as a no oil pressure condition After two minutes 15 seconds dependent on 50 or 60 cycle frequency the Sentronic internal timer will time out The module will trip the circuit between 1 and M will open and it will no longer pass current to t
153. l 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 amp 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 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 OL1 CH Center Line ERN gt 3i 20 PSI lt 5 PSI 30 PSI 3 8 x i Es EM ES 3 1 Bs EN N Top 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
154. lculated by taking the square root of the product of the suction and the discharge pressure 10 psi NOTE If an economizer Figure 1 is not used the intermediate pressure may be up to 30 psi lower that the AIP Discharge Pressure Range C3 compressors are designed to operate at discharge pressures ranging from 70 to 130 F SCT Saturated Condensing Temperature Economizer Two stage systems have the inherent benefit of being able to utilize interstage subcooling and desuperheating through the use of a heat exchanger Figure 1 is a diagram of an economizer cycle Liquid at the saturated condensing temperature SCT passes through a heat exchanger on the way to the evaporator The liquid is subcooled A tap off the main liquid line is directly expanded across the subcooler pressure to interstage pressure The subcooling is done at interstage pressure where the refrigerant can be compressed more efficiently This increases the compressor capacity and energy efficiency ratio EER SUBCOOLED LIQUID MAIN LIQUID FROM TO EVAPORATOR CONDENSOR TAP FROM MAIN FIGURE 1 LIQUID LINE BRAZED PLATE HEAT EXCHANGER TO COMPRESSOR INTERSTAGE ECONOMIZER CONNECTION Desuperheating Expansion Valve A desuperheating expansion valve is used to limit the discharge temperature to a maximum of 220 F to 230 F leaving each compressor This valve only operates when the economized flow alone cannot prevent this maximum temperature 22 2 Carlyle
155. ld installed C Sightglass field installed D 7 8 OD Check Valve field installed Branch Circuit Liquid Line Components A Watsco bullet type Check Valves 5 8 OD B Ball Shutoff Valves 5 8 OD C Two valves each are required per branch circuit D Normally Closed 5 8 Solenoid Valve June 2007 Enviroguard 24 31 PARALLEL COMPRESSORS TYLER REFRIGERATION amp ENVIROGUARD Diagram for Enviroguard with Gas Defrost In Pi 3ATVA GION3IOS eA SSVIOLHDIS dunssdud 80 ON WNIVHIS GALVINSNI 03430108S add YAM SIHONI X QO t l THINS NOILLONS AHO LOVA Pena aa 1 NOILONS op EC ire im ssv19 F I SVS A v O 1918 m m P WS dj X 20 X 84 Ad Ad ss3oov 3tunssatid AHOLOVA mats E nS STONIS HOSN3S LOH ONidid AINON ERE A 19 l 1 NOISS3HdINOO 39716 319NIS mya 2 z HLIMWALSAS 13
156. life due to overall runtime Facts to Consider The Enviroguard system is piped with the liquid header and the receiver in parallel of each other The liquid header begins at the outlet of the condenser At or below approximately 70 F ambient temperature there should be NO liquid present in the receiver The system charge is balanced through a bleed solenoid and tubing located between the bottom of the receiver and the suction manifold Under normal operating conditions this process is constant as long as one compressor is running Enviroguard s control strategy targets net subcooling for EG valve operation Enviroguard provides control strategy that prevents elevated condenser operation 26 2 Enviroguard III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Enviroguard and Heat Reclaim Space or hot water reclaim may be used with Enviroguard however the value of space heating is very limited with the condenser fan controls set to maximize the energy savings The resetting of these controls to increase heat recovery or the addition of holdback valves will also increase the compressor operating cost in cool weather Enviroguard and Hot Gas Defrost A discharge differential pressure regulating valve DDPR is used on Enviroguard systems with hot gas defrost The DDPR should be field adjusted to maintain a differential of 20 psig plus one half the riser height Example If
157. lve arrangement provides the necessary pressure difference to ensure a reverse flow through the specific branch circuit The OLDR valve 7 and the DDPR valve 6 operate together during any defrost cycle When the defrost is terminated the DDPR valve 6 and the OLDR valve 7 are returned to the open position allowing normal system operation to resume This valve arrangement provides both system stability and the necessary difference in liquid pressures to ensure flow of the condensed hot gas liquid from the defrosting fixture June 2007 Refrigeration Circuits 15 3 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Receiver Gas Defrost Receiver gas defrost is accomplished by using the relatively cool gas from the top of the receiver The cool gas is discharged down the suction line to the evaporator where it begins to condense giving up latent heat in melting the accumulated frost from the evaporator The defrost gas being at a relatively cool temperature at the start of defrost reduces thermal stress on the piping thereby reducing the possibility of line breakage and loss of refrigerant The gas volume in the receiver is constantly being supplied from the compressor discharge line which maintains gas flow throughout the defrost cycle Receiver gas defrost is available for case lineups operated by a parallel compressor system Defrost is accomplished by using the cool saturated gas from the receiver at elevated p
158. lve 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 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 n
159. m 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 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
160. meters 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 Installation 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
161. mperature gt OLDR Liquid Solenoid Valve is energized during defrost to create a pressure differential Refer to table on page 10 2 for proper adjustment June 2007 Receiver Gas Defrost 16 1 REFRIGERATION TYLER TWNOILdO Diagram for Parallel System with Demand Cooling Mechanical Subcooling amp Latent Gas Defrost PARALLEL COMPRESSORS amp ENVIROGUARD Pi ddl TIVE AAWA TIVE gt udAl3odu 3ATVA 38189 Tiva MO3HO gt lt CANN SSW HOlv1n53H 8 150 97 19161 ans 3ATVAMO3HO A VA ES ETE E NOILONS IN3LSAS 3ivuvd3s Ad ms 69 19 9NIIOOOSnS 1 ONIdld AHO LOVJ YASNACNOO 3 TIONIS 18044340 59 INSLV1 0 M AINON G 131d 1 NOISS3HdINOO 3915 3 TENIS HLIM WALSAS T3 TTvuvd qr sz 80 HOlVHOdV d HO1VHOdV 3 HOlVHOdV 3 awa u ANNY 10dd MO3HO MO3HO June 2007 16 2 Receiver Gas Defrost PARALLEL COMPRESSORS amp ENVIROGUARD Installation amp Service Manual ing Diagram for Parallel System with Latent G
162. mpressor rack for temperature regulation by pressure of the entire lineup A variation of omits the liquid line solenoid valve Instead the EPR 3 is equipped with a solenoid valve controlled by the multi circuit clock or computer controller When the solenoid valve is energized it will force the EPR to shut Suction stop and refrigerant flow in the lineup will cease C When precise case temperature control is desired each case is equipped with a liquid line solenoid valve 4 normally closed which is cycled by a thermostat The thermostat will use a bulb to sense entering air temperature No EPR valve is required The control circuit for these multiple solenoids will be controlled by the multi circuit clock or computer controller D This lineup is a variation of A The suction stop feature of an EPR 5 is employed for defrost in combination with a liquid line solenoid This slows and eventually stops the feeding of refrigerant through the expansion valve while in defrost and is often used on medium temperature circuits June 2007 Refrigeration Circuits 15 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Gas Defrost Piping Arrangements E SORIT BEPRS This type of EPR valve 8 is a minimum pressure drop valve which uses the system s high pressure to operate the valve With regards to Sporlan s SORIT the initial S stands for the solenoid stop ORI stands for Open on Rise of Inlet Pres
163. n rise temperature for the 75 TXV circuit and to the close on rise temperature for the 25 TXV circuit switch functions The sensing bulbs of both thermostats are mounted on the main liquid line entering the subcooler or the condenser liquid dropleg For systems equipped with an EPR on the suction outlet of the subcooler the EPR should be set at a pressure corresponding to a 30 F saturated evaporating temperature for the refrigerant type being used The typical subcooler leaving target liquid temperature is 40 F Subcooler expansion valves should be set to achieve a superheat of 10 F MANIFOLD SUBCOOLER SUCTION THERMOSTAT SPDT June 2007 Enviroguard 24 25 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Servicing the System Servicing the entire system requires a total shutdown of the unit Following the procedures below will provide the shutdown instructions Refer to Figure 1 on page 24 9 to locate the components that are referred to in these procedures 1 3 Close the main liquid line ball valve 1 before the unit liquid drier 3 and hand valve 15 The system will be pumped down when all compressors cycle OFF on the backup low pressure controls and the system suction pressure is 1 psig or less The system is now shutdown and ready for servicing To restart the system after servicing follow this set of procedures Figure 1 on page 24 9 shows the locations of th
164. nd 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 from fixtures warms too much on its way to the compressor WITH GAS DEFROST INS
165. ne solenoid contacts will open 6 Press RESET The red LED will turn OFF and the green amp yellow LEDs will turn ON The contactor is now energized NOTE The control will remain locked until the RESET button is pressed even if power is removed from the control The control cannot be reset without power 7 De energize the supply voltage Reconnect the compressor leads to the contactor or reset the disconnect If an R310AD switch is used reconnect the compressor leads to the contactor If a R10A Series Relay is used remove the jumper and reconnect the relay leads to the control See Figure 4 8 Re energize the supply voltage If the operating and limit controls are closed and power has been removed for longer than the anti short cycle delay the compressor will start and both the green amp yellow LEDs will be ON The yellow LED will turn OFF when the lube oil pressure level reaches the switch opening point or sensor setpoint generally within seconds of starting the compressor June 2007 Electronic Oil Pressure Control 23 5 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Operational Control Test Use this test to check that the control is operating correctly This test simulates a low oil pressure condition and initiates an immediate lockout of the compressor with the P545 control or an abbreviated 8 second timing cycle followed by a lockout of the compressor with the P445 P345 control 1 With power to the
166. ne the outputs At the OUTPUT line press F3 Edit scroll to the selection Alternate I O Formats then Enter Enter the number that corresponds to Board Point This is the Board and output Point number that relates to the SPR solenoid valve or relay Press the Home key house symbol then when asked to save changes 26 32 Enviroguard III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Recommended Charging Procedures Ambient air temperature above 70 F Charging the system should be to a 20 receiver level Ambient air temperature below 70 F Make sure the condenser setpoint is set to a pressure whose saturated temperature is at least 35 F above the ambient air temperature Close off the SPR line Add charge until the SUBCOOLING Sensor Control point achieves an average of 30 F NOTE Southern climates may use 25 F for low temp systems Condenser Setpoints Medium Temp Low Temp Low Temp Refrigerant Time Off Hot Gas Electric Time Off Type 60 F 45 F 40 F June 2007 Enviroguard III 26 33 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Enviroguard Control Set Up for Danfoss AKC 55 Controller Screen 1 Condenser Configuration To get this screen Select Condenser under Rack Configuration Control Sensor Pressure NOTE Use the dropleg pressure transducer although AKC 55 labels it as discharge pr
167. ned to be versatile and adaptable These systems can be controlled by a variety of controller systems supplied by the leading electronic controller system manufacturers The most widely used electronic controllers for Medium Temp applications are Comtrol MCS 4000 Controller CPC s RMCC Controller CPC s Einstein 2 Controller Danfoss AKC 55 Controller Micro Thermo Controller All of these controllers be used with the Enviroguard Ill system The following pages describe the set up of the Enviroguard Ill system using each one of these controllers Enviroguard Control Set Up for Comtrol MCS 4000 Controller Comtrol Enviroguard Operation Comtrol EG when selected as the control method will setup three Inputs data readings and two Outputs data readings in the electronic controller These five data readings are the base operating information needed to properly run the system INPUT 1 Ambient Air Temperature INPUT 2 Condenser Outlet Liquid Temperature INPUT 3 Dropleg Pressure OUTPUT 1 SPR Solenoid Valve Setting OUTPUT 2 Receiver Vent Solenoid Valve Setting Comtrol Cond Fan Set Up Screen and Procedure When setting up the Comtrol EGIII the following are selections to be made for Enviroguard III set up The Cond Fans set up screen is shown on page 26 15 1 Season Switch Temperature This is the ambient air temperature that the controller will switch to the lower subcooling target temperature 85 F Ambie
168. nitored 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 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 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
169. ns If you receive an error message that the format is incorrect change the I O format by the following method Make sure the cursor is on the DISH TRIP IN line Press F3 to enter the Edit mode Scroll to Alternate I O Formats Enter Select the number that corresponds with Board Point This will bring you to the screen where you can modify the DISH TRIP IN Add a Conversion Cell for Enviroguard Access the MAIN MENU screen by pressing the menu key Scroll to or press the item number that corresponds to Add Delete Applications then Enter Scroll to or press the item number that corresponds to Add Application then Enter At the Add Application screen select the Type line and press F4 LOOKUP to access the list of available applications Scroll to or press the item nuber that corresponds to Conversion Cell then Enter Scroll to How Many input 1 then Enter A dialog box will ask if you wish to edit the new application press lt Y gt for Yes to enter the conversion SETUP screen Scroll to the Name line and enter the name as SAT gt then scroll down to Conversion this should be set to Press to Temp If not press F4 LOOKUP select Press to Temp then Enter 26 28 Enviroguard III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Scroll down to Refrig
170. nser is any level ABOVE the liquid supply manifold on the compressor unit The condenser liquid manifold and compressor unit liquid supply manifold can be at the same horizontal level A direct horizontal condensate line from the condenser outlet to the compressor unit liquid line manifold is to be avoided when both are at the same level The line should be routed from the condenser manifold outlet to a level below the condenser then be routed horizontally towards the compressor unit location See the Preferred Condenser Piping on the next page Condensate lines routed over or above the condenser to the compressor unit are NOT recommended The horizontal portion of the condenser condensate line should be sloped toward the compressor unit at 1 2 per 10 of horizontal run See page 4 1 to reference High Side Field Piping information June 2007 Enviroguard 24 3 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Condenser Piping Diagrams DISCHARGE PREFERRED CONDENSER LIQUID MANIFOLD d RACK LIQUID MANIFOLD DISCHARGE ACCEPTABLE RACK LIQUID MANIFOLD O SAMELEVL LEVEL RACK LIQUID MANIFOLD CONDENSER n LIQUID MANIFOLD DISCHARGE UNACCEPTABLE RACK LIQUID MANIFOLD ABOVE CONDENSER LIQUID CONDENSER MANIFOLD NOT RECOMMENDED 1 LIQUID MANIFOLD 24 4 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp EN
171. nt Target Summer Subcooling This is the lower of the two subcooling set points used when above the season switch temperature setpoint 10 F Subcooling Target Winter Subcooling This is the setpoint used when below the season switch tem perature 15 F Subcooling Subcooling control dead band 0 1 F Minimum Condensing Temperatures in the Enviroguard set up 45 F for Low Temp with electric or time off defrost 60 F for Low Temp with hot gas defrost 65 F for Medium Temp systems 26 14 Enviroguard III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD 7 Condenser Height above the rack This is the height of the liquid return line from the liquid transducer to the condenser outlet 8 SPR Override 25 F This will operate the SPR output if the saturated condensing temperature is 25 F above the ambient air temperature and the minimum subcooling is met 9 Minimum Subcooling 7 F 10 Bleed Valve Time Delay Receiver Vent Solenoid 5 minute delay 11 Low Subcooling Alarm Limit 6 F Alarm activates when the setpoint continuously for the time specified 12 Low Subcooling Alarm Delay 60 minutes Condenser Fan Group Set Up Screen File Edi View Utilities Reports Help File Exit File Name fop333 01 4 1 RACK E EDIT DELETE HIDE CONDENSER FAN GROUP FansA Task Analog Inputs Digital
172. nts tab Adjust the Pres Ctrl Stpt pressure control setpoint to a saturated pressure corressponding with the system refrigerant and following temperatures 40 F for low temperature applications using electric defrost 45 F for low temperature applications using hot gas defrost 60 F for all medium temperature applications Enter or Scroll Down Scroll to Fan min ON set this value to 0 00 00 Enter or Scroll Down Scroll to Fan min OFF set this value to 0 00 00 June 2007 Enviroguard III 26 27 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Press F2 for NEXT until you access the Inputs tab Enter the PRES CTRL IN number value for the condenser drop leg pressure input board lt Enter or Arrow over gt and the input point location lt Enter or Arrow over gt NOTE If the input board and point have not yet been defined the system will alert you to define them now in the Sensor Selection screen Following are the definitions Press lt Enter gt this takes you to the Sensor Selection screen Scroll to Sensor press lt F4 gt for LOOKUP Scroll to select 5v 500psi Enter or F1 After defining the sensor return to the condenser setup Inputs tab press Home then F2 for the CONDENSER F5 for SETUP and F2 to the Inputs tab Arrow down to select DISH TRIP IN enter the same board and point locatio
173. nual amp ENVIROGUARD 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
174. o access the list of available descriptions Scroll to or press the item number that corresponds to DF degrees Fahrenheit then Enter Scroll down to Comb Method line and press F4 for LOOKUP to access the list of avaialble descriptions Scroll to or press the item number that corresponds to 1 in2 in3 then Enter Scroll down to Update Rate this should be set to 0 00 02 If not enter this value now Press F2 NEXT TAB to C2 Inputs You are now ready to define the control analog inputs June 2007 Enviroguard III 26 29 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Analog Input Setup At the INPUT line press lt F3 gt Edit then select Alternate Formats and lt Enter gt Enter the number that corresponds to Controller Application Property with the cursor in the Controller field for INPUT1 press lt F4 gt for LOOKUP Scroll down to find this controller s name then press lt F1 gt Select Scroll the cursor to the Application field for INPUT1 press lt F4 gt for LOOKUP Scroll or page down to find the Conversion Cell that was set up prior named SAT TEMP Press F1 Select Back at the SETUP screen scroll down to INPUT2 line press F3 Edit then select Alternate I O Formats and Enter Enter the number that corresponds to Board Point At the input fields f
175. o the fixtures Defrost will continue until the temperature termination thermostats on all cases in the defrosting lineup close When all the termination thermostats are satisfied the hot gas solenoid will close Refrigeration will not restart until the entire time period set on the defrost clock passes This allows adequate clear time without overheating 13 2 Gas Defrosting June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Multi Circuit Time Clock Module The multi circuit time clock is a modular time clock with a frame drive motor and individual program modules The program modules clip into the frame and are held in place by a spring loaded latching lever Operation MOTOR MODULE TERMINAL BLOCK When the time clock is to be set up for initial operation the following must be done 1 The number of defrosts for a specific circuit is set by inserting the black trippers into the 24 hour time dial 1 for each defrost 2 Each of the 2 hour minute dials must be set HEXAGONAL NUT for the length of the defrost period failsafe MOTOR MODULE As the 2 hour dial rotates so do the 24 hour dials The 2 hour dial makes a complete rotation every 2 hours Defrosts will start when a tripper is reached on the 24 hour dial and will continue for the time period set on the 2 hour time dial Setting the Multi Circuit Time Clock Setting the defrost times on the clock is a simple procedure F
176. oling Mechanical Liquid Subcooling Diagram 24 25 Servicing the System 24 26 Evaporative Condenser Settings 24 27 Low amp Medium Temp System Example Charts 24 27 Evaporative Condenser Sensing Bulb Diagram 24 28 Gas Defrost Application 24 29 Application Guidelines 24 30 Gas Defrost Return Piping Diagram 24 31 System Components with Gas Defrost 24 31 Piping Diagram for Enviroguard with Gas Defrost 24 32 Piping Diagram for Enviroguard with Gas Defrost amp Space Heat Recovery 24 33 Gas Defrost Control Settings 24 34 Wiring Diagram for Defrost Return Solenoid Field Installed 24 34 Troubleshooting Enviroguard Problems 24 35 25 Enviroguard Contact Tyler Service Department 26 Enviroguard Ill 26 1 Theory of Operation 26 1 Subcooling 26 1 Nature s Cooling 26 1 Enviroguard and TXV Operation 26 2 June 2007 Installation amp Service Manual J
177. oller systems These controllers include Comtrol MCS 4000 CPC s RMCC Einstein 1 8 2 Danfoss AKC 55 Micro Thermo Any of these controllers work with Enviroguard lll to provide Nature s Cooling with lower compressor runtimes that lower operational and maintenance cost Theory of Operation Enviroguard was developed by TYLER to expand on floating head technology Nature s Cooling The concept of which is to take advantage of lower ambient operating conditions and thereby lower system liquid temperatures below actual condensing temperature This process is called Subcooling The net effect is lower compressor runtimes which result in lower operational and maintenance cost Subcooling Defined Subcooling is defined as the point at which liquid is cooled below it s condensing temperature Example Refrigerant R404A Condensing Pressure psig Converted to Condensing Temperature F Actual Temperature of Liquid at Outlet of Condenser F Acquired Subcoling F Nature s Cooling Concept Example At 100 F condensing and 0 F subcooling 47 of the refrigerant s BTU capacity is lost through the TXV on an evaporator operating at a 25 F SST This only leaves 53 of the systems total capacity to address the evaporator load The same system at 100 F condensing and 50 F subcooling loses only 27 of it s total capacity through the TXV with 73 available for the evaporator load Less of the refrigerant s tot
178. ollow these precautions PRECAUTIONS Do not set the program timer with the circuit energized De energize the control circuit to prevent personnel injury or inadvertently tripping too many defrosts at one time Do not use excessive force when turning the minute dial levers Rotate the dial in a counter clockwise direction Settin 1 Insert black plastic trippers into the 24 MODULE PLATE hour time clock at the times of day the 2 HOUR DIA SOR ELO defrosts indicated by the black numbers Ju 6 BLACK PLASTIC on the white dial are to occur TRIPPER by rotating the copper termination lever so the pointer indicates the desired time period LEVER 2 Set the failsafe time on the 2 hour clock DAY DIAL 3 Set clock to the correct time of day 2 indicated by the white numbers on the smaller black wheel to the left of each 24 hour module using the black drive gear on the motor module June 2007 Multi Circuit Time Clock Module 14 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Multi Circuit Time Clock Module Replacement module needs to be replaced be sure to use the right part There are 4 different modules The modules are designated with the letters A B D and E Replace an A with A a B with a B and so on These modules have been factory set Do not try to change them Modules Red Tab set at 75 minutes Modules Red
179. ontacts that are mounted on the compressor contactors or a computer digital input point DI monitoring compressor run status These compressor contactors are for the suction group it is piped to on the suction header This solenoid is active if any compressors on that suction group are running If there is liquid in the receiver the liquid will be allowed to pass through a cap tube then through a 1 4 OD line wrapped around the discharge line This vaporizes the liquid before it vent to the suction header 26 4 Enviroguard IlI June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Liquid Return and Enviroguard Piping See piping diagram below and photos on pages 26 6 amp 26 7 B B B 5 1 5 8 SOLENOID VALVE e 09 50 EXP X Dropleg Temp Sensor 100 EXP VALVE DROPLEG TEMP SENSOR Liquid Dropleg Transducer TO LIQUID MANIFOLD ENVIROGUARD INLET PRESS SUL VALVE NC TO SUCTION MANIFOLD ENVIROGUARD RECEIVER VENT SOL VALVE N C RELIEF RELIEF VALVE VALVE 450 PSI 450 PSI D lt n RESERVOIR RECEIVER 4 TO SUCTION MANIFOLD m pud VALVE N GEASS Subcooling is Calculated by The dropleg pressure covered to the temperature then compare that temperature to the actual dropleg temperature Example 150 70 F saturated liquid temperature Correction f
180. or INPUT2 enter the corresponding board number and input number for the drop leg temperature sensor Press F2 NEXT for C4 Setpoint to define the inputs Scroll to Cut In value field and enter 15 0 Scroll to Cut Out value field and enter 14 9 Both Delay fields should be set at 00 00 00 Press the Home key house symbol then when asked to save changes 26 30 Enviroguard III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Add Digital Combiner for Enviroguard Ill on 300 amp RX 400 NOTE Before you begin programming this section use the Home key to view the Home screen and note the number of fan control points used for the Condenser This will be located in the bottom left section of the screen and the fan points will be labeled F1 F2 F3 etc A digital combiner falls under the category of Configured Application you can view this after it has been defined from the MAIN MENU screen Access the MAIN MENU screen by pressing the menu key Scroll to or press the item number that corresponds to Add Deleate Applications then Enter Scroll to or press the item number that corresponds to Add Application then Enter Scroll the curor to the Type line and press F4 LOOKUP to access the list of available applications Scroll to or press the item number that corresponds to Digital Combiner then
181. or the condenser height above the rack equals1 2 for every foot of rise Static Pressure Condenser elevation is 20 Corrected reading of 140 or 66 F saturated temperature Actual dropleg temperature of 56 F 10 F of subcooling June 2007 Enviroguard III 26 5 PARALLEL COMPRESSORS TYLER REFRIGERATION amp ENVIROGUARD X E IOS 914 pien6ouAud June 2007 26 6 Enviroguard IlI PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD gt 5 o c o Site Glass Heat Exchanger June 2007 Enviroguard III 26 7 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Failsafe for Enviroguard Control outputs are wired so the SPR valve fails to the closed position The contacts are set for inverted operation This failsafe activates under the following conditions 1 The outputs will be de energized if there is a controller and or communication failure 2 If any of the three sensors Dropleg Pressure Transducer Dropleg Temperature Sensor or Ambient Air Temperature Sensor fail Guidelines for Enviroguard III 1 All liquid lines MUST BE INSULATED This includes the condenser liquid return line from the machine room roof to the rack 2 If heat recovery is used an additional check valve is needed at the inlet to the heat recovery coil This prevents refrigerant from pumping out of the recovery co
182. ormal 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 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 It 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 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
183. oss Each compressor has a replaceable core suction line filter 7 A schrader valve is on the filter body one can also be installed on the suction service valve of the compressor to make a pressure drop check of the filter s condition possible June 2007 Parallel System w NC 2 amp Heat Recovery 17 1 PARALLEL COMPRESSORS TYLER ENVIROGUARD REFRIGERATION A Discharge gas from the compressors is piped through an oil separator 8 Refrigeration oil is removed from the hot gas and oil mixture to be sent back to the oil float system This lubricates the compressors and minimizes the amount of oil getting in the evaporators Oil from the separator is piped into an oil reservoir and distributed to the oil level controls on each compressor Most parallels are equipped for heat recovery HR so that heat may be reclaimed and put back into the building A diverting valve 9 redirects hot gas to the HR coil 10 when heat is demanded by the Environmental Control Panel thermostat The Heat Recovery HR coil is optionally equipped with an inlet Pressure Regulator IPR on systems with Nature s Cooling NC 2 or NC 3 The IPR valve is standard on NC 2 systems The valve raises the system pressure during heat recovery to get more heat out of the discharge gas In most other systems liquid from the remote condenser returns directly to the receiver Natural subcooling is diminished since the liquid mixes in the receiver and warms to some ex
184. oves a nomma 2 or 2 2 4 Nom 2 4 2 32 36 M 68 6 9 N2 P 33 43 56 6 28 nouma s 4 2 4 24 Ngug as ss PENGPENON 4 8 6 NNUMH 4 57 6 6 Woewmom LO LL ALL APTN p NPE SSE NPWEE NPE BULK N5DL 35 PNSDSC f 3 2 55 35 35 4 NB e 5 PNP UL 3 4 pim s NP 3 PNIPHP 42 O NLF NFF NVF TLM TLF TLM 2 4 6 L R Termination thermostats are open on rise See case specific Installation amp Service Manuals for proper locations 12 4 Defrost Control Strategies June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Hot Gas Defrost Requirements Chart CASE DATA HOT GAS DEFROST 1 7 HOTGASDEFROST __ SETTINGS PER TIME TEMP CYCLE MODEL F 22 R404A DAY MIN F TEMPS ncs 3 253 5 ewm s pee NCBX NCEX
185. own or drain period delay is designed into the system to allow condensate to drain from the fixture before resuming refrigeration June 2007 Enviroguard 24 29 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A At the end of defrost when the defrost clock has timed out 1 After termination of defrost based on time the branch circuit hot gas solenoid valve closes The suction stop solenoid valve or EPR opens after the drip down delay and the DDPR returns to the Normally Open mode 2 Refrigeration is reestablished in the defrosted branch circuit and all refrigerant flows resume to the normal directions Application Guidelines See Section 13 Gas Defrosting for additional information 1 Defrost Differential Pressure Regulator Valve DDPR for Hot Gas Defrost The DDPR is located in the discharge line downstream of the takeoff tee to the hot gas supply manifold Its purpose is to develop a pressure differential between the hot gas supply manifold and the hot gas return manifold This ensures effective defrosting and good liquid return from the evaporators being defrosted 2 Hot Gas Return Manifold for Gas Defrost When Used An important area is the field piping of the 7 8 OD gas return line to the condenser This line must be field piped from the defrost return manifold and tapped into the discharge line at the condenser This can be just before but preferably after the inverted trap into the condenser manifold A 7
186. pressure is below the switch opening point or sensor setpoint The timing circuit is active NOTE The P345 models are available with either accumulative or nonaccumulative lube oil pressure time delays Both timers start when the net oil pressure drops below the setpoint If pressure does not rise above the setpoint before the end of the timer s cycle the P345 will lockout the compressor contactor Accumulative Timing Copeland Models If the pressure returns to the setpoint value or higher before the time delay is complete the timer will stop and run back down towards 0 at one half of its forward rate If low pressure is detected before the timer reaches 0 the timer will again run forward at its normal rate without resetting at 0 The timer will automatically reset at 0 seconds if power is removed from the P345 Nonaccumulative Timing Carlyle Model Each time the pressure reaches the setpoint the timer stops and resets to 0 seconds Yellow LED Power to the control has been interrupted and restored before the anti short cycle delay has elapsed The compressor contactor remains de energized until the anti short cycle delay is complete and then restarts automatically Red LED The control has de energized the compressor contactor lock condition because of a lube oil pressure problem at the compressor 23 4 Electronic Oil Pressure Control June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD El
187. r mountings for tightness Vibration may cause the mountings to loosen placing unnecessary stress on the compressor piping Check mountings every 6 months Line Connection Check and tighten all compressor lines and service connections including access fittings such as schrader valves Check line and valve connections every 6 months Electrical Turn off all power to rack before checking or tightening any wire connections Check all electrical connections to see that they are tight Loose connections can cause several problems including low voltage conditions and line arcing Check electrical connections every 6 months Refrigerant Piping Refrigerant piping and fittings should be checked for tightness and leak integrity on a regular basis Any time a refrigerant charge is required for a system a careful leak check should be made of the system Refer to EPA and local requirements for expected leakage and repair documentation process June 2007 Maintenance amp Troubleshooting 20 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Troubleshooting SYMPTOMS POSSIBLE CAUSES A Compressor hums but will PO not start B Compressor will not run and will not try to start hum circuit breaker or open disconnect C Compressor starts but trips 3 Defective run or start capacitor the compressor 3 Discharge pressure too high 4 Discharge valve plate leaking
188. r or Liquid Line Manifold RECEIVER TO RECEIVER TO CAPACITY CONDENSER EVAPORATOR CONDENSER EVAPORATOR BTUH 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 the 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
189. remain running The sensor is position sensitive and should be mounted with the pilot line at the top as shown below 1 4 1 4 CORRECT METHOD INCORRECT METHOD If an evaporative condenser is used the sensor should be mounted in the evaporative condenser sump The sensor should be halfway submerged in the sump water with the pilot line connection pointing downward Refer to page 24 28 C Refrigerant Bleed Circuit The refrigerant bleed circuit consists of the following component parts 1 Hand Valve Strainer Solenoid Valve Normally Closed Sightglass Capillary Tube 1 4 Heat Exchanger 7 1 4 O D Copper Tube D qe Whenever any compressor is running the 1 4 solenoid valve is energized to allow liquid refrigerant to be drained from the receiver and metered back into the suction manifold The heat transfer between the 1 4 O D tubing and the discharge header ensures that no liquid refrigerant is injected directly into the suction header This would cause liquid floodback and possible compressor failure 24 6 Enviroguard June 2007 PARALLEL COMPRESSORS amp ENVIROGUARD Installation amp Service Manual amp Components Diagram Basic Enviroquard System In Pi 88400 H3NIVHIS GION3IOS O31V I SNI 03430710S DNIGNL 9NOTS3HONI 94 X GO THLNO uod
190. ressures The compressor discharge gas is injected into the receiver As the discharge gas passes over the liquid in the receiver it is desuperheated This provides a positive pressure which helps maintain the flow of liquid to the refrigerated fixtures during defrost About 25 of the total load can be defrosted at one time and the remaining 75 of the load is needed as a heat source for the defrosting cases Receiver gas defrost is initiated by either a mechanical or electronic multi circuit time clock or computer controller These devices provide the proper sequence of defrosts Only one circuit is to be defrosted at a time if this is not adhered to the entire system may operate improperly Systems having a DDPR valve in the discharge line are to be set for a 20 psid differential across the valve This valve is necessary in cold ambient areas below 30 F because it ensures adequate gas flow during defrost to the defrosting fixtures Control Strategy NC 1 Latent Heat Receiver Gas Defrost 1 Remote Condenser Fans are controlled by a pressure control set for the minimum target pressure corresponding to 88 89 F saturation temperature This ensures adequate defrost during cold ambient temperatures m Outlet Pressure Regulator OPR Valve is set for the target pressure corresponding to 86 87 F saturation temperature w Inlet Pressure Regulator IPR Valve is set for the target pressure corresponding to 94 95 F saturation te
191. rigerant will be flooding the condenser This is because less condenser surface is required during winter operation because of the lower ambient air temperatures Application Guidelines The following application guidelines MUST be followed regarding the application and use of ENVIROGUARD on customer systems 1 Space or hot water reclaim may be used with Enviroguard however the amount of space heating is very limited with condenser fan controls set to maximize energy savings The resetting of these controls to increase heat recovery or the addition of holdback valves will also increase compressor operating costs in cool weather 2 For air cooled applications only remote air cooled condensers furnished by TYLER will be supplied 3 The condenser drain line should be sized appropriately based on previously established design guidelines 4 All liquid refrigerant lines located inside the building including the condenser drain line MUST be insulated to preserve subcooled liquid temperatures and prevent condensation from forming 5 For lineups greater that three cases some type of suction stop device is required The exception to this is no more than 24 per circuit of multi shelf freezers 6 Receiver liquid level alarms WILL NOT BE AVAILABLE but receiver liquid level indicators will still be installed as standard equipment 7 Parallel unit compressor suction pressure should be controlled using floating suction pressure to achiev
192. right Set Digital Input 2 format to Controller F7 Choose Condenser 01 Enter Application Output Choose the last Scroll right F7 Choose last Fan Out condenser fan output for Digital Input 2 Enter F2 board Scroll right point Tab to Outputs and assign the proper board point for the SPR Recommended Charging Procedures Ambient air temperature above 70 F Charging the system should be to a 20 receiver level Ambient air temperature below 70 F Make sure the condenser setpoint is set to a pressure whose saturated temperature is at least 35 F above the ambient air temperature Close off the SPR line Add charge until the SUBCOOLING Sensor Control point achieves an average of 30 F NOTE Southern climates may use 25 F for low temp systems Condenser Setpoints Medium Temp Low Temp Low Temp Refrigerant Time Off Hot Gas Electric Time Off Type 60 F 45 F 40 F 26 26 III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Enviroguard Control Set Up for CPC s Einstein 2 Controller The following information applies to programming software packages RX 300 and RX 400 from the controller keypad The same information may be entered using the UltraSite software available through Emerson CPC In each method there are addi tional values in each screen that apply to the refrigera
193. roller installation manual when using thermostats for termination instead of electronic sensors Some controllers require a close on rise indication If close on rise is used wire the thermostats in series Other controllers allow open on rise or close on rise indication If open on rise is used wire the thermostats in parallel Fan Control amp Defrost Termination Temperatures The following charts list specific fan control and defrost termination temperatures for electric time off and gas defrost Additional information or models not shown in the following charts should be obtained from the O E M These guidelines were established to help assure that electronic defrost controllers will not sacrifice proper equipment operation or cause costly problems The best sensing points for termination vary with manufacturer and style of case These locations should be adhered to per the manufacturer s recommendations Electric amp Time Off Defrost Requirements Chart CASE DATA ELECTRIC DEFROST TIME OFF FAILSAFE TERM FAILSAFE SETTINGS DEF TIME TEMP CYCLE DEF TIME MODEL R 22 R404A MIN NCSX NCSGX NCNX NCNGX 3 NCBX NCEX NCJGCX NCJGECX NTJCX NTJGCX 25 15 3 7 8 14 DUAL TEMP NOWY is 25 EU NME BENE Ese 36 60 NFX NFSX NFSGX NFBX NFBGX 45 NFEX NFGEX Dp NFJCX NFJCGX NFJECX NFJGECX NFMJCX NFMJGCX 15 22 14 50 DUAL TEMP
194. s 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 ay 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 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 s o o4 2 10 05 oa 2 5 15 o 35 2 38
195. s will be running most of the time but should be controlled by an electronic pressure controller for optimum performance During this period condenser fans are not cycled to achieve the benefit of reduced condensing pressure variations and to achieve maximum liquid subcooling The reduced condensing pressure variation and liquid subcooling lead to improved expansion valve operation Allowing condenser fans to cycle will increase condensing pressure variation and result in erratic expansion valve operation If a refrigerant leak should occur in the system it will be noticed earlier by way of higher evaporator temperatures Overall less refrigerant will be lost to the atmosphere than with conventional system designs before a problem is detected Whenever any or all of the compressors are running a bleed circuit opens to bleed refrigerant from the receiver back into the system for use This patented design allows the refrigerant working charge in the system to seek its own level of equilibrium relative to the ambient temperatures During typical system operation when the ambient air temperature is above approximately 70 F part of the refrigerant charge normally flooding the condenser will be stored in the receiver This is because more condenser surface is required to reject the total heat of rejection at the higher ambient air temperatures Whenever the ambient air temperature is below approximately 70 F the receiver will be empty because ref
196. set 1 2 the condenser height above the rack Make sure the board point for the dropleg sensor is set up to Type Temperature Add the Controls If they are not already added The following four controls can be added to the electronic control set up Condenser Control Conversion Cell Analog Sensor Control and Digital Combiner Condenser Control Set Up General Set Control Type for Pressure Enter the number of fan stages Setpoint Enter a pressure setpoint whose saturated temperature is 40 F for low temp 45 F for low temp with hot gas or 60 F for medium temp Minimum ON and Min OFF times must be 0 00 00 Inputs Assign the PRES CTRL IN board point location Fan Outs Assign board point location for each fan Conversion Cell Set Up General Name it Sat Temp Choose press to temp conversion Choose the proper refrigerant Set update rate to 0 00 01 Display must be in FULL options to change it F8 Inputs Set its pressure input board point location 26 22 Enviroguard lll June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Analog Sensor Control Set Up General Name it Subcool Give it 2 inputs Choose DF for Engr Units Choose In1 In2 In3 for Comb Set update rate to 0 00 02 Display must be in FULL options to change it F8 Q Inputs Assign Sat Temp to Input 1 Assign dropleg temp sensor board point locat
197. sig with a 20 psig differential Install a gauge in the liquid return line and open the hand valve upstream of the SPR 8 Check to make sure the Normally Open solenoid valve is configured to be de energized open 9 Adjust the SPR so that it opens at 180 psig and above and closes at 179 psig and below NOTE Observe the sightglass to determine when the SPR opens and closes 10 Reset the fan control as follows 85 psig for electric defrost Refer to chart on page 24 24 114 psig for gas defrost Refer to chart on page 24 24 Fan staging differential 5 psig On Off delays 20 to 30 seconds Rapid recovery 5 psig above the highest setting 10 seconds above the last stage See examples on next page 24 12 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Examples b Controllers without Capability to a Condenser Fan Control Set Differential Between Stages Example 1 R404A Hot Gas Example 2 R404A Hot Gas Condenser Fan Set Point Lowest Stage 114 psig Count Stages Lowest Stage 114 psig Second Stage 119 psig stages x 5 Differential Fourth Stage 124 psig Four Stages 4 x 5 20 Differential Fifth Stage 134 psig Rapid Recovery Setting Rapid R 1 would be 5 psig above 114 20 5 39 psig highest seting 139 11 The Normally Open solenoid valve should be configured to be energized closed when the head pressure falls to 5 psig above
198. ssure is sufficient the cable connections are good and the yellow LED still flickers replace the switch or sensor Control does P545 not lock out 1 Press the TEST button If the control does not lock out is 8 seconds replace the compressor control If control locks out properly go to Step 2 when lube oil pressure 2 Disconnect the wiring harness from the control Press the RESET button is low 3 If the compressor starts and runs through the time delay yellow amp green LEDs ON and then locks out check the wiring harness for shorted condition If the wiring harness test OK replace the P400 switch P445 P345 1 Check sensor cable at circuit board for proper installation 2 Follow the procedure described Figure 7 for troubleshooting the control and sensor June 2007 Electronic Oil Pressure Control 23 7 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER REFRIGERATION Right Terminal Step 1 A Place a short length of 22 gauge wire in the left terminal and another Short piece in the center terminal and measure the voltage Step 2 If the voltage between the left and center terminals is correct remove the wire from the left terminal and jumper the center and right terminals together with The voltage between the left and the remaining wire center terminals should be about 5V between 4 75 and 5 35V Press Reset If the green LED If this voltage is incorrect replace comes On and the yellow LED the P
199. stablished between the compressor discharge pressure and the liquid header When defrost is initiated a DDPR valve throttles the normal hot vapor flow to the condenser An OLDR valve adjusted for a minimum of 20 pounds of differential located at the outlet to the receiver is also placed on the line to drop the pressure in the liquid manifold and ensure flow from the defrosting evaporator to the liquid manifold For proper adjustment see table on page 10 2 June 2007 Gas Defrosting 13 1 PARALLEL COMPRESSORS TYLER ENVIROGUARD REFRIGERATION Gas Defrosting Programming Gas defrosts are programmed to allow for a defrost period and dripdown period or clear time This type of defrost operation allows the problem areas in the case to completely clear without subjecting the refrigerated product to excessive warm up Temperature termination thermostats are used to sense when the refrigerant in the evaporator coil reaches a specific temperature DEFROST GAS FLOW REFRIGERATION INITIATION STOPS CYCLE RESUMES DEFROST TIME CLEAR TIME When the termination temperature is reached 70 75 F the hot gas solenoid will close If the coil cools and the termination time has not elapsed then the hot gas flow will resume This will continue until the allotted failsafe time on the time clock or computer controller has been reached The multi circuit time clock or computer controller will initiate defrost by introducing hot gas flow t
200. stalled tightly The system is now set for proper operation 24 16 Enviroguard June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD SPR Bleed Pressure at Various Ambients at Condenser Design Low Temp with R507 x 95 100 105 110 E i i 15 psig psig 135 3825 4325 435 4385 4405 444 206 26 2585 22 24 2675 151 24 295 7 7172825 27 2295 23 5 2585 29 ss s 955 54 865 9 Lud oS fe er 9 ete 85 5 69 5 63 5 5 10 9 5 5 39 __ 625 ec CR e 40 5 5 55 8 Table includes condenser TD 5 F safety 3 June 2007 Enviroguard 24 17 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Low Temp with R404A 90 95 100 105 110 15 15 15 15 15 49 4 52 54 7 57 4 60 2 CF psig psig 140 461 1 185 436 9 130 403 413 8 125 381 389 391 8 120 370 7 115 350 7 110 331 6 105 313 4 100 96 5 279 6 263 9 249 1 35 221 6 09 197 1 185 8 175 2 57 165 2 155 8 146 9 138 6 0 130 8 25 123 6 20 116 8 E 502 96 1022 149 1076 1104 448 937 963 99 10017 1045 2 5 2 99 0 338 82 858 885 912 94 20 17 664 6 717 744
201. subtract crankcase pressure from discharge oil pressure If the oil pressure switch trips it is a warning that the system has been without proper lubrication for a period of two minutes Repeated trips of the oil pressure safety control are a Clear indication that something in the system requires immediate remedial action On a well designed system there should be no trips of the oil pressure safety control Repeated trips should never be accepted as a normal part of the system operation June 2007 Optional Sentronic Electronic Oil Pressure Control 19 1 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Once the oil pressure control has tripped it must be manually reset to restore the system to operation If the compressor net oil pressure falls below the cut out setting of the control during operation and does not re establish sufficient pressure within 120 seconds the time delay circuit will open the L M contacts and stop compressor operation IMPORTANT If a power interruption occurs after an oil pressure safety trip wait two minutes after the power is restored before resetting Installing Sentronic All OEM Copeland compressors with oil pumps shipped after September 1986 have a plug fitting in the oil pump for mounting the sensor The current oil pump is designed to accept either the Sentronic sensor or a capillary tube for the traditional mechanical oil pressure control Optional Terminal Configurations
202. sure and the T is the schrader access valve used in adjusting the valve 8 The SORIT s suction stop solenoid is controlled by the time clock or computer controller and closes the valve during defrost F An optional variation of E adds a liquid solenoid 9 just upstream of the expansion valve The solenoid can be used for temperature control in conjunction with the EPR On all of these arrangements the hot gas line is equipped with a solenoid valve At the beginning of defrost the valve is opened allowing hot gas to flow to the evaporator coil A termination thermostat operating a pilot circuit shuts off the gas flow when termination temperature has been reached in the fixture The EPR valve does not open again until a drip down or drain down time has been allowed A 10 to 26 minute time period allows the evaporator coil and drain pan to clear The entire time period set the multi circuit time clock or computer controller is called the Failsafe time period it includes both the defrost and the drip down time However if at any time during this drip down period a fixture s temperature drops 10 F or more the defrost will be reinitiated Although this is true for all cases it is most prevalent in the N6F L NFJGCX P5FG and P5FGN cases It will continue until either temperature termination or Failsafe time from the initial defrost termination passes 15 2 Refrigeration Circuits June 2007 PARALLEL COMPRESS
203. sure is established across the DDPR When the differential setting of the DDPR is reached part of the hot gas is bypassed through the DDPR into the heat recovery coil or condenser while maintaining defrost pressure to the evaporators Halfway through the defrost period 1 The defrost pressure and saturated temperature continues to rise as the liquid returns from the evaporators This is a two phase mixture of liquid and vapor as the frost is melted off the evaporators 2 This two phase mixture of liquid and vapor flows through the liquid line into the discharge line to the condenser The returning liquid increases the liquid supply in the condenser and any vapor returning from the evaporators is also condensed to liquid in the condenser This increases the liquid supply for the branch circuits in refrigeration The returning liquid condenser and main liquid supply circuit is at a pressure corresponding to the defrost discharge pressure minus the DDPR differential pressure setting About three quarters of the way through the defrost period The defrost pressure and corresponding saturated temperature continues to rise as all frost is melted from the evaporators The fixture discharge air temperature begins to rise until the termination temperature is reached The branch circuit hot gas solenoid valve is then closed The hot gas solenoid valve may cycle open and closed several times before the defrost is terminated completely A drip d
204. sures the net oil pressure Oil Pump a Viki When the compressor is started the time dum delay heater is energized If the net oil pres yo ae sure does not build up to the heater off or cut out value within the required time limit Schrader the time delay trips to stop the compressor Valve gt E 2 38 MEM DID 4 If the net oil pressure rises to the heater off or cut out value within the required time after the compressor starts the time delay heater is automatically de energized and the com pressor continues to operate normally Crankcase Connection If the net oil pressure drops below the heater on or cut in value during the running cycle the time delay is energized If the net oil pressure does not return to the heater off or cut out value within the time delay period the compressor will be shut down June 2007 Component Description amp Definitions 18 5 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION A Mechanical Oil Pressure Safety Switch P45 COPELAND COMPRESSORS 120 SECONDS TIME DELAY CUT IN 12 to 14 psig CUT OUT 7 to 9 psig SENTRONIC CONTROLS 120 SECONDS TIME DELAY CUT IN 12 to 14 psig CUT OUT 7 to 9 psig CARLYLE COMPRESSORS 120 SECONDS TIME DELAY CUT IN 11 psig CUT OUT 4 to 8 psig Sentronic Copeland Only Oil Pressure Failure Switch Wiring L1 L2 L3 Time Delay
205. t 2004 ver 1 0 2m File Edit View Utilities Reports Help NE a B co ed 2 60 29 90 OM 12 47PM 26 16 Enviroguard III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Comtrol Alarm Setpoints Screen Ez Set 2004 ver 1 0 2m pps ee 1911 File Edit View Utilities Reports Help File Exit Eile Name e 333 01 4 1 DELETE RACK HIDE lt P aa GCO33301 4x1 Brd Pnt Name 563567 Trip Delay Priority 1 3 High Head 3000 00 05 NNNA 00 00 Description Quakerstown ENSE Analog Inputs 3 NNNA Digital Inputs 0 Relay Outputs 7 3 1 Otsd Tmp High Temp 1500 01 00 NNNN 00 00 0 Analog Outputs 5 Low Temp 500 01 00 NNNA Schedules NNNA Graphs Floats Astar Em a 2 Bg 22 5 21 s mq mE d oO CDU RA 1219 June 2007 Enviroguard III 26 17 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER Enviroguard Control Set Up for CPC s RMCC Controller RMCC Controller Set Up The SPR solenoid is controlled by the liquid subcooling at the condenser The valve will be opened when 7 F or more of subcooling is achieved only when all the condenser fans are running Subcooling is the differential between the sa
206. t cross controlling In lieu of sensors the standard defrost klixons may be monitored by the computer controller to terminate defrost Gas Defrost When using a standard clock system with gas defrost the clock will initiate the defrost based on time and it will restart the refrigeration based on a fail safe time plus 5 minutes drain down time Defrost termination by thermostats at the display fixture will only close the gas supply solenoid at the compressor rack Termination thermostats at the display case or evaporators in a walk in cooler should be connected in parallel and wired for open on rise Once all thermostats are satisfied simultaneously flow to the fixtures will cease Once the fail safe drain time has expired the valves at the compressor rack will return to the refrigeration mode and pull down begins All termination sensors should be mounted on the bypass check valves around the expansion valve Fans are cycled off during the defrost except on horizontal type freezers dual temps will cycle in medium temp mode An alternative using electronic controllers to control the gas valve from sensors that replace the original defrost limiting thermostats The sensors are located at the same sensing points as the thermostats For best results these should be connected to cycle only the gas valve June 2007 Defrost Control Strategies 12 1 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Refer to the electronic cont
207. te 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 TYLER 8 ENVIROGUARD REFRIGERATION R404A Suction Line Sizing 35 F SUCTION TEMPERATURE 25 F SUCTION TEMPERATURE 20 F SUCTION TEMPERATURE 15 F SUCTION TEMPERATURE BTUH ni 55 ab 5 75 m BTUH E 5 25 ES BTUH do 45 A BTUH 45 amp Ji Reamt Equivalent Feet Equivalent Feet Equivalent Feet Equivalent Feet TO 50 100150 200 250 300 scone 50100150200 250 300 once 50100150200 250 300 50 TITL 300 5 5 5 5 7 8 10 10 H ae 10 10 15 15 13 15 15 x 20 20 20 20 5 8
208. tent in the machine room NC 2 preserves the naturally cooled liquid s temperature by bypassing the receiver when advantageous to do so The bypass line is operated by a liquid temperature sensing thermostat 11 When liquid returning from the remote condenser rises to 70 F the valve closes The liquid then flows directly into the receiver When outside temperature drops the condenser fans begin shutting off because they are set on a temperature sensing thermostat When the temperatures fall pressure in the system also drops However the pressure inside the receiver is allowed to fall only so far the minimum allowable pressure is the point where system performance will be hurt The receiver pressure is kept from falling below this minimum point by an Outlet Pressure Regulator OPR valve 12 located in a gas bypass line run from the compressor discharge to the receiver As temperatures pressures drop the OPR valve opens allowing gas from the compressor discharge to maintain the pressure in the receiver This also causes liquid to start backing up in the condenser because the receiver will be at a higher pressure than the condenser During low ambient periods the system pressure will be maintained at the setpoint of the OPR valve The OPR is also known as a downstream pressure regulator NC 2 This system operates with the receiver continuously at the same head pressure as the condenser Refer to Pressure Regulator Settings on pages 9 1
209. 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 BE 5 8 MINIMUM NOTE TEES POINT DOWN EVEN WITH JUST 1 CASE i a n NT 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 1 5 per 100 feet of run medium temp Expansion loops are designed to provide a definate amount of trav
210. the cut out pressure of the lowest condenser fan setting Listed below for reference is a Temperature Pressure Chart for R 22 R404A R 502 R 507 R401A and R 402A refrigerants TEMPERATURE PRESSURE CHART Black Figures Vacuum Black Figures Vapor psig Bold Figures Liquid REFRIGERANT CODE REFRIGERANT CODE 6 22 R 404A 502 R 507 R 401A R 402A K 2 R 404A 502 R 507_ R 401A R 402A June 2007 Enviroguard 24 13 PARALLEL COMPRESSORS amp ENVIROGUARD Sample Worksheet for R 22 Low Temp System Application A Design ambient air temperature Design condenser TD TD safety factor Adjusted condensing temperature Corresponding saturated refrigerant pressure equal to the condensing temperature F Corresponding saturated refrigerant pressure equal to the ambient air temperature Target SPR differential Actual ambient air temperature at time of system start up J Target SPR differential pressure Target SPR bypass pressure Corresponding saturated refrigerant pressure equal to the ambient air temperature TYLER REFRIGERATION 95 F F 102 psig In this low temperature example the actual pressure at which the SPR will be set to bypass refrigerant to the receiver is 147 psig with the ambient air temperature measured at 60 F Sample Worksheet for R 22 Medium Temp System Application A Design ambient air temperature B Design condenser TD TD sa
211. 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 Open the 1 4 flare connection on the top of the reservoir 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 Copeland compressors use Sunisco 3G 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 32CF Carl
212. the riser height between the case level and the condenser inlet is 24 feet the setting for the DDPR would be 20 12 32 psig Important to Know The condenser dropleg temperature and the outdoor temperature should be within 2 to 4 F of each other under normal operating conditions and a proper refrigerant charge Head pressures run considerably lower than fixed head systems In fact an R404A system with electric defrost has a condenser pressure set point of 85 psig 60 F is the target condensing temperature for medium temp systems 40 F is the target condensing temperature for low temp systems with electric defrost Low temp systems with hot gas defrost have a 55 F condensing temperature set point For multi temp systems use the 60 F medium temp target condensing temperature setting Inputs Enviroguard uses three inputs 1 Dropleg Pressure Transducer See page 26 5 2 Dropleg Temperature Sensor See page 26 5 3 Ambient Air Temperature Sensor field installed by contractor See page 26 10 The controller will process the information from these three inputs to perform the Enviroguard function NOTE Prior to system start up the information from all three of these inputs SHOULD BE CHECKED for accuracy June 2007 Enviroguard III 26 3 PARALLEL COMPRESSORS amp ENVIROGUARD TYLER SPR Operation 1 SPR solenoid will not operate until all of the condenser fan outputs ON This will allow
213. the same manner as in Diagram 5B but the oil pressure switch requires no power to reset so it needs no external relay to provide a reset power path NOTE On some 550 volt motor compressors it may be necessary to loop the current carrying wire so that it passes through the current sensing relay twice in order to increase the metered amperage to close the relay contacts Using a Separate Control Voltage with the The Current Sentronic New Sentronic LI LELY Diagram 6 shows how the current Sentronic might be used with a voltage on its S PD T contact that is different from the voltage that supplies its power Any A C voltage up to and including 240V might be used To use the Sentronic contact S PD T for a separate voltage remove the jumper between terminals 2 and M In this diagram the separate control voltage is supplied by LL1 LL2 The separate voltage powers the v PRESSOR CONTACTOR compressor contactor CC by means of a DIAGRAMS 19 6 Optional Sentronic Electronic Oil Pressure Control June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Remote Relay When the Remote Relay is energized requesting the compressor to run its contact RR closes to deliver LL1 voltage energizes the compressors contactor coil CC When the compressor contactor closes it provides the power through a control circuit trans former
214. the system to take advantage of the additional subcooling during the lower ambient temperature conditions It also disables the SPR override until all the fans are ON in the lower ambient conditions 2 The receiver vent solenoid may be wired to the same output point as the SPR solenoid or wired to a separate output point controller dependent The receiver vent solenoid will delay 5 minutes behind the SPR solenoid when turning ON but will not delay when cycling OFF The time delay function is handled with a solid state timer or controller programming controller dependent This solenoid is used to lower the receiver pressure if all of the condenser fans are ON and the subcooling set point is achieved If after 5 minutes the SPR is still energized the solenoid will energize allowing the receiver to vent to the suction header This allows the liquid in the receiver to boil off which lowers the receiver pressure and allows the refrigerant to flow from the condenser to the receiver An alternative method to sharing a common output point with the SPR solenoid is to wire the receiver vent solenoid to a dedicated output control point with a preprogrammed time delay The three output points are as follows Bleed Out Solenoid Liquid from the Receiver to the System SPR Solenoid Liquid from the System to the Receiver Receiver Vent Solenoid Vapor from top of the Receiver to Suction 3 The Receiver Bleed Solenoid is controlled by auxiliary c
215. ther and within 4 of the hot gas return tap in as described on page 24 30 This reduces the potential for excessive liquid storage in long discharge lines and associated piping causing unbalance to occur in the condenser liquid supply during a defrost cycle This applies to both horizontal and vertical discharge lines CONDENSER HEAT RECOVERY HEAT RECOVERY 3 WAY VALVE DISCHARGE LINE CHECK ig ROOF LINE TO FROM FIXTURES SOLENOID VALVE ta SP DEFROST RETURN MANIFOLD LIQUID MAIN One check valve is mounted in the liquid line leaving the main liquid supply manifold Its purpose is to allow liquid flow during refrigeration and block liquid flow to the main liquid supply manifold during a gas defrost A Normally Closed solenoid valve is located in the line connecting the main branch circuit liquid line to hot gas return manifold Its purpose is to allow flow from the branch circuit liquid line to the hot gas return manifold during defrost This assures refrigeration of all circuits during defrost regardless of field routing of the branch liquid lines System Components with Gas Defrost 1 Defrost Differential Pressure Regulator DDPR Refrigeration Specialties Hot Gas Return Manifold and Return Lines A Manifold 1 1 8 OD B Ball Shutoff Valve 7 8 OD if used fie
216. tion design which may not be addressed in this section Refer to the pre programming information supplied with the rack or the standard E2 installation manual for information regarding additional pro gramming values The standard Einstein key pad uses the following icon keys 2 Help key Bell symbol Advisory log House symbol Home key Staircase with arrow symbol Back to previous key The Menu key can be used to go to any input screen where values or programming have been established If you follow these steps the system will warn you of overwrit ing or editing any existing programming Check the Menu for existing programming Enviroguard Condenser Set Up Procedure Using the Log In Out key log into the E 2 with your Username lt Enter gt and Password lt Enter gt Press lt ALT F gt to toggle on full options FULL should be indicated at the top of the screen Press lt F2 gt to access the Condenser Status screen then press lt F5 gt to access the SETUP screen Press lt F2 gt for NEXT TAB until you access the C1 General tab Scroll down to Control Type approx 3 lines to verify that it is set to PRESSURE If not press lt F4 gt for LOOKUP to bring up the Option List Selection Scroll up or down to PRESSURE then lt enter gt to return to the SETUP screen Press lt F2 gt for NEXT TAB until you access the C2 Setpoi
217. tions to defrost frequency or duration need to be made B For Gas Defrost minimum defrosting discharge pressure is to be maintained at a minimum refrigerant saturation pressure corresponding to 55 F for any refrigerant type used 2 Defrost Differential Pressure Regulator Valve DDPR for Gas Defrost The table on page 24 26 lists the differential pressure settings for the DDPR for various heights of net liquid lifts from the lowest fixture liquid line elevation to the condenser inlet manifold Settings are presented and include the pressure drops for the liquid line the check valve and the defrost return solenoid valve 3 Condenser amp Normally Open Solenoid Settings A Normally Open solenoid valve is located in the SPR bypass line downstream of the SPR The Normally Open solenoid valve function is to provide a low limit for the system operating pressures to prevent excessive refrigerant bleedoff See page 24 23 Wiring for Defrost Return Solenoid Field Installed Gas Defrost with Suction Stop TO TB L2A TO TB L3A 2 a DEFROST PILOT CIRCUIT BREAKER Q 4 OPTIONAL ELECTRONIC 9 CONTROLLER INTERFACE 12 8 1 BRN E TIMER MODULE 24 34 Enviroguard RED ZBCR BLU TIME CLOCK MOTOR DEFROST INHIBIT RELAY HOT GAS PRESSURE REGULATOR VALVE NC DEFROST RETURN SOLENOID NC FIELD INSTALLED REFRIGERATION
218. turated condensing temperature and the condenser outlet liquid temperature Sensor control logic is used for the SPR operation The required controller screens are listed below in bold face Sensor Set Up Sensor 1 Sensor point to the monitor liquid temperature Name COND LIQ TEMP Type Temp Sensor 2 Sensor point to the control liquid subcooling monitoring pressure sensor input as a saturated temperature Name SUBCOOLING Type 5 Pres 2 Temp Refrigerant Type Specify Pre Input Offset 0 0 Sensor Setpoints for Subcooling Sensor 2 Setpoint to target 7 F of subcooling Using Diff of Sensor 2 Sensor 1 CUT ON 7 0 CUT OUT 6 9 ON Delay 0 sec OFF Delay 0 sec Min time ON 0 min Offset Field set up Use a negative offset that is 1 2 the vertical distance in feet from the rack bottom to the condenser Example If the vertical distance is 15 feet the offset is 7 5 Condenser Set Up Control Strategy AIR COOLED Control Source OUTLET Control Type PRESSURE Condenser Fan Type SINGLE SPEED 26 18 Enviroguard III June 2007 PARALLEL COMPRESSORS Installation amp Service Manual amp ENVIROGUARD Condenser Pressure Inputs Set Up Input Pres Offset 0 0 Outlet Pres Offset Field set up as explained above Condenser Pressure Delays Set Up Fan Minimum ON Time 0 Fan Minimum OFF Time 0 Condenser Single Speed Fan Set Up Fan ON Delay 5 sec Fan OFF Delay 5 sec Fast
219. uard ENVIROGUARD is a patented refrigerant control system in which the amount of liquid refrigerant being used in the system is controlled by a system pressure regulator SPR The refrigerant system charge is reduced by taking the receiver out of the refrigerant circuit and allowing liquid refrigerant to return directly to the liquid manifold which feeds the branch refrigeration circuits With the receiver out of the refrigerant circuit a minimum receiver charge is no longer required as with conventional system designs The receiver is only used as a storage vessel to store the condenser charge variations between summer and winter operation The system pressure regulator SPR is controlled by a pilot pressure from a remote mounted ambient air or water temperature sensor connected to the SPR by a pilot line The remote mounted ambient air sensor is located under the air cooled condenser to sense the ambient air temperature entering the condenser For evaporative condenser applications the water temperature sensor is located in the sump When the ambient air or water temperature rises or falls the pressure inside the sensor and pilot line also rises or falls This exerts a corresponding higher or lower pressure on the pilot of the SPR The SPR setting is adjusted to achieve a differential of approximately 45 psig for R 22 low temperature air cooled applications and approximately 61 psig for R 22 medium temperature air cooled applications
220. une 2007 PARALLEL COMPRESSORS amp ENVIROGUARD Page Enhanced Nature s Cooling 26 2 Effects and Facts to 5 26 2 Enviroguard and Heat Reclaim 26 3 Enviroguard and Hot Gas Defrost 26 3 Important to 26 3 TED 26 3 SPR Operation ct a eae 26 4 Liquid Return and Enviroguard Piping Diagram amp Photos 26 5 Failsafe for Enviroguard Ill 26 8 Guidelines for 26 8 Condenser Set Points Chart 26 9 Recommended Charging Procedure 26 9 Enviroguard Piping Diagrams Evaporator 2 Defrosting 26 9 Electric or Time Off Defrost Summer Operation 26 10 Electric or Time Off Defrost Winter Operation 26 11 Hot Gas Defrost Summer Operation 26 12 Hot Gas Defrost Winter Operation 26 13 Enviroguard Control Set Ups 26 14 Enviroguard Control Set Up for Comtrol MCS 4000 Controller 26 14 Enviroguard Ill Operation 26 14 Comtrol Cond Fan Set Up Screen amp Procedure 26
221. ver on frozen food or other critical temperature applications where a product loss may occur due to a compressor shutdown over night or weekend it may be desirable to prevent the possible nuisance trip by means of a current sensing relay The PENN R10A current sensing relay has been developed for this purpose It is mounted on the load side of the contactor The relay senses by induction the full operating current of one phase of the motor It closes on a rise in load current above 14 amps and opens if the load current falls below 4 amps June 2007 Optional Sentronic 4 Electronic Oil Pressure Control 19 5 PARALLEL COMPRESSORS TYLER amp ENVIROGUARD REFRIGERATION Current Sentronic Previous Sentronic Me aby earn DIAGRAM 5 DIAGRAM 58 Both Diagrams 5A and 5B use a current relay C S When the current relay is not energized by motor current its Normally Open N O contact opens the circuit that powers the Sentronic to avoid a nuisance trip Diagram 5B shows the circuit used with the older model Sentronic An external control relay is required to maintain power to the module in the event of an oil pressure safety trip since the module requires power to reset When the module is tripped on low oil pressure relay is not energized and the relay Normally Closed N C contact provides a voltage path to the module The circuit of Diagram 5A uses the new Sentronic The current relay operates in
222. vice Manual amp ENVIROGUARD Setting the Normally Open Solenoid for Enviroguard 1 The Normally Open solenoid valve should be configured to be energized closed when the head pressure falls to 5 psig above the cut out pressure of the lowest condenser fan setting The Normally Open solenoid valve should be configured to be de energized opened at 10 psig above the lowest fan setting Adjusting the Branch Circuit Expansion Valve The expansion valve in the branch refrigeration circuits should be adjusted after the refrigeration system has been running for several days and has reached steady operating conditions Reference Case Manufacturers Manual for proper Valve Adjustments Condenser Fan Settings 1 Condenser fans are cycled by an electronic compressor and condenser control unit The preferred method uses a dropleg pressure transducer mounted on the condenser side of any pressure regulating valves The first fan or set of fans should run continu ously in areas having ambients above 20 F In areas ambients can go below 20 F ALL condenser fans or sets of fans can be cycled on the electronic control Fan staging differential 5 psig with ON OFF delays 20 to 30 seconds Rapid recovery feature 5 psig above the last stage with 5 to 10 seconds delay on If conventional pressure controls are used set the last stage per chart with a minimal differential approximately 7 psig and stage other fans above this point
223. wer 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 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 1 2 SLOPE PER 10 M SLOPE PER 10 1 2 gt 1 2 SLOPE PER 1 2 SLOPE PER 10 SLOPE PER 10 REDUCER HERE WHEN REQUIRED REDUCER LOCATION gt 2 1 2 SLOPE 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 Siz
224. y 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 DEFROST 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 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 DEFR
225. y 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 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 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 instructions Horizontal suction lines should slope 1 2 per 10 foot of run toward
226. yle MT recommends Mobil ARTIC EAL 68 Castrol SW68 Castrol E68 EMKARATE RL 68H Lubrizol 2916S and CPI SOLEST 68 Carlyle LT recommends Castrol SW68 Castrol E68 EMKARATE RL 68H Lubrizol 2916S and CPI SOLEST 68 Carlyle Screw Compressor Applications Carlyle MT recommends Castrol SW100 CPI SOLEST BVA 120 ICI EMKARATE RL 1005 and Castrol E100 Carlyle LT recommends CPI SOLEST BVA 120 Castrol E100 and EMKARATE RL 1005 NOTE Castrol SW100 is not recommended for low temperature operations June 2007 Oil Control System 8 5 PARALLEL COMPRESSORS TYLER 8 ENVIROGUARD REFRIGERATION A 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 for MT LT R22 recommends CPI CP4214 150 Bitzer Copeland model SHM L for R22 recommends CPI CP421 4 320 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 re

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