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WALK-IN REFRIGERATIONINSTALLATION TRAINING
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Contents
SECTION 1 OVERVIEW OF RUSSELL SIERRA REFRIGERATION SYSTEM Page 1.1 Features and Benefits 4
1.2 Conventional Condenser Unit Piping 51.3 Sierra System Condenser Unit Piping 61.4 Sierra System Piping 71.5 EC Motors/Testing 8
SECTION 2 GENERAL INSTALLATION PROCEDURES2.1 Equipment & Accessory Inspection/Inventory 112.2 Verification of Model Numbers, voltage, phase 122.3 Evaporator Placement 132.4 Condensing Unit Placement 152.5 Electrical - Main Power / Control Circuit Wiring 162.6 Refrigerant Line Sizing 232.7 Refrigerant Piping 242.8 Piping Design 322.9 Leak Testing 33
SECTION 3 CHARGING AND SUPERHEAT ADJUSTMENT PROCEDURES 3.1 System Evacuation 353.2 Refrigerant Charging Guidelines 37
3.3 Pressure Fan Cycling Control 403.4 TXV / Superheat Adjustment 413.5 System Start-up / Adjustments 423.6 Start-Up Checklist (To be provided by QuikTrip) 43
SECTION 4 SEQUENCE OF OPERATION / SYSTEM TROUBLESHOOTING
4.1 Sequence of Operations 2-6 HP 454.2 Sequence of Operations 8 HP 464.3 Troubleshooting 47
SECTION 5 SUGGESTED MAINTENANCE5.1 Maintenance & Inspection Schedule 495.2 Defrost Heater Replacement 52
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SECTION 1
Overview of Russell Sierra Refrigeration System
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FLOATING HEAD PRESSURE
=ENERGY SAVINGS +
INCREASED PERFORMANCE
NO LIQUID RECEIVER =
REDUCED INSTALLATION COSTS
REDUCED OPERATING COSTS
INCREASED SYSTEM RELIABILITY
1.1 SIERRA SYSTEM FEATURES & BENEFITS
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1.2 CONVENTIONAL FIXED HEAD PRESSURE CONDENSING UNIT PIPING
Compressor
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1.3 SIERRA SYSTEM CONDENSING UNIT PIPING
“RECEIVER”
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1.4 SIERRA SYSTEM PIPING
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1.5 NEW EC MOTOR vs. OLD PSC MOTOR
PSC MotorEC Motor
Check Motor Mount Attachment- The mounting screws have a
tendency to vibrate loose.
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1.5 EC MOTOR TESTING
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SECTION 2
Installation
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2.1 EQUIPMENT INSPECTION
Inspect shipment for damage and completeness against shipping documents. Report any damage immediately to the General Contractor. Inventory and count accessories to insure all necessary components have been received.
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2.2 VERIFY UNIT MODEL NUMBERS, VOLTAGE & PHASE with PROJECT PLANS
Model Number Detail
R or H = Russell
L = Outdoor unit
H = Type of compressor (H-hermetic, O-Scroll, S-Semi-hermetic, D-Discus)
75 = Compressor horsepower (7.5 hp)
H = Temperature range (H-High temperature, M-Medium temperature, L-low temperature)
22 or 44 = Refrigerant type (22- R22, 44- R404A)
D = Electrical type (C-230/60/1, D-208/230/60/1, E-208/230/60/3, G-460/60/3)
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2.3 EVAPORATOR PLACEMENT
(TOP VIEW - LOW PROFILE TYPE UNIT)
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2.3 EVAPORATOR PLACEMENT (SIDE VIEW)
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2.4 CONDENSING UNIT PLACEMENT
Condensers Mounting:• Mounted on treated 4” x 4” lumber
with roof membrane pads placed beneath the lumber.
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2.5 UNIT ELECTRICAL REQUIREMENTS(MCA / MOPD)
This is the UL tag on the condensing unit providing MCA & MOPD
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2.5 FIELD WIRING REQUIREMENTS - MAIN POWER WIRING
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2.5 FIELD WIRING REQUREMENTS AIR DEFROST CONTROL WIRING
LIQUID SOLENOID VALVE IS FACTORY MOUNTED
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2.5 FIELD WIRING REQUREMENTS ELECTRIC DEFROST
DASHED WIRING (IN FIELD)
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2.5 ELECTRIC DEFROST CONTROL OPTION
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2.5 ELECTRIC DEFROST EVAPORATOR WIRING
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2.6 REFRIGERANT PIPING
LIQUID LINE SUCTION LINE
Minimum distance between condensers is equal to the length of the condenser
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2.6 LIQUID LINE DESIGN CRITERIA
MINIMIZE PRESSURE DROP AT DESIGN CONDITIONS IN ORDER TO MAXIMIZE SYSTEM EFFICIENCY (APPROX. 5 PSIG)
OIL FLOW WILL NOT NORMALLY BE A PROBLEM DUE TO LIQUID REFRIGERANT / OIL MIXTURE
AVOID INSTALLING ADDITIONAL EXTERNAL FILTER DRIERS, BALL VALVES, ETC. SINCE PRESSURE DROP IS CUMMULATIVE
TO HELP MAINTAIN LIQUID SUBCOOLING AND AVOID THE POSSIBILITY OF FLASH GAS AT THE TXV INLET, INSULATE THE LIQUID LINE TO MINIMIZE EXCESSIVE HEAT GAIN WITH 1” INSULATION
ALL EXPOSED REFRIGERATION LINES AND INSULATION SHALL BE PAINTED WITH UV PROTECTIVE PAINT.
ADDITIONALLY, UNDER CERTAIN OPERATING / AMBIENT CONDITIONS, FLOATING HEAD PRESSURE SYSTEMS CAN EXPERIENCE SWEATING OF THE LIQUID LINE THEREFORE IT IS ALWAYS DESIREABLE TO INSULATE THE LIQUID LINE, PARTICULARLY WHERE SWEATING OR CONDENSATE DRIPAGE COULD PRESENT A HAZARD TO THE BUILDING STRUCTURE, PRODUCT OR PERSONNEL!
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MINIMIZE PRESSURE DROP AT DESIGN CONDITIONS WHILE MAINTAINING MINIMUM INTERNAL VELOCITIES TO ENSURE ADEQUATE OIL RETURN BACK TO COMPRESSOR
(LOW TEMP – APPROX. .5 PSIG / MED TEMP – APPROX. 1 PSIG)
OIL RETURN IS CRITICAL!
LOW TEMPERATURE AND A LACK OF LIQUID REFRIGERANT AT THE EVAPORATOR OUTLET INHIBIT OIL RETURN
USE GRAVITY TO ASSIST OIL RETURN WHENEVER POSSIBLE
PITCH ALL SUCTION LINES IN DIRECTION OF FLOW (MIN ¼” FT)
USE “P” TRAPS AT THE BOTTOM OF ALL VERTICAL RISERS
RUN PIPE INSULATION COMPLETELY THROUGH WALK-IN CELING PANEL TO PREVENT SWEATING UNDER PANEL SKINS.
2.6 SUCTION LINE DESIGN CRITERIA
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2.7 REFRIGERANT LINE SIZING
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2.7 REFRIGERANT LINE SIZING
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2.7 ADD THE EQUIVALENT FEET OF TUBING REQUIRED FOR ELBOWS, TRAPS, ETC
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2.7 CONDENSATE DRAIN LINE PIPING
Pitch all drain lines a minimum of 1” per foot – 4” per foot is recommended
Do not reduce line size from fitting size on evaporator
Increase size of drain line for multiple evaporators
Protect drain line from freezing in walk-in freezers
Install P-Trap outside of walk-in
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2.7 TXV SENSING BULB LOCATION
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2.8 OIL FLOW INSIDE A VERTICAL SECTION OF SUCTION LINE
OIL FILM
OIL DROPLETSProperly sized riser will help insure return of oil to compressor – where it belongs
OIL DROPLETS
OIL FILM
FLOW
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2.8 POOR SUCTION LINE DESIGN FOR OIL RETURN
GAS FLOW
OIL FLOWOIL FLOW
Title
Author
File
Revision
Document
Date Sheets1.0 1 of 1
Improper suction line design will cause oil and vapor to separate – reducing
proper oil return to compressor.
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2.8 OIL TRAPPING
A P-Trap must be installed at the bottom of the suction line riser and at every 15’ to 20’ of riser height.
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2.9 LEAK TESTING
FOLLOW EPA REGULATIONS REGARDING THE USE & DISPOSAL OF REFRIGERANTS.
PRESSURIZE SYSTEM WITH REFRIGERANT TO APPROX 25 TO 35 PSI PRESSURIZE WITH REGULATED NITROGEN TO APPROX 120 TO 140 PSI ALLOW PRESSURE TO STABILIZE FOR APPROX 30 MINUTES LEAK CHECK USING SOAP BUBBLES AND / OR ELECTONIC LEAK DETECTOR CHECK ALL SYSTEM CONNECTIONS AND COMPONENTS (BOTH FIELD AND FACTORY MADE) IDENTIFY ALL LEAKS, REDUCE SYSTEM PRESSURE TO 0 PSI AND EFFECT REPAIRS REPEAT ABOVE PROCEDURE UNTIL ALL LEAKS HAVE BEEN LOCATED AND REPAIRED FINAL PRESSURE TEST SHOULD ALLOW SYSTEM TO REMAIN PRESSURIZED OVERNIGHT TO VERIFY THAT THE PRESSURE REMAINS UNCHANGED
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SECTION 3
Charging & Adjusting
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3.1 SYSTEM EVACUATION
Use the right size pump (minimum 1.2 CFM)
Change the vacuum pump oil frequently
Use a micron vacuum gauge whenever possible
Don’t overlook the importance of a deep vacuum
Use oversized hoses or copper tubing whenever possible
Make sure all system components / piping are accessible to ensure evacuation of the
entire sealed system
Avoid evacuating through Schrader valves or similar restrictions
Evacuate from at least (2) system connection points
Operate the vacuum pump continuously for no less than (4) hours to achieve a maximum
of 400 microns.
Blank off the system and allow to sit for a minimum of 20 minutes. (no measureable
increase in vacuum reading indicates the system is dry and tight)
Break the vacuum with a small amount of refrigerant vapor and proceed to system
charging instructions
Use 3-Stage evacuation - sweep and purge method
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3.1 SYSTEM EVACUATION POINTS
GAUGE PORT
GAUGE PORT
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3.2 SYSTEM CHARGING REQUIREMENTS
KEY POINTS TO REMEMBER:
SIERRA IS A FLOATING HEAD SYSTEM SIERRA HAS NO LIQUID RECEIVER NO ADDITIONAL CHARGE REQUIRED FOR
WINTER OPERATION NO STORAGE CAPACITY FOR “EXTRA”
REFRIGERANT Critical Charge – Clear Sight Glass Only Do not add additional refrigerant
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3.2 SYSTEM CHARGING REQUIREMENTS
(ALL CONDENSER FANS MUST BE ON)
STEP 1
INITIAL CHARGE SHOULD
BE BASED ON A MAXIMUM OF 3 LB’S PER UNIT HP
EXAMPLE:
MODEL RIO301M44
3 HP X 3 LB’S = 9 LB’S
STEP 2
REFER TO SATURATED CONDENSING TEMP VS AMBIENT TEMP ENTERING CONDENSER
LOW TEMP = 15 DEGREES ABOVE AMBIENT AIR
MED TEMP = 20 DEGREES ABOVE AMBIENT AIR
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3.2 SYSTEM CHARGING (EXAMPLE)
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3.3 PRESSURE FAN CYCLING CONTROL ADJUSTMENT
MED TEMP UNITS
125 PSI CUT-IN 95 PSI CUT-OUT
LOW TEMP UNITS
90 PSI CUT-IN 60 PSI CUT-OUT
Sierra Fan Setting
Adjust the pressure fan cycling cut-out to be 30 PSIG above the design suction pressure and the cut-in at 30 PSIG higher differential.
Tech Note: If the design suction pressure is unknown, then for a 35 degF box temp for 404A use 60# cut-out and 90# cut-in.
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3.4 TXV SUPERHEAT - CKECK / ADJUSTMENT
To reduce the superheat, turn the adjusting stem counterclockwise.To increase the superheat, turn the adjusting stem clockwise. When adjusting the valve, make no more than one turn of the stem at a time and observe the change in superheat closely to prevent over-shootingthe desired setting. As much as 30 minutes may be required for the new balance to take place after an adjustment is made.Evaporator Super Heat typically runs 6 to 12 deg. (8 to 10 preferred)Compressor Super Heat Copeland required minimum of 20 deg. (25 to 40 preferred)
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3.5 START-UP CKECK / ADJUSTMENT
Run System for 24 hours before making any adjustments including
Superheat unless there is flood-back to condenser.
Check pressures, temperature, amp draw, pressure switch settings
and Superheat at TXV and compressor.
Once sight glass is clear - NO additional refrigerant is needed.
The Russell Sierra is a CRITICAL CHARGED system –
DO NOT OVERCHARGE
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3.6 START-UP CKECKLIST
Add QuikTrip Start-up Checklist
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SECTION 4
Sequence of OperationsTroubleshooting
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4.1 SEQUENCE OF OPERATION - (2 - 6 HP UNITS)
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4.2 SEQUENCE OF OPERATION(8 HP UNIT)
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4.4 TROUBLESHOOTING
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4.4 TROUBLESHOOTING (CONTINUED)
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SECTION 5
Suggested Maintenance
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5.1 SUGGESTED MAINTENANCE / INSPECTION SCHEDULE FOR SIERRA REFRIGERATION SYSTEM
(Service / Maintenance to be performed only by a qualified refrigeration service technician)
The physical inspection of any rotating parts and ALL electrical components should be performed only
after the system has been pumped down and all electrical supplies turned off and locked out.
EVERY 6 MONTHS Visually inspect the entire sealed refrigerant system for any evidence of leaks, line movement or
component damage. Check all flange connection bolts, fittings and line clamps for tightness. Properly “dress” all capillary tubes, control lines and flexible hoses to prevent chafing and potential rub-throughs.
Inspect the entering air face of the condenser coil for accumulation of dirt and debris. Clean as
necessary and straighten fins as required to ensure proper air flow through the coil.
Inspect the condenser fan blades and motor mounts for stress cracks, loose set screws, mounting bolts
and resilient clamping rings. Replace any cracked or out of balance fan blades or motors exhibiting excessive shaft end play.
Check compressor oil level (if equipped with a crankcase sight glass). Maintain at least ¼ to ½ sight
glass during stable system operation.
Check operation of compressor crankcase heater. Heater should be energized when compressor is off.
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5.1 SUGGESTED MAINTENANCE / INSPECTION SCHEDULE (CONTINUED)
Check the refrigerant charge via the liquid line sight glass at receiver outlet. NOTE: During normal operation bubbles will occasionally appear in the sight glass as the expansion valve(s) modulate open or the condenser fan(s) cycle. This is not necessarily an indication of an undercharged system.
Tighten all electrical connections. Check operation and condition of contacts of all contactors and relays
and replace as necessary.
Test all operating and safety controls with an accurate service gauge manifold installed. Confirm actual
control set points agree with recommended values listed in unit operation and installation manual.
Check operation of unit cooler(s). Refer to items (1) through (3) above for applicable inspection details.
NOTE: Excessive moisture infiltration into conditioned areas may result in unusually heavy frost accumulation that may require periodic manual cleaning of fan blades, guards, or sheet metal housings in order to avoid fan unbalance condition and potentially destructive vibration.
Record all critical operating pressures and temperatures during stable system operating conditions in the
normal refrigeration and defrost modes. Example; suction, discharge and liquid refrigerant pressures and temperatures, compressor superheat, motor amp draws, etc. Investigate and correct any abnormal readings.
NOTE: The above information is provided only as a general guideline to aid servicing personnel and equipment owners in maintaining SIERRA refrigeration systems. Due to variables in the actual equipment application and / or operating conditions, recommended service intervals may vary.
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5.2 DEFROST HEATER