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REMOTE RACK SYSTEM

OWNERS MANUAL

INSTALLATION – OPERATIONS - MAINTENANCE

4401 Blue Mound Rd. Fort Worth, TX 76106

Phone: (714) 870-8661 Toll-Free: (800) 833-1106 Fax: (714) 870-6473 www.kairak.com

© KAIRAK, a Division of ITW Food Equipment Group, LLC. All Rights Reserved

ANSI/UL Std. 1995-CAN/CSA C22.2 No. 236 M05 (Intertek #4004142)

http://www.kairak.com/

KAIRAK REMOTE RACK SYSTEM PAGE 1 REV: 2-2014

1. INTRODUCTION..................................................................................................................................................................... 3

2. COMPLETION REPORT – SERVICE RECORD – WARRANTY ...................................................................................................... 3

3. FEATURES ............................................................................................................................................................................. 4 3.1 CONDENSING UNIT ................................................................................................................................................................... 4 3.2 REFRIGERANT ........................................................................................................................................................................... 5 3.3 CONTROL PANEL ....................................................................................................................................................................... 5 3.4 ELECTRICAL DEFROST ............................................................................................................................................................... 5 3.5 ELECTRICAL REQUIREMENTS .................................................................................................................................................... 6 3.6 STANDARD COMPONENTS ....................................................................................................................................................... 6 3.7 ACCESSORIES – STANDARD ....................................................................................................................................................... 6 3.8 HEAD PRESSURE CONTROL VALVE ............................................................................................................................................ 6 3.9 ETL APPROVAL .......................................................................................................................................................................... 6 3.10 WALK IN EVAPORATOR COILS ................................................................................................................................................... 7

4. DIMENSIONAL DATA ............................................................................................................................................................. 8

5. INSTALLATION ...................................................................................................................................................................... 9 5.1 RECEIPT AND INSPECTION OF EQUIPMENT .............................................................................................................................. 9 5.2 LIFTING INSTRUCTIONS ............................................................................................................................................................ 9 5.3 LOCATION AND VENTILATION ................................................................................................................................................ 10 5.4 ROOF PLATFORM REQUIREMENTS ......................................................................................................................................... 11 5.5 PITCH POCKET ......................................................................................................................................................................... 11 5.6 ELECTRICAL ............................................................................................................................................................................. 11 5.7 PLATFORM DIMENSIONS ........................................................................................................................................................ 13 5.8 WIRING DIAGRAM – WALK IN COOLER ................................................................................................................................... 14 5.9 WIRING DIAGRAM – WALK IN FREEZER .................................................................................................................................. 15

6. REFRIGERATION .................................................................................................................................................................. 16 6.1 PIPING ..................................................................................................................................................................................... 16 6.2 STANDARD PIPING PROCEDURES ........................................................................................................................................... 17 6.3 LEAK TESTING ......................................................................................................................................................................... 17 6.4 SYSTEM EVACUATION ............................................................................................................................................................. 18 6.5 SYSTEM CHARGING (LESS FLOODED HEAD PRESSURE CONTROL)........................................................................................... 18 6.6 SYSTEM CHARGING (WITH FLOODED HEAD PRESSURE CONTROL) ......................................................................................... 18 6.7 THERMAL EXPANSION VALVE ................................................................................................................................................. 20 6.8 HOT GAS BYPASS ..................................................................................................................................................................... 21 6.9 FAN CYCLE CONTROL .............................................................................................................................................................. 21

7. START-UP PROCEDURE........................................................................................................................................................ 21 7.1 CONDENSING UNITS ............................................................................................................................................................... 22 7.2 EVAPORATOR COIL – BEFORE START UP ................................................................................................................................. 22 7.3 EVAPORATOR COIL – AFTER START UP .................................................................................................................................... 23 7.4 OPERATIONAL CHECK-OUT ..................................................................................................................................................... 23 7.5 TIMER DIAL ............................................................................................................................................................................. 25 7.6 SHUT DOWN ........................................................................................................................................................................... 26 7.7 SYSTEM RESTART AFTER SHUT DOWN .................................................................................................................................... 26

8. MAINTENANCE ................................................................................................................................................................... 27 8.1 AIR-COOLED CONDENSER ....................................................................................................................................................... 27

KAIRAK REMOTE RACK SYSTEM REV: 2-2014

8.2 ELECTRICAL AND PIPING CONNECTIONS ................................................................................................................................ 27 8.3 CRANKCASE LUBRICATION ...................................................................................................................................................... 27 8.4 MAINTENANCE CHECKLIST (AT THE RACK) ................................................................................................................................. 28 8.5 EVAPORATOR COIL ................................................................................................................................................................. 28 8.6 HEATER REPLACEMENT IN LOW TEMP EVAPORATOR COIL .................................................................................................... 29

9. TROUBLESHOOTING ............................................................................................................................................................ 30

10. TABLES AND CHARTS .......................................................................................................................................................... 39 10.1 TEMPERATURE PRESSURE CHART ........................................................................................................................................... 39 10.2 LINE SIZING FOR REFRIGERATION SYSTEMS ............................................................................................................................ 40

Table 1: Pressure loss ...................................................................................................................................................................... 40

Table 2: Equivalent Feet of Pipe Due to Valve and Fitting Friction .................................................................................................. 40

Table 3: Weight Of Refrigerant ....................................................................................................................................................... 41

Table 4: Recommended Remote Condenser Line Sizes. ................................................................................................................... 42

Chart 5: Recommended Line Sizes For R-404A ................................................................................................................................ 43

Chart 6: Recommended Line Sizes For R-404A (Cont’d) .................................................................................................................. 44

11. WIRING DIAGRAMS ............................................................................................................................................................ 45 11.1 SINGLE EVAPORATOR W/WO DEFROST TIMER ....................................................................................................................... 45 11.2 SINGLE EVAPORATOR W/DEFROST TIMER ONLY .................................................................................................................... 46 11.3 MULTIPLE EVAPORATORS W/DEFROST TIMERS ONLY ............................................................................................................ 47 11.4 SINGLE EVAPORATOR SINGLE PHASE DEFROST/EVAPORATOR FAN ....................................................................................... 48 11.5 SINGLE EVAPORATOR DEFROST AND EVAPORATOR FAN CONTACTORS ................................................................................ 49 11.6 MULTIPLE EVAPORATOR W/FAN CONTACTORS/NO HEATER LIMIT DEFROST ........................................................................ 50 11.7 MULTIPLE EVAPORATOR WITH HEATER LIMIT DEFROST AND EVAPORATOR ......................................................................... 51 11.8 MULTIPLE EVAPORATOR DEFROST AND EVAPORATOR FAN CONTACTORS W/UNIT COOLER HOLDOUT RELAY .................... 52 11.9 DEFROST CONTACTOR W/EVAPORATOR HOLDOUT RELAY W/O HEATER LIMIT .................................................................... 53 11.10 DEFROST CONTACTOR W/EVAPORATOR HOLDOUT RELAY W/HEATER LIMIT ........................................................................ 54 11.11 MULTIPLE EVAPORATORS W/DEFROST SWITCHES IN SERIES, W/O HOLDOUT RELAYS/HEATER LIMITS ................................ 55

12. PARTS LIST .......................................................................................................................................................................... 56

13. WARRANTIES ...................................................................................................................................................................... 63

14. REMOTE REFRIGERATION START-UP AND INSTALLATION COMPLETION REPORT AND RECORD .......................................... 65 14.1 REMOTE RACK CONDENSING UNIT ......................................................................................................................................... 66 14.2 WALK-INS EVAPORATOR COIL .............................................................................................................................................. 71 14.3 FIXTURES PREP TABLES COLD RAILS UNDER-COUNTER EQUIPMENT STANDS ALL OTHER ITEMS .............................. 75 14.4 INSTALLTION/PIPING .............................................................................................................................................................. 77


REMOTE RACK SYSTEM

1. INTRODUCTION

Kairak is committed to producing environmentally friendly and sustainable product offerings without

sacrificing quality or reliability. Kairak Remote Rack system assures customers maximum energy savings and

a substantially smaller environmental footprint. Kairak systems have been successfully integrated into LEED

certified buildings.

The Kairak air cooled Remote Rack cooling system utilizes safe HFC’s and offers excellent operating

efficiency by using multi-circuited condensers for up to 20 compressors and ice makers. This high operating

efficiency is made through effective use of the condenser coil surface area. The large condenser coils

provide the unit with summer design temperature differences (TD’s) lower than traditional designs allow.

Lower design TD’s produce lower condensing temperatures which produce lower compression ratios and

higher compressor capacities, thereby reducing operating cost. Kairak Remote Rack systems are easier to

install, easier to service and much less expensive to operate. Complete factory assembly eliminates on-sight

construction costs of built-up systems by refrigeration technicians and electricians in the field. The Kairak

Remote Rack system is designed primarily for institutional food service operations including: hospitals,

universities, schools, hotels, restaurants, coffee shops and convenience stores.

Kairak Remote Rack systems pull fresh air over the compressor bodies to reduce their operating

temperature. Compressor ventilation has become increasingly important to extend its life span. R-404A

refrigerant is used for all applications.

2. COMPLETION REPORT – SERVICE RECORD – WARRANTY

The Kairak completion report and record is located at the back of this manual. This must be filled

out and a copy sent to Kairak for their review to begin warranty coverage of your rack system.


Figure 1

3. FEATURES

3.1 CONDENSING UNIT

Kairak Remote Rack systems will typically provide many years of trouble-free operation with

minimal maintenance. The length of service from a condensing unit is greatly affected by the care

taken during the original installation.

Cleanliness is absolutely mandatory when installing a condensing unit. Utmost care has been taken

at the factory to insure that the unit is free of all contamination. The factory-applied seals must not

be removed until the unit is ready for installation. All tubing, valves, and fittings must be carefully

inspected to insure cleanliness.

The required electrical supply must be provided to the condensing unit control panel. The voltage

at the motor-compressor terminals should be checked during start-up and unit operation under full

load to insure a tolerance of +/- 10% of the system nameplate rating.

The lubrication recommendations for the motor-compressor and fan motors (where applicable)

must be carefully adhered to.

REMOTE REFRIGERATION RACK

WALK-IN EVAPORATOR

REFRIGERANT LINES IN WALL


CAUTION: Do not remove factory-applied seals before installation to aid in keeping contaminates

from entering system.

3.2 REFRIGERANT

R404a is used for all walk-in coolers, walk-in freezers, under counter refrigerated bases, pan chillers

and prep tables.

3.3 CONTROL PANEL

Each Kairak Remote Rack system is provided with a pre-wired control panel for single point

connection with main disconnects.

The control panel is designed to assure efficient unit operation and provide a pre-selected

sequence of operation during the refrigeration and defrost cycles. Each control panel is equipped

with a main disconnect, motor compressor breakers, contactors, fan motor capacitor, defrost time

clock for freezer, and wiring diagram for service.

The control panel only requires 3 wires for power supply (and neutral if indicated) plus ground

wire, at least 4 wires for defrosts heaters and evaporator coil fan motors in freezer. All system

circuits are labeled for easy identification.

3.4 ELECTRICAL DEFROST

An electrical defrost heater in the freezer is field connected to the time clock in the control panel.

Defrost is initiated by the time clock and stopped by a termination solenoid in the time clock

connected to defrost limit thermostat in the freezer coil. The time clock is set to fail safe

termination period at 45 minutes.

NOTE: Refer to electrical schematics to determine control wire quantities for defrost and alarm features.

NOTE: The freezer requires four defrost cycles per day: 4:00 A.M. and 10:00 A.M.,

4:00 P.M. and 10:00 P.M.


3.5 ELECTRICAL REQUIREMENTS

The Kairak Remote Rack system is equipped with 208-230 volts, 3 phase, 60 hertz power supply.

460-480 volts power supply is available on request.

3.6 STANDARD COMPONENTS

The Kairak Remote Rack system consists of multiple hermetic/glacier scroll compressors, multi-

circuited condenser with heavy duty fan motors, oversized receivers, and factory installed

accessories, evaporator coils with T-Stat, solenoid valve, TX valve, electrical panel and all electrical

controls.

3.7 ACCESSORIES – STANDARD

Standard accessories factory installed in the Kairak Remote Rack system include: drier, sight glass,

head pressure control, dual pressure control, pre-wired control panel and fan cycle switches.

3.8 HEAD PRESSURE CONTROL VALVE

A head pressure control valve is provided as a standard on all outdoor rack systems to provide

stable head pressure in low ambient temperatures. The valve will maintain 180 lbs. PSIG in the

receiver. This is accomplished by the modulation of the valve regulating flow from the condenser

and the discharge line. It provides a minimum head pressure to insure refrigerant flow at the

expansion valve. It also provides a minimum head pressure to assure refrigerant flow at the TXV

and provide hot gas to the receivers for cold start situations.

3.9 ETL APPROVAL

The Kairak Remote Rack system is approved by Intertek and displays the ETL label on the control

panel. ETL listed under the standard for heating and cooling equipment, ANSI/UL Std. 1995-

CAN/CSA C22.2 No. 236 M05 (Intertek #4004142)


3.10 WALK IN EVAPORATOR COILS

FREEZER

A lower temperature electric defrost low silhouette evaporator coil for the freezer is provided

with each Kairak Remote Rack system. The evaporator coil draws air in through the coil and

discharges it through the fans. For best results, the evaporator coil should be located 18” from

the back wall and blow towards the door. Thermostat, solenoid valve and TX valve are installed

in the evaporator coil at the factory. A suction line P-Trap should be installed at evaporator coil

by installer in the field for improved oil return.

COOLER

A medium temperature low silhouette evaporator coil for the cooler is provided with each Kairak

Remote Rack system. Air defrost is used for defrosting the evaporator coil. The evaporator coils are

provided with a thermostat, solenoid valve and TX valve and air defrost timer. Units are pre-piped

and pre-wired for final connections. A suction line P-Trap should be installed at evaporator coil by

installer in the field.

CAUTION: Kairak Remote Rack systems are tested and assembled under strict quality

assurance procedures. Each unit is tested and charged with nitrogen prior to shipment. Use

caution and exercise safety procedures at all times when preparing for final hook-up.


4. DIMENSIONAL DATA

Figure 2

KAIRAK MODEL DIMENSION (INCH)

NUMBER L W H

KMR-4 48 48 54

KMR-6 72 48 54

KMR-8 96 48 54

KMR-10 120 48 54

KMR-12 144 48 54

KMR-14 168 48 54

KMR-16 192 48 54

KMR-18 216 48 54

KMR-20 240 48 54

CAUTION: Installation clearance: a minimum of 3 feet on all sides.

H

NOTE: Refrigeration lines are stubbed at right end of Rack. Electrical lines are stubbed at left end of Rack. Control Panel adds 10” to length of unit.


5. INSTALLATION

5.1 RECEIPT AND INSPECTION OF EQUIPMENT

The utmost care has been taken in crating your Kairak Remote Rack system to protect it against

damage in transit. Carefully inspect your unit for damage that may have occurred during delivery. If

damage is detected, you should save all crating materials and make a note on the carrier’s Bill of

Lading describing the damage. Pictures should be taken to document the damage. A freight claim

should be filed immediately with the freight carrier. If damage is later noted, either during or

immediately after installation, contact the respective carrier and file a freight claim. There is a

fifteen (15) day limit to file a freight damage claim with most carriers. Under no condition may a

damaged unit be returned to Kairak without first obtaining written permission (return

authorization). Any damage must be documented and reported to Kairak. The documentation as

well as pictures showing damage should be included. Contact Kairak customer care at (800) 833-

1106.

5.2 LIFTING INSTRUCTIONS

The Kairak Remote Rack system is a heavy piece of machinery and can weigh from approximately

500 to 10, 000 lbs. Careful consideration of lifting procedures should be made before the unit is

lifted by any means. Cables or other load-bearing devices must not be allowed to press against the

unit frame body, piping, electrical conduit or the motor control panel. The only area of the unit

designed to carry the lifting load is the base. Lifting loads should be distributed evenly around the

base to avoid twisting. When lifting the unit by crane, the lifting space provided in the lower

portion of the base frame is the recommended attachment points for the lifting cables. (See Figure

3). A spreader bar or similar device should be used to prevent the lifting cables from contacting the

unit


WARNING: CABLES OR OTHER LOAD-BEARING DEVICES MUST NOT BE ALLOWED TO PRESS

AGAINST THE UNIT FRAME BODY, PIPING, ELECTRICAL CONDUIT OR THE MOTOR CONTROL

PANEL.

5.3 LOCATION AND VENTILATION

The Kairak Remote Rack unit must be located in an area which allows easy access for installation

and service of all electrical lines, refrigeration piping and any accessory equipment. The unit must

be level to insure proper lubrication. A minimum of 3 feet clearance must be provided on all sides

of the unit.

Equipment should be mounted on a smooth, hard, level surface. Mounting surface should be rigid

and provisions should be made to prevent noise transmission (structural) to surrounding areas. Air

SPREADER

PLATFORM

SPREADER

Figure 3


cooled equipment should not be installed under low structural overhangs which can cause

condenser air recirculation restriction. Two units side by side should have a minimum of 1 ½ unit

width between them. Care should be taken to prevent air from other sources from entering

condenser if this air is at an elevated temperature.

5.4 ROOF PLATFORM REQUIREMENTS

The suggested roof platform requirements are shown in Figure 4. The location and installation of all

equipment should be in accordance with all local code requirements. The unit can usually be placed

directly on the roof platform since each compressor is mounted on vibration isolation pads. For

light roof construction vibration isolation pads can be used underneath the supporting frame.

Figure 4

5.5 PITCH POCKET

A. 9” x 24” pitch pocket must be provided for refrigeration lines. After lines are installed,

backfill opening with hot pitch and make sure there are no leaks.

5.6 ELECTRICAL

To insure operation of equipment and reduce the possibility of electrical power interruption, the

following precautions must be observed:


A. All electrical must be done in accordance with the National Electrical Code and existing

local codes.

B. The power supply must be the same as that which appears on the data plate of the

motors.

C. An adequate power supply must be provided.

D. Voltage fluctuations in excess of +/- 10% should be corrected.

E. 120 volts, 1 phase, 60 Hz power supply must be provided for walk-in cooler.

F. All unit wiring terminals should be checked for tightness before power is applied to the

equipment.

G. When wiring is completed, fan motors should be checked for proper rotation. All fan

motors of multiple fan equipment have been factory wired to operate with the same

rotation. If rotation is found incorrect, reverse two of the three leads on the main

incoming power.

Before starting a Kairak Remote Rack System, check that all breakers and motor protective devices

are in place and that all wiring is secure. A wiring diagram for troubleshooting the unit is included

on the cover.


5.7 PLATFORM DIMENSIONS

Figure 5

KAIRAK MODEL

NUMBER

KAIRAK REMOTE RACK SYSTEM DIMENSIONS ROOF PLATFORM DIMENSIONS (INCHES)

ENCLOSURE DIMENSION (INCH) CONDENSER

FAN MOTORS OVERALL

PLATFORM CURB

OPENING

WEIGHT (LBS) L W H 208V/1PH/60Hz

QTY L W H A B

KMR-4 440 48 48 54 2 62 57 6 20 8

KMR-6 640 72 48 54 2 86 57 6 20 8

KMR-8 695 96 48 54 3 110 57 6 20 8

KMR-10 870 120 48 54 4 134 57 6 23 8

KMR-12 1000 144 48 54 5 158 57 6 23 8

KMR-14 1240 168 48 54 5 182 57 6 23 8

KMR-16 1440 192 48 54 6 206 57 6 30 8

KMR-18 1600 216 48 54 7 230 57 6 30 8

KMR-20 1820 240 48 54 8 254 57 8 30 8


5.8 WIRING DIAGRAM – WALK IN COOLER

Figure 6


5.9 WIRING DIAGRAM – WALK IN FREEZER

Figure 7


6. REFRIGERATION

6.1 PIPING

Connect suction and liquid lines with the evaporator coils and condensing unit on the roof. Leave

access tubing in the attic space and backfill opening with hot pitch after installation so that there

are no leaks. Precautions must be taken to insure no foreign material enters the pipes during

installation.

All piping must be supported with hangers that can withstand the combined weight of tubing,

insulation, valves and fluid in the tubing.

Refrigeration piping must be in compliance with the National and local code and apply good

refrigeration standard practice for proper operation of the system.

Figure 8

CURBED OPENING FOR ELECTRICAL LINES

CURBED OPENING FOR REFRIGERATION LINES

PLATFORM

FINISHED ROOF

EVAPORATOR COIL

P–TRAP @ SUCTION RISER

P–TRAP EVERY 10 FT.

INVERTED TRAP AT END OF RISER


6.2 STANDARD PIPING PROCEDURES

A. Refrigeration pipes should be sized properly. (See Chart 5)

B. For the point of connection at the Remote Rack unit and the condensing unit or

evaporator fixture, the pipe sizes may not be the same size as the interconnecting pipes.

C. Use only dehydrated copper tubing listed for refrigeration grade and application. Only

long radius elbows are to be used.

D. Use a minimum of 15% silver solder alloy on suction and liquid lines. Dry nitrogen should

be passed through when brazing the lines at a low pressure to eliminate oxidation and

scaling.

E. Suction lines should be sloped ½” for every 10 feet towards the remote rack. “P” traps

should be installed at the bottom of each suction riser and at least every 10 feet of the

riser. Inverted traps are also necessary on the top of the risers. This will allow good oil

return for the compressors. Double risers are highly recommended on the large suction

lines with a high capacity and parallel system, ran parallel, to compensate during

minimum load and full load.

F. Suction lines should be insulated using listed insulation and plenum rated. The installer

must select the correct thickness of the insulation material. At a minimum, insulation

should have a ¾” wall thickness. Any pipe insulation located outdoors should be covered

and waterproofed to protect it from rain and UV.

G. Installers should provide and add isolation valves on suction and liquid to be able to

isolate and service evaporator coils in walk-ins, fixtures, reach-ins, prep tables, under

counters or any other units.

6.3 LEAK TESTING

After all refrigeration lines are connected, the entire system must be leak tested. Particular care

should be given to those parts which will be inaccessible at a later date. Pressurize pipes with

nitrogen at 300 PSI for at least 48 hours. The use of an electric leak protector is highly

recommended because of its greater sensitivity to small leaks.


6.4 SYSTEM EVACUATION

With refrigerant piping completed and leak tested, equipment is ready to evacuate. Do not use

compressor to evacuate system. A quality vacuum pump of 500 microns vacuum is necessary for

adequate and dependable system vacuum. Moisture in a refrigeration system can cause corrosion,

expansion valve freeze-up and oil sludge.

Attach vacuum pump to both high and low side of the system through compressor service valves

and evacuate to 500 microns (all service valves*, hand valves and solenoids must be open during

evacuation). It is suggested that the vacuum pump be run for a period of time after vacuum has

been reached.

*Service valves are back setting valves and must be mid-position to open both sides of the system.

6.5 SYSTEM CHARGING (LESS FLOODED HEAD PRESSURE CONTROL)

With system wired, piped and evacuated, the unit is ready for refrigerant charging. All charging

lines and manifolds must be evacuated prior to admitting refrigerant into the system to prevent

contaminating the system with non-condensable.

Connect charging line to receiver outlet valve and admit “liquid” refrigerant into high side of

system until flow stops due to pressure equalization between high side and drum pressure.

Backseat outlet valve and disconnect charging line.

Connect charging line to compressor suction service valve and admit “vapor” into low side system.

Energize equipment and continue to admit vapor into low side of system until liquid line sight glass

clears, indicating a fully charged system. It may be necessary to defeat low pressure control on

initial start to prevent nuisance trip until low side pressure is above cut out point of control.

6.6 SYSTEM CHARGING (WITH FLOODED HEAD PRESSURE CONTROL)

Initial charging is the same as outlined in “Less flooded head pressure control”.

Do not adjust control valves. These are either factory preset or non-adjustable, depending on size.

The non-adjustable valves are set at 180 psi for by pass.


Set unloaders (if supplied) to load compressors to 100% while charging. Add additional refrigerant

to bring total up to required charge as listed on the system ETL label located on the control panel

or the system drawings provided. For the low side charge, energize equipment and continue to

admit vapor until liquid line sight glass clears indicating a fully charged system. It may be necessary

to defeat low pressure control on initial start to prevent nuisance trip until low side pressure is

above cut out point of control.

This is a continuation of “system charging” and must be performed before equipment can be left

operating and unattended. This will involve checking and adjusting of all safety and operating

controls (pressure and temperature controls have not been set at the factory). Adjust and confirm

that the settings are correct and that all controls function properly. Do not attempt to function

safety controls without some means of stopping compressor in event of extreme high or low

pressure conditions that could damage the equipment. If controls fail to function at set points,

determine cause and correct. Jumping any safety control other than for testing purposes is

dangerous to personnel and equipment and nullifies equipment warranty.

Energize crankcase heaters and allow a minimum of 24 hours operation before a compressor start.

A. High Pressure Control -connect a gauge to the compressor discharge service valve. Stop

the condenser airflow by stopping fans on air cooled equipment or restricting water

flow on water cooled equipment. Control should open immediately when discharge

pressure reaches control set point.

B. Low Pressure (Pump-Down) Control – Connect a gauge to the compressor suction

service valve. Throttle receiver outlet valve to lower suction pressure at compressor.

Compressor should pump-down and be de-energized when suction pressure reached

“cut-out” setting of control. Open receiver outlet valve and observe rise in pressure at

compressor suction connection. Compressor should be energized when pressure

reaches “cut-in” setting of control.

C. Oil Pressure Control – Copeland Compressor – jumper between terminals T1 and T2 of

the oil pressure safety control. Compressor should run approximately 120 seconds and

cycle off. Remove jumper and reset control. Check operating oil pressure. This is the

differential between oil pump discharge pressure and suction pressure and should be a

minimum of 10 psig. After several hours running time check oil level in compressor,

acceptable oil level is approximately ¼ on sight glass.


6.7 THERMAL EXPANSION VALVE

Adjust superheat setting to job requirements. To correctly determine superheat:

A. Measure the temperature of the suction line at the point the bulb is clamped.

B. Obtain the suction pressure that exists in the suction line at the bulb location by either

of the following methods:

If the valve is externally equalized, a gauge in the external equalizer line will

indicate the desired pressure directly and accurately.

OR

Read the gauge pressure at the suction valve of the compressor. Add the

estimated pressure drop through the suction line between bulb location and

compressor suction valve to the gauge pressure.

The sum of the gauge reading and the estimated pressure drop will equal the approximate suction

line pressure at the bulb.

C. Convert the pressure obtained (above) to saturated evaporator temperature by using a

temperature-pressure chart.

D. Subtract the temperature reading of the suction line at the point of the bulb and the

converted saturated evaporator temperature from the chart. The difference is

superheat.

E. (Figure 9) illustrates a typical example of superheat measurement on a refrigeration

system using refrigerant 22. The temperature of the suction line at the bulb location is

read at 52°F. The suction pressure at the evaporator bulb location is read at 68 psig

which is equivalent to a 40°F saturation temperature. 40°F subtracted from 52°F = 12°F

superheat.


Figure 9

6.8 HOT GAS BYPASS

(If Supplied) connect gauge to compressor suction service valve. Throttle receiver outlet valve to

lower suction pressure at compressor. Hot gas regulator should begin to open as suction pressure

approaches design suction pressure. This should be done before unit has bulled down to design

condition.

6.9 FAN CYCLE CONTROL

The fan cycle control is located at the discharge lines or at the compressor discharge service valve.

The non-adjustable fan cycles are set to close at 260 psi and open at 190 psi. The adjustable fan

cycle control must be set and adjusted per the factory settings as indicated in the system rack

drawings.

7. START-UP PROCEDURE

After the installation has been completed, before beginning start-up procedures the following

checks should be performed:


7.1 CONDENSING UNITS

A. Check electrical connections to insure all connections are properly tightened. Verify

supplied voltage rating and phase meet system requirements as listed on the system ETL

label located on the control panel.

B. Check the motor-compressor oil level before start-up. The oil level should be at or

slightly above the center of the sight glass. To add oil, use only manufacturer

recommended oil as noted on each compressor tag.

C. Insure that the rubber grommets are installed under the motor-compressor mounting

nuts and that the motor compressor rides freely on its mounting vibration isolators.

D. Check the high and low pressure controls and all other safety controls. Adjust if

necessary.

E. Check the walk-in cooler and freezer thermostats for correct operation. Confirm

solenoids are opening and closing as required.

F. Tags are provided to indicate refrigerant used in the system.

G. The instruction manual, bulletins, tags, etc., are attached to the unit and should be

placed inside the electrical panel for future reference.

H. Observe system pressures during initial operation. Do not add oil while the system is

short of refrigerant unless the oil level is dangerously low.

I. Open all isolation valves, including all service valves at the compressors suction and

discharge and at the receivers. Check that all Rotalock nuts are tightened securely.

Tighten all valves to avoid leaks after start up.

WARNING: DO NOT OVERCHARGE WITH OIL.

7.2 EVAPORATOR COIL – BEFORE START UP

A. Make sure system is wired correctly. Verify voltage rating.

B. Check to make sure all electrical terminals are tight.


C. Check fan set screws to confirm they are tight

D. Check unit to confirm it is mounted securely using all hangers and is as level as possible.

E. Make sure the drain connection is tightened to the drain line securely.

F. Pour water into the drain pan to check for complete drainage of the drain pan and drain

line.

7.3 EVAPORATOR COIL – AFTER START UP

A. On initial start-up for the freezer evaporator coil, the fans will not start until the coil

temperature reaches approximately 25°F.

B. Check the expansion valve superheat setting. It is important that the valve is set

properly for efficient operating and even frost formation.

C. Make sure the drain line heater is working properly.

D. Heavy moisture loads are usually encountered when starting a system for the first time.

This will cause a rapid frost build-up that will need to be closely watched. Manually

defrost the unit as required.

E. Observe the system as it goes through the first defrost cycle to make sure the timer,

defrost heaters, termination thermostat and other system components function

properly.

7.4 OPERATIONAL CHECK-OUT

Only after the system has operated for at least two hours at normal operating conditions without

any indications of malfunctions should it be allowed to operate overnight on automatic controls. A

thorough re-check of the entire system operation should be made as follows:

A. Check the motor-compressor head and suction pressure. If the pressures are not within

the system design limits, determine why and take corrective action.

B. Check the liquid line sight glass and expansion valve operation. If there are indications

that more refrigerant is required, leak test all connections and system components and

repair any leak before adding refrigerant.


C. Observe the oil level in the motor-compressor crankcase sight glass and add oil as

necessary to bring the level to the center of the sight glass.

D. Thermostatic expansion valves must be checked for proper superheat settings. Feeler

bulbs must be positive thermal contact with the suction line. Valves with high superheat

settings produce little refrigeration and poor oil return. Too little superheat causes low

refrigeration capacity and promotes liquid slugging and compressor bearing washout.

Liquid refrigerant must be prevented from reaching the crankcase. If proper controls

cannot be achieved with the system in normal operation, a suction accumulator must be

installed in the suction line just ahead of the motor-compressor to prevent liquid

refrigerant from reaching the motor-compressor.

E. Using suitable instruments carefully check line voltage and amperage at the compressor

terminals. Voltage must be +/- 10% of that indicated on the compressor nameplate

rating. If amperage draw is excessive, immediately determine the cause and take

corrective action. On three phase motor-compressor units, check to see that a balanced

load is drawn by each phase.

F. Check the fan motor on air-cooled condensers and in walk-in evaporator coils for

correct rotation. Fan motor mounts should be carefully checked for tightness and

proper alignment.

G. High pressure controls on condensing unit using R-404 should be set to cut out at 350

PSIG. The cut-out point of these controls should be checked by stopping the condenser

fan and simultaneously monitoring the head pressures with an accurate gauge.

H. Re-check all safety controls and operating controls for proper operation and adjust if

necessary.

I. Check the defrost time clock for initiation, termination and length of defrost period. The

standard defrost timer furnished by Kairak provides frequency controls including a fail-

safe feature that automatically terminates defrost after a set period of time if the

termination thermostat fails to function properly. The standard timer is furnished with a

240 volt clock motor and has a contact rating of 40 amps at 240 volts. (See Figure 10

below)


To set the number of defrost cycles every 24 hours, pull the pins out and set at the

desired cycle off times. Each pin represents a 15 minute interval. Pins pulled out away

from center of time clock represent refrigeration off and defrost on (See Figure 10,

shown in red). Pins pushed toward center indicate refrigeration on and defrost off.

Make sure time clock is set to correct time of day. Kairak recommends 4 times a day

defrost for a typical walk in freezer, 45 minutes each defrost period, set at 4:00 A.M.

and 10:00 A.M., 4:00 P.M. and 10:00 P.M. (See Figure 10).

To set the time of day, rotate the disc clockwise until the arrow lines up the correct time

of day. Note that the clock face is divided into 24 hours.

J. The time should initially be set for 4 defrost cycles per day. Each installation should be

checked so the system operates efficiently with a minimum number of defrost cycles.

The fail-safe works more efficiently with a minimum number of defrost cycles. The fail-

safe setting should not normally exceed 45 minutes because of danger of overheating

the unit if the defrost cycle is prolonged too long.

7.5 TIMER DIAL

Figure 10

Off Cycle - Pins Out (Shown in red)

Timer shown with clock set at 8 P.M.

On Cycle - Pins In


A. Dual pressure controls settings on the condensing unit should be cut in and out close to:

R-404A High Low (R-404A)

Fixture Description Cut Out

psig In

psig Out psig

Walk-In Freezer 350 25-30 5

Walk-In Cooler 350 45-55 20

7.6 SHUT DOWN

A. Equipment which will not be required to operate for a period of time should be secured

by storing refrigerant charge in the receiver or condenser.

B. Front seal the receiver outlet valve. Set thermostat at a setting below system

temperature to insure that liquid line solenoid is energized. Defeat the low pressure

control and allow unit to pump down to a suction pressure of approximately 5 psig. It

may be necessary to repeat pump-down as some refrigerant will remain in oil and will

slowly boil off. When suction pressure holds at 5 psig, front seal suction service valve.

Lock disconnect in position.

C. On units with water-cooled condensers, special precautions must be taken to

completely drain the vessels to prevent freezing if ambient should be below 32°F.

D. Inspect system for possible worn or faulty components and repair if required.

7.7 SYSTEM RESTART AFTER SHUT DOWN

A. A thorough leak test should be performed.

B. Coil(s) should be checked for dirt accumulation or obstruction and cleaned if necessary.

C. Energize crankcase heaters and allow a minimum of 24 hours operation before a

compressor restart.

D. Install gauges, start system and check for correct refrigerant charge, proper system

operation and balance.


8. MAINTENANCE

8.1 AIR-COOLED CONDENSER

The air-cooled condenser(s) should be cleaned with a brush and vacuum cleaner every four to six

months to remove all accumulations of dust, leaves and other debris. If your air-cooled condenser

must operate in unusually dusty locations, cleaning should be scheduled as often as conditions

dictate.

WARNING: BE SURE THAT THE MAIN DISCONNECT SWITCH IS IN THE OFF POSITION BEFORE

ANY CLEANING OR MAINTENANCE OF THE CONDENSERS.

8.2 ELECTRICAL AND PIPING CONNECTIONS

All electrical connections should be periodically checked to be sure they are tight. Loose

connections contribute to low voltage conditions which can cause motor failure.

Refrigerant connections should be inspected to insure that they have not loosened. Whenever it is

necessary to add refrigerant, a careful leak check of all refrigerant connections should be made.

8.3 CRANKCASE LUBRICATION

As indicated under the operational check-out procedures, the oil level in the motor compressor

crankcase should be at the center of the sight glass as all times. If the oil level is low, more oil

should be added to bring the level up to the center of the sight glass. The expansion valve

adjustment and the size of the risers and traps should be checked to locate the cause of the oil

migration to correct it.

The quality of the compressor oil can be checked by using an oil sample. Visual examination for the

compressor oil can disclose the condition of the system. Acid test is highly recommended to

measure the extent of contamination in the system. Dirty, discolored oil indicates one of the

following:

A. Contaminations such as moisture, air, etc., trapped in the system.

B. Excessive pressure drop of improper control settings allows motor compressors to

operate at a dangerously low suction pressure. This may cause motor compressor

overheating and oil discoloration.


If this situation occurs and oil discoloration is not too dark, the installation of a new liquid line

filter/drier may be enough to remove contamination and clear the oil. If the discoloration is severe,

the oil should be replaced and a new liquid filter/drier installed as many times as necessary to

eliminate the contamination. After the oil is replaced, the system controls should be readjusted.

8.4 MAINTENANCE CHECKLIST (at the rack)

A. Condenser – check to insure it is clean. Adjust cleaning schedule if necessary.

B. Compressor – Excessive noise: check mounting grommets, tighten if loose; check for

excessive ice buildup at the suction side and signs of liquid slogging back to it; make sure

compressor is not short cycling.

C. Pressure reading – high side and low side. Check cut in and cut out; adjust if necessary.

D. Sight glasses – check for flashing or bubbling. Add refrigerant to clear it.

E. Check for oil residue or stain around entire unit. Oil residue or stain should be an

indication of a refrigerant leak.

F. Condenser fan motor rotation – check for any sign of excessive vibration or loud noise.

G. Electrical components – check that all timers are properly set. Check all electrical

connections and contacts for signs of burns.

8.5 EVAPORATOR COIL

Evaporator coil should be checked at least once a month for proper defrosting to maintain amount

and pattern of frosting. It is dependent on the temperature of the room, the type of product being

stored, how often new product is brought into the room and the percentage of time the door to

the room is open. Also, if the coil is not defrosting completely, check for faulty defrost heaters.

Under normal usage, maintenance should cover the following items at least once every six months:

A. Tighten all electrical connections.

B. Tighten fan set screws.

C. Clean the coil surface.


D. Clean the fan blades.

E. Check the operation of the control system.

F. Clean the drain pan and check for proper drainage.

G. Check the drain line heaters.

8.6 HEATER REPLACEMENT IN LOW TEMP EVAPORATOR COIL

A. Make sure the electrical power to the heaters is turned off.

B. Disconnect heater leads on both ends of the heater to be removed.

C. Remove the sheet metal screws holding the heater retainer to the heater plate on the

electrical connection end of the unit.

D. Pull the heater(s) to be replaced out of the tube holes in the coil. It is necessary to lower

the drain pan to remove the bottom heater.

E. Replacement coil heaters are received coiled in a two foot diameter. Before inserting

the heater in the coil, uncoil about one foot of the straight end to make it easier to

insert the heater into the tube hole.

F. Insert end of the heater into tube hole and uncoil it while pushing it through the coil.

G. Attach tube clamp and retaining bracket to new heater just before rubber boot. Push

heater in until bracket meets the header plate. Fasten bracket to the header plate to

prevent heater “creep”.

H. Reconnect the heater leads as shown on the wiring diagram.


9. TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION

Compressor does

not run

Motor line open. Close start or disconnect switch.

Fuse blown. Replace fuse.

Tripped overload. See “Compressor will not start”

Control contacts are dirty

or jammed in open

position.

Repair or replace.

Frozen compressor or

motor bearings. Repair or replace.

Control in off position

because of cold location.

Use thermostatic control or move control

to warmer location.

Defective starting

component. (Single phase

compressor only)

Locate and replace.

Unit short cycles

Control differential set too

closely. Widen differential.

Discharge valve leaking. Correct condition.

Motor compressor

overload.

Check for high head pressure, tight

bearings, seized, pistons, clogged air cooled

condenser.

Refrigerant shortage. Repair leak and recharge.

Refrigerant overcharged. Purge System.



Cycling on high pressure. Check water supply, dirty condenser or

defective fan.

Compressor will not

start – hums

intermittently

(cycling on

overload).

Improperly wired. Check wiring against diagram.

Low line voltage. Check main line voltage and determine

location of voltage and drops.

Relay contacts not closing. Check by operating manually. Replace relay

if defective.

Open circuit in starting

winding.

Check stator leads. If leads are ok, replace

stator.

Stator winding grounded. Check stator leads. If leads are ok, replace

stator.

High discharge pressure. Eliminate cause of excessive pressure.

Make sure discharge shut-off valve is open.

Tight compressor. Check oil level. Correct binding.

Unit operates long or

continuously.

Refrigerant shortage Repair leak and re-charge.

Control contacts sticking

in closed position. Clean points or replace control.

Dirty condenser. Clean condenser.

Air in system. Purge system to remove air.

Compressor inefficient. Check valves and piston.



Improper wiring. Check wiring to schematic. Correct if

necessary.

Fixture temperature

too high.


Control set too high. Reset control.

Control wiring loose. Check wiring to control.

Expansion valve or

strainer plugged. Clean or replace.

Compressor inefficient. Check valves and pistons.

Expansion valve set too

high. Lower settings.

Iced or dirty coil. Defrost or clean.

Unit too small. Add unit or replace.

Clogged or small gas lines. Clear clog. Increase line size.

Oil logged system. Remove excess oil. Check Refrigerant.

Charge if needed.

Head pressure too

high.

Refrigerant overcharge. Purge system.

Air in system. Purge system.

Dirty air-cooled

condenser.

Clean area around air-cooled condenser

and inspect for airborne dirt source.



Insufficient water supply. Check water isolation valves. Adjust water

pressure regulator valve. Inspect chiller.

Recirculating cooling air. Seal off unit from other machines and

provide intake isolated from air outlet.

High side restriction. Remove blockage.

Head pressure control

valve set wrong. Readjust.

Head pressure too

low.


Compressor suction or

discharge valves

inefficient.

Clean or replace leaky valve plates or

replace compressor.

Cold ambient or cold

water.

Check condenser fan motors cycle controls

and adjust. Check head pressure valve and

adjust or replace. Adjust water pressure

regulator valve.

Head pressure control

valve set wrong or no

head pressure valve

installed.

Readjust or install a head pressure control

valve.

Noisy unit.

Insufficient compressor

oil. Repair leak and recharge.

Tubing rattles. Bend tubes away from contact and secure.

Mounting loose. Tighten.



Oil slugging or refrigerant

flood back.

Adjust oil level or refrigerant change. Check

expansion valve for leak or oversized

orifice. Adjust the superheat

Unbalanced fan or

defective fan motor.

Replace bent or broken fan blades. Check

motor bearings. Tighten motor holder or

replace. Replace motor.

Compressor loses oil.

Short of refrigerant. Repair leak and recharge.

Gas/oil ratio low. Add oil to compressor to reach half sight

glass level.

Plugged expansion valve

or strainer. Clean or replace.

Oil trapped in lines. Drain tubing toward compressor.

Short cycling. See “Unit short cycles” above.

Superheat too high at

compressor suction.

Change location of expansion valve bulb or

adjust valve to return wet gas to

compressor.

Improper installation and

piping practice.

Check piping sizes and methods and

confirm suction lines are sloped toward

compressor. Check for oil traps on the

risers. Correct piping.

Frosted or sweating

suction line.

Expansion valve admitting

excess refrigerant. Adjust expansion valve.



Poor or improper

insulation. Repair, or replace with thicker insulation.

Hot liquid line.

Shortage of refrigerant. Repair leak and recharge.

Expansion valve open too

wide. Adjust expansion valve.

Refrigerant overcharge. Purge system.

Insufficient condensing. Check if the condenser is dirty, fan motor

operational, sufficient water supply.

Frosted liquid line.

Receiver shut-off valve

partially closed or

restricted.

Open valve or remove.

Clogged dehydrator or

restricted. Replace clogged part.

Unit on vacuum

Ice plugging expansion

valve.

Apply hot wet cloth to expansion valve. If

suction pressure increases, there is

moisture in the system and the filter drier

should be replaced.

Plugged expansion valve. Clean strainer or replace expansion valve.

Defective pressure switch. If the pressure switch is stuck closed, replace. If the switch is set too low adjust to proper setting, above 5 psi.

Compressor will not Defective capacity control. Replace.



unload or load up. Unloader mechanism

defective. Replace.

Faulty thermostat stage or

broken capillary tube. Replace.

Stages not set for

application. Replace.

Little or no oil

pressure.

Clogged suction oil

strainer. Clean strainer.

Excessive liquid in

crankcase.

Check crankcase heater. Reset expansion

valve for higher superheat. Check liquid line

solenoid valve operation.

Oil pressure gauge

defective.

Repair or replace. Keep valve closed except

when taking reading.

Low oil pressure safety

switch defective. Replace.

Worn oil pump. Replace.

Oil pump reversing gear

stuck in wrong position. Reverse direction of compressor rotation.

Worn bearing. Replace compressor.

Low oil level. Add oil.

Loose fitting on oil lines. Check and tighten system.

Pump housing gasket

leaks. Replace gasket.



Flooding of refrigerant

into crankcase. Adjust thermal expansion valve.

Motor overload

relays or circuit

breaker open.

Low voltage during high

load conditions.

Check supply voltage for excessive line

drop.

Defective or grounded

wiring in motor or power

circuits.

Replace compressor motor.

Loose power wiring. Check all connections and tighten.

High condensing

temperature.

See corrective steps for high discharge

pressure.

Power line fault causing

unbalanced voltage.

Check supply voltage. Notify power

company. Do not start until fault is

corrected.

High ambient

temperature around the

overload relay.

Provide ventilation to reduce heat.

Failure of second starter

to pull in on part winding

system.

Repair or replace starter or time delay

mechanism.

Compressor thermal

protector switch

open.

Operating beyond design

conditions.

Add facilities so that conditions are within

allowance limits.

Discharge valve partially

shut. Open valve.



Blown valve gasket. Replace gasket.

Freeze protection

opens.

Thermostat set too low. Reset to 40°F or above.

Low water flow. Adjust GPM.

Low suction pressure. See “Low suction pressure”


10. TABLES AND CHARTS

10.1 TEMPERATURE PRESSURE CHART

Temp (F) R404A

Temp (F) R404A

-50 0.6

55 114.7

-45 2.7

60 125.3

-40 5.0

65 136.6

-35 7.6

70 148.6

-30 10.4

75 161.2

-25 13.4

80 174.6

-20 16.8

85 188.8

-15 20.5

90 203.7

-10 24.5

95 219.4

-5 28.8

100 235.9

0 33.5

105 253.4

5 38.6

110 271.7

10 44.0

115 290.9

15 49.9

120 311.1

20 56.2

125 332.3

25 63.0

130 354.5

30 70.3

135 377.8

35 78.1

140 402.2

40 86.4

145 427.7

45 95.2

150 454.4

50 104.7


10.2 LINE SIZING FOR REFRIGERATION SYSTEMS

The following tables indicate liquid lines and suction lines for all condensing units. When

determining the refrigerant line length, be sure to add an allowance for fittings, (see table 2

below). Total equivalent length of refrigerant lines is the sum of the actual linear footage and the

allowance for fittings.

Table 1: Pressure loss

Pressure loss of liquid refrigerant in liquid line risers. (Expressed in pressure drop, PSIG and sub-

cooling loss, °F).

LIQUID LINE RISE IN FEET

REFRIGERANT

10' 15' 20' 25' 30' 40' 50' 75' 100'

PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F

R404A 4.1 1.1 6.1 1.6 8.2 2.1 10.2 2.7 12.2 3.3 16.3 4.1 20.4 5.6 30.6 8.3 40.8 11.8

Table 2: Equivalent Feet of Pipe Due to Valve and Fitting Friction

Copper Tuber, OD, Type "L" 1/2 5/8 7/8 1 1/8 1 3/8 1 5/8 2 1/8 2 5/8 3 1/8 3 5/8 4 1/8 5 1/8 6 1/8

Globe Valve (Open) 14 16 22 28 36 42 57 69 83 99 118 138 168

Angle Valve (Open) 7 9 12 15 18 21 28 34 42 49 57 70 83

90° Turn Through Tee 3 4 5 6 8 9 12 14 17 20 22 28 34

Tee (Straight Through) or Sweep Below 0.75 1 1.5 2 2.5 3 3.5 4 5 6 7 9 11

90° Elbows or Reducing Tee (Straight Through) 1 2 2 3 4 4 5 7 6 10 12 14 16


Table 3: Weight Of Refrigerant

Weight of refrigerant for copper lines during operation.

(Pounds per 100 lineal feet of type “L” tubing)

Line Size

O.D. in Inches Refrigerant

Liquid Line

Hot Gas Line

Suction Line at Suction Temperature

-40˚F -20˚F 0˚F +20˚F +40 ˚F

3/8 404A 3.4 0.31 0.03 0.04 0.06 0.09 0.13

1/2 404A 6.4 0.58 0.04 0.07 0.13 0.16 0.24

5/8 404A 10.3 0.93 0.07 0.11 0.17 0.25 0.35

7/8 404A 21.2 1.92 0.15 0.23 0.37 0.51 0.72

1-1/8 404A 36.1 3.27 0.26 0.39 0.63 0.86 1.24

1-3/8 404A 55 4.98 0.4 0.58 0.95 1.32 1.87

1-5/8 404A 78 7.07 0.56 0.82 1.35 1.86 2.64

2-1/8 404A 134 12.25 0.98 1.43 2.35 3.23 4.58

2-5/8 404A 209 18.92 1.51 2.21 3.62 5 7.07

3-1/8 404A 298 27.05 2.16 3.15 5.17 7.14 9.95

3-5/8 404A 403 36.5 2.92 4.25 6.97 19.65 13.67

4-1/8 404A 526 47.57 3.8 5.55 9.09 12.58 17.8


Table 4: Recommended Remote Condenser Line Sizes.

Net Evaporator Capacity

Total Equiv. Length

R404A

Discharge Line (O.D.) Liquid Line Cond. To

Receiver (O.D.)

3,000 50 3/8 3/8

100 3/8 3/8

6,000 50 1/2 3/8

100 1/2 3/8

9,000 50 1/2 3/8

100 1/2 3/8

12,000 50 1/2 3/8

100 5/8 1/2

18,000 50 5/8 1/2

100 7/8 1/2

24,000 50 5/8 1/2

100 7/8 5/8

36,000 50 7/8 5/8

100 7/8 7/8

48,000 50 7/8 5/8

100 1-1/8 7/8

60,000 50 7/8 7/8

100 1-1/8 7/8

72,000 50 1-1/8 7/8

100 1-1/8 1-1/8

90,000 50 1-1/8 7/8

100 1-1/8 1-1/8

120,000 50 1-1/8 1-1/8

100 1-3/8 1-3/8

180,000 50 1-3/8 1-3/8

100 1-5/8 1-5/8

240,000 50 1-5/8 1-3/8

100 2-1/8 1-5/8

300,000 50 1-5/8 1-5/8

100 2-1/8 2-1/8

360,000 50 2-1/8 1-5/8

100 2-1/8 2-1/8

480,000 50 2-1/8 2-1/8

100 2-1/8 2-5/8

600,000 50 2-1/8 2-1/8

100 2-5/8 2-5/8

720,000 50 2-1/8 2-5/8

100 2-5/8 3-1/8

840,000 50 2-5/8 2-5/8

100 2-5/8 3-1/8

960,000 50 2-5/8 2-5/8

100 3-1/8 3-5/8

1,080,000 50 2-5/8 3-1/8

100 3-1/8 3-5/8

1,200,000 50 2-5/8 3-1/8

100 3-5/8 4-1/8

1,440,000 50 3-1/8 3-5/8

100 3-5/8 4-1/8

1,680,000 50 3-1/8 3-5/8

100 3-5/8 4-1/8


Chart 5: Recommended Line Sizes For R-404A

SYSTEM

CAPACITY

BTU/H

SUCTION LINE SIZE

SUCTION TEMPERATURE

+20°F +10°F -10°F -20°F

25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75'

1,000 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 1/2 3/8 3/8 3/8 1/2 1/2 1/2 3/8 3/8 1/2

3,000 3/8 3/8 1/2 1/2 1/2 5/8 3/8 1/2 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 5/8 7/8 1/2 1/2 5/8

4,000 3/8 1/2 1/2 1/2 5/8 5/8 1/2 1/2 1/2 5/8 5/8 7/8 1/2 5/8 5/8 5/8 7/8 7/8 1/2 5/8 5/8

6,000 1/2 1/2 5/8 5/8 7/8 7/8 1/2 1/2 5/8 5/8 7/8 7/8 1/2 5/8 5/8 7/8 7/8 7/8 5/8 5/8 7/8

9,000 5/8 5/8 7/8 7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 1-1/8 5/8 7/8 7/8

12,000 5/8 7/8 7/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 1-1/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 7/8 7/8 7/8

15,000 5/8 7/8 7/8 7/8 7/8 1-1/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 7/8 7/8 1-1/8

18,000 7/8 7/8 7/8 7/8 1-1/8 1-1/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 7/8 1-1/8 1-1/8

24,000 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8

30,000 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8

36,000 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-1/8 1-1/8 1-3/8

42,000 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8

48,000 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8

54,000 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-3/8 1-3/8 1-5/8

60,000 1-1/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-5/8

66,000 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-3/8 1-5/8 1-5/8

72,000 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-3/8 1-5/8 1-5/8

78,000 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1-5/8 1-5/8 1-5/8

84,000 1-1/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-5/8 1-5/8 2-1/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8

90,000 1-3/8 1-3/8 1-5/8 1-5/8 2-1/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-5/8 1-5/8 1-5/8 2-1/8

120,000 1-3/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 1-3/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 1-5/8 2-1/8 2-1/8

150,000 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-1/8 2-1/8 2-1/8

180,000 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 2-1/8 2-1/8 2-5/8

210,000 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-1/8 2-1/8 2-5/8 2-5/8 3-1/8 3-1/8 2-1/8 2-5/8 2-5/8

240,000 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-5/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 2-1/8 2-5/8 2-5/8

300,000 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 2-5/8 2-5/8 2-5/8

360,000 2-1/8 2-1/8 2-5/8 2-5/8 3-1/8 3-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 3-5/8 2-5/8 2-5/8 3-1/8

480,000 2-1/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 2-5/8 2-5/8 2-5/8 2-5/8 3-5/8 3-5/8 2-5/8 3-1/8 3-1/8 3-5/8 3-5/8 4-1/8 2-5/8 3-1/8 3-1/8

600,000 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 3-5/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 3-5/8 3-1/8 3-1/8 3-1/8 3-5/8 4-1/8 4-1/8 3-1/8 3-1/8 3-1/8

1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size. Properly placed suction traps must also be used for adequate oil return. All sizes shown are for O.D. Type L copper tubing.

2. Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly.

3. Recommended liquid line size may increase with reverse cycle hot gas systems. 4. If system load drops below 40% of design, consideration to installing double suction risers should be made.


Chart 6: Recommended Line Sizes For R-404A (Cont’d)

SUCTION LINE SIZE LIQUID LINE SIZE

SYSTEM CAPACITY

BTU/H

SUCTION TEMPERATURE RECEIVER TO EXPANSION VALVE EQUAVALENT LENGTHS -20°F LENGTHS -30°F EQUIVALENT LENGTHS -40°F EQUIVALENT LENGTHS

100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200'

1/2 1/2 1/2 3/8 3/8 1/2 1/2 1/2 5/8 3/8 1/2 1/2 1/2 5/8 5/8 3/8 3/8 3/8 3/8 3/8 3/8 1,000

5/8 7/8 7/8 1/2 1/2 5/8 5/8 7/8 7/8 1/2 1/2 5/8 5/8 7/8 7/8 3/8 3/8 3/8 3/8 3/8 3/8 3,000

7/8 7/8 7/8 5/8 5/8 5/8 7/8 7/8 7/8 1/2 5/8 5/8 7/8 7/8 7/8 3/8 3/8 3/8 3/8 3/8 3/8 4,000

7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 1-1/8 3/8 3/8 3/8 3/8 3/8 3/8 6,000

7/8 1-1/8 1-1/8 5/8 7/8 7/8 7/8 1-1/8 1-1/8 5/8 7/8 7/8 7/8 1-1/8 1-1/8 3/8 3/8 3/8 3/8 3/8 3/8 9,000

1-1/8 1-1/8 1-1/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 3/8 3/8 3/8 3/8 3/8 1/2 12,000

1-1/8 1-1/8 1-3/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 3/8 3/8 3/8 3/8 1/2 1/2 15,000

1-1/8 1-3/8 1-3/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 3/8 3/8 3/8 1/2 1/2 1/2 18,000

1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 3/8 3/8 1/2 1/2 1/2 1/2 24,000

1-3/8 1-3/8 1-5/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 3/8 1/2 1/2 1/2 1/2 1/2 30,000

1-3/8 1-3/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1/2 1/2 1/2 1/2 1/2 5/8 36,000

1-5/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1/2 1/2 1/2 1/2 5/8 5/8 42,000

1-5/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1/2 1/2 1/2 5/8 5/8 5/8 48,000

1-5/8 1-5/8 1-5/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 2-1/8 1/2 1/2 1/2 5/8 5/8 5/8 54,000

1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 1/2 1/2 5/8 5/8 5/8 5/8 60,000

1-5/8 1-5/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1/2 1/2 5/8 5/8 5/8 5/8 66,000

1-5/8 1-5/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 1/2 5/8 5/8 5/8 5/8 5/8 72,000

1-5/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 5/8 5/8 5/8 5/8 5/8 7/8 78,000

2-1/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 5/8 5/8 5/8 5/8 7/8 7/8 84,000

2-1/8 2-1/8 2-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 5/8 5/8 5/8 7/8 7/8 7/8 90,000

2-1/8 2-5/8 2-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 5/8 5/8 7/8 7/8 7/8 7/8 120,000

2-5/8 2-5/8 2-5/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-5/8 5/8 7/8 7/8 7/8 7/8 1-1/8 150,000

2-5/8 2-5/8 3-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 180,000

2-5/8 3-1/8 3-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 210,000

2-5/8 3-1/8 3-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 240,000

3-1/8 3-5/8 3-5/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 4-1/8 2-5/8 2-5/8 3-1/8 3-5/8 3-5/8 4-1/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 300,000

3-5/8 3-5/8 4-1/8 2-5/8 3-1/8 3-1/8 3-5/8 3-5/8 4-1/8 2-5/8 3-1/8 3-5/8 3-5/8 4-1/8 4-1/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-5/8 360,000

3-5/8 3-5/8 4-1/8 3-1/8 3-5/8 3-5/8 4-1/8 4-1/8 4-1/8 3-1/8 3-5/8 3-5/8 4-1/8 4-1/8 4-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 480,000

3-5/8 3-5/8 4-1/8 3-1/8 3-5/8 3-5/8 4-1/8 4-1/8 5-1/8 3-1/8 3-5/8 3-5/8 4-1/8 4-1/8 5-1/8 1-1/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 600,000

1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not

exceed horizontal size. Properly placed suction traps must also be used for adequate oil return. All sizes shown are for O.D. Type L copper tubing.

2. Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly. 3. Recommended liquid line size may increase with reverse cycle hot gas systems. 4. If system load drops below 40% of design, consideration to installing double suction risers should be made.


11. WIRING DIAGRAMS

11.1 SINGLE EVAPORATOR W/WO DEFROST TIMER


11.2 SINGLE EVAPORATOR W/DEFROST TIMER ONLY


11.3 MULTIPLE EVAPORATORS W/DEFROST TIMERS ONLY


11.4 SINGLE EVAPORATOR SINGLE PHASE DEFROST/EVAPORATOR FAN


11.5 SINGLE EVAPORATOR DEFROST AND EVAPORATOR FAN CONTACTORS


11.6 MULTIPLE EVAPORATOR W/FAN CONTACTORS/NO HEATER LIMIT DEFROST


11.7 MULTIPLE EVAPORATOR WITH HEATER LIMIT DEFROST AND EVAPORATOR


11.8 MULTIPLE EVAPORATOR DEFROST AND EVAPORATOR FAN CONTACTORS

W/UNIT COOLER HOLDOUT RELAY


11.9 DEFROST CONTACTOR W/EVAPORATOR HOLDOUT RELAY W/O HEATER LIMIT


11.10 DEFROST CONTACTOR W/EVAPORATOR HOLDOUT RELAY W/HEATER

LIMIT


11.11 MULTIPLE EVAPORATORS W/DEFROST SWITCHES IN SERIES, W/O

HOLDOUT RELAYS/HEATER LIMITS


12. PARTS LIST

Figure 11

ITEM PART NUMBER DESCRIPTION

1

3300703 FAN GUARD, 16" FAN



2 2401314 VALVE, HEAD PRESSURE, 5/8"

2401317 VALVE, HEAD PRESSURE, 1/2"

3

2106701 CONDENSER, 6 X 36 W/MANIFOLD






4 N/A HEATED/INSULATED RECEIVERS

①

③

②

④


Figure 12


1 3202503 FAN CYCLE SWITCH, CUT IN 260PSI- CUT OUT 190PSI

2

2300900 PRESSURE CONTROL, SINGLE, LOW SIDE FLARED CONNECTION

2300902 PRESSURE CONTROL, DUAL, FLARED CONNECTIONS

2300904 PRESSURE CONTROL, SINGLE, HIGH SIDE FLARED CONNECTION

2300905 PRESSURE CONTROL, DUAL , CAP TUBE CONNECTIONS

3 N/A HERMETIC COMPRESSOR

4 N/A SCROLL COMPRESSOR

5 N/A DTC VALVE

①

②

③

④

⑤


Figure 13


1

3203200 COND FAN MOTOR CAPACITOR, 10MFD X370V-(1/2 &3/4 HP)

3203201 COND FAN MOTOR CAPACITOR, 5MFD X 370V -(1/4 HP)

2

3300505 FAN BLADE, 20"/33DEG,

3300507 FAN BLADE, 16"/33DEG CCW LAU FOR MINI RACK

3300605 FAN BLADE, 24"/27DEG

3

3300806 FAN MOTOR, ¾ HP, 1075 RPM BALL BEARING

3300808 FAN MOTOR, ¼ HP

3300809 FAN MOTOR, ½ HP, 1075 RPM BALL BEARING

4 3301100 HUB, 1/2" FAN

5

3301201 MOTOR MOUNT, 20; MH20 ZINC

3301202 MOTOR MOUNT, 24; MH24 ZINC

6 3301317 MOTOR ANTI WINDMILL BRAKE AW12 1/2"

7 3204601 GASKET, CAPACITOR BOOT, COND FAN MOTOR

①

③

② ④ ⑥

⑤

⑦


Figure 14


1 2400200 DRIER, FILTER 1/2”, SWEAT CONNECTIONS

2400202 DRIER, FILTER 3/8”, SWEAT CONNECTIONS

2 3202503 FAN CYCLE SWITCH, CUT IN 260PSI- CUT OUT 190PSI

3 2400601 SIGHT GLASS, 3/8" SWEAT CONNECTIONS

2400612 SIGHT GLASS, 1/2" SWEAT CONNECTIONS

4 2404100 DISCHARGE ISOLATION VALVE

5 N/A CRANKCASE HEATER

① ③

②

④

⑤


Figure 15


1 2402610 OIL REGULATOR

2 3807003 ULTRACAP HOSES

3

2300900 PRESSURE CONTROL, DUAL,FLARED CONNECTIONS

2300902 PRESSURE CONTROLDUAL ,CAP TUBE CONNECTIONS

2300904 PRESSURE CONTROL, SINGLE, HIGH SIDE FLARED CONNECTION

2300905 PRESSUR CONTROL, SINGLE, LOW SIDE FLARED CONNECTION

4 N/A DISCHARGE LINE T-STAT

5 N/A DTC VALVE

6 N/A OIL SEPARATOR

7 N/A SCROLL COMPRESSOR

① ③

②

④ ⑥

⑤

⑦



1 1600 RELAY, 208/240 VOLT COIL/DOUBLE POLE/THROW CONTACT

2 2300400 KNOB, PANEL CLOSURE FOR LARGE PANEL, 36" 45" 48" 60"

3 2300401 KNOB, PANEL CLOSURE FOR 24" X 24" PANEL

4 2300707 TIME CLOCK, 120 VOLT FOR WALK IN EVAP COIL

5 2300900 PRESSURE CONTROL, DUAL, FLARED CONNECTIONS

6 2300902 PRESSURE CONTROL, DUAL, CAP TUBE CONNECTIONS

7 2300904 PRESSURE CONTROL, SINGLE HIGH SIDE FLARED CONNECTION

8 2300905 PRESSURE CONTROL, SINGLE LOW SIDE FLARED CONNECTION

9 2301400 DEFROST TIMER, NO ENCLOSURE- FREEZER EVAP

10 2302110 T-STAT, WATERTIGHT, OUTDOOR - ETC

11 2304000 T-STAT, (FOR HEATER& COND MOTOR) MECHANICAL

12 2400106 VALVE, EXPANSION, WALK IN COOLER EVAP A-C

13 2400110 VALVE, EXPANSION, WALK IN FREEZER EVAP A-ZP

14 2400112 VALVE, EXPANSION, WALK IN FREEZER EVAP B-ZP

15 2400113 VALVE, EXPANSION, WALK IN FREEZER EVAP C-ZP

16 2400118 VALVE, EXPANSION, WALK IN COOLER EVAP C-C

17 2400119 VALVE, EXPANSION, WALK IN COOLER EVAP B-C

18 2400231 OIL FILTER, 3/8" SWEAT CONNECTIONS

19 2403003 PRESSURE RELIEF VALVE

20 2502707 VALVE, 1/2" WATER PRESSURE REGULATOR



23 2902000 DUPLEXOR, 240 VOLT

24 2902001 TRIPLEXOR, 240 VOLT

25 2902006 QUADRAPLEXOR, 120 VOLT

26 3200500 AUX CONTACT KIT , N.O

27 3200501 AUX CONTACTOR, N.C

28 3200647 SWITCH MECHANISM/HANDLE/ SHAFT, FOR JGE BREAKER

29 3200810 HANDLE, ROTARY SWITCH, GC&GHC BREAKER

30 3201530 CONTACTOR 30A-3 POLE-208/240

31 3201536 CONTACTOR 30A-2 POLE-208/240

32 3203200 COND FAN MOTOR CAPACITOR, 1/2 &3/4 HP

33 3203201 COND FAN MOTOR CAPACITOR, 1/4 HP)

34 3203301 FAN CYCLE SWITCH, ADJUSTABLE FLARE CONNECTION

35 3203400 FUSE, BLOCK, COND FAN MOTOR

36 3203500 FUSE, 5 AMP COND FAN MOTOR

37 3203503 FUSE, 10 AMP COND FAN MOTOR

38 3204200 POWER RELAY, DOUBLE POLE/THROW CONTACT, NC/N0

39 3204431 RELAY, CURRENT SENSING-N.O.

40 3204432 RELAY, CURRENT SENSING-N.C.

41 3204810 RELAY, 120 VOLT COIL/DOUBLE POLE/THROW CONTACT

42 325-60001-12 VALVE, 3/8 SOLENOID, EXTENDED SWEAT CONNECTIONS

43 325-60001-13 VALVE, 1/2 SOLENOID, EXTENDED SWEAT CONNECTIONS

44 2404100 VALVE, DISCHARGE, ISOL

45 3300705 FAN GUARD/MOTOR MOUNT, 16”, FOR MINI RACK

46 2402210 SOLENOID COIL, DUAL VOLTAGE, W/O BOX


NOTES:


13. WARRANTIES

Kairak’s warranty coverage warrants that Kairak-branded products are free of defects in materials and factory workmanship. The

following applies to all Kairak Model and Serial numbers.

Kairak’s warranty is extended only to the original purchaser and shall not apply to any failures resulting from damage in transit,

improper installation, alteration, normal wear, misuse, abuse, improper voltage, accident or negligence. The warranty excludes; T-

stat adjustments, time clock adjustments, gaskets, cutting boards, filters, clogged drains, ice build-up with no mechanical failures,

and the loss of contamination of food due to mechanical or electrical failure. Warranty does not apply outside the United States.

In order to be covered under this warranty, prior authorization to perform the necessary and appropriate service must be obtained

from the factory. Model and Serial number must be provided at the time of service request. Kairak does not assume responsibility

for any expenses, including labor, parts or travel expenses incurred without such prior authorization. Kairak shall not be liable,

whether in contract or in tort or under any other legal theory for loss of use, revenue or profit, substitute use or performance,

incidental, indirect or special and/or consequential damages, loss of refrigerant or for any other loss or cost of similar type. Such

related charges will be back charged to the responsible party. The decision of the Kairak Service and Warranty, as to whether a

defect is within the terms of this warranty shall be final.

Failure to object or provision contained in a customer’s purchase order or other communication shall not be deemed as a waiver of

terms or conditions of their warranty, nor shall it be considered acceptance of such provisions. This warranty supersedes and is in

lieu of all other warranties, expressed or implied and of other obligations of liabilities, on the part of Kairak.

In case of freight damage, do not refuse shipment, but call agent’s attention to its condition, making careful note of the details on

freight bill before freight charges are paid. File claim for damages with freight agent immediately.

BLU FIXTURES manufactured by Kairak hold a 3-year parts and labor warranty. Kairak holds a 5-year compressor warranty, with a

one-time compressor only replacement after the first year. Kairak will warranty the labor to replace the compressor for the first

three years, 30 days from the ship date. After the first three years, labor, tax, shipping and miscellaneous parts will not be included.

Please contact our warranty department for compressor replacement procedures during the warranty period. BLU remote Fixtures

are designed to operate with Kairak remote systems only. Violation of these terms will void all warranty.

REFRIGERANT FIXTURES manufactured by Kairak hold a 3-year parts and labor warranty (1 year for KRD fixtures). Kairak holds a 5-

year compressor warranty, with a one-time compressor only replacement after the first year. Kairak will warranty the labor to

replace the compressor for the first year, 30 days from the ship date. After the first year, labor, tax, shipping and miscellaneous parts

will not be included. Please contact our warranty department for compressor replacement procedures during the warranty period.

REMOTE SYSTEMS manufactured by Kairak hold a 1-year parts and 90-day labor warranty on the remote system, with an option to

purchase 1-year labor warranty at the time of purchase order receipt. This warranty does not apply to motors, switches, controls,

accessories or parts manufactured by others and purchased by Kairak, unless the manufacturer warranties the same to Kairak.

Kairak holds a 5-year compressor warranty, with a one-time compressor only replacement after the first year. Kairak will warranty

the labor to replace the compressor for the first year, 30 days from the ship date. After the first year, labor, tax, shipping and

miscellaneous parts will not be included. Please contact our warranty department for compressor replacement procedures during

the warranty period.

To request authorized service, call the Kairak Service and Warranty Hotline: Day: 800-833-1106, Nights/Weekends: 714-870-8661.

After-hour requests must be urgent in nature and documented with Kairak’s after-hours service line prior to service being

performed. Kairak is responsible for straight time only, unless otherwise approved by the warranty department.


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14. REMOTE REFRIGERATION START-UP AND INSTALLATION COMPLETION REPORT AND RECORD

This report must be prepared, completed and signed by the refrigeration contractor at the

completion of the installation and start-up.

A copy of this report should be kept at the installation site inside the rack panel. Additional copies

should be distributed to the owner, dealer, general contractor, location service and Maintenance

Company as applicable.

A copy of this report must be forwarded to Kairak for review from the refrigeration contractor or

dealer in order to begin the warranty coverage of the rack. This report is critical to the

equipment’s’ proper future operations. An owner’s manual is provided with each unit to aid in the

design operation and installation as well as maintenance.

GENERAL INFORMATION:

RACK/ MODEL/SERIAL NUMBER:

PROJECT NAME/ADDRESS:

INSTALL COMPLETION DATE STARTUP DATE

REFRIGERATION CONTRACTOR/INSTALLER/CONTACT/ADDRESS:

SIGNATURE DATE

WARRANTY SERVICE PROVIDER (NAME/ADDRESS)


14.1 REMOTE RACK CONDENSING UNIT

SYSTEM # COMPRESSOR MODEL/SERIAL NUMBER

SYSTEM INFORMATION:

AMPERAGE – MAIN BREAKER

L1 L2 L3

VOLTAGE – MAIN BREAKER L1 L2 L3

AMPERAGE AT EACH COMPRESSOR MATCH RLA? YES NO

AMBIENT TEMPERATURE AT STARTUP °F

WATER COOLED UNIT WATER SUPPLY TEMPERATURE °F GPM PSI

WATER COOLED UNIT WATER RETURN TEMPERATURE °F PSI

SYSTEM ARRIVED UNDER NITROGEN PRESSURE? YES NO PSI

FREIGHT DAMAGE? YES NO LOOSE OR SHIFTED COMPONENTS? YES NO

OIL STAIN OR LEAK? YES NO BROKEN REFRIGERANT LINES? YES NO

EVACUATE SYSTEM AT: FINAL MICRON # TIMES:


FREON CHARGE:

SYSTEM # LB: SYSTEM # LB: SYSTEM # LB:

SYSTEM # LB: SYSTEM # LB: SYSTEM # LB:

RECEIVER LIQUID LEVEL INDICATOR (IF APPLICABLE) AT: % YES NO

SIGHT GLASSES CLEAR? YES ALL ISOLATION VALVES OPEN? YES

COMPRESSORS PHASE MONITOR/ROTATION YES

SERVICE VALVES AT THE COMPRESSORS SUCTION AND DISCHARGE ARE OPEN YES

SERVICE VALVES AT THE RECEIVERS/OIL RESERVOIR ARE OPEN YES

ROTALOCK NUTS AND VALVES ARE TIGHTENED AND FREE OF LEAKS YES

ROTALOCK VALVES STEMS/CAPS ARE TIGHTENED AND FREE OF LEAKS YES

COMPRESSORS RUBBER GROMMETS/MOUNTINGS & VIBRATION ISOLATORS TIGHTENED YES

COMPRESSORS VIBRATION AND NOISE LEVEL ARE NORMAL YES

RACK INTERNAL PIPES ARE SECURED - NO VIBRATION OR RATTLING YES

RACK LOCATION:

PER ORIGINAL PLAN ROOF LEVEL GROUND PLAN INDOOR MECHANICAL

ROOM OTHER LOCATION:

RACK MOUNTING METHODS: CHECK ALL THAT APPLY

MEETS LOCAL CODE GC REQUIREMENT SPRING ISOLATORS

VIBRATION PADS OTHER METHOD USED:

RACK CLEARANCE (ALL 4 SIDES):

ELECTRICAL PANEL SIDE FT PIPE SIDE FT

RACK FRONT FT RACK REAR FT

RACK PITCH POCKET ROOF PENETRATIONS ARE SEALED/WATER TIGHT YES

COMPRESSORS OIL LEVEL ABOVE CENTER OF SIGHT GLASS YES

OIL RESERVOIR LEVEL ABOVE CENTER OF UPPER SIGHT GLASS YES

STANDARD HEAD PRESSURE VALVES NOT ADJUSTABLE AT 180 PSI FUNCTIONAL YES


REFRIGERANT OIL ADDED TO SYSTEM: YES OIL TYPE # GAL

HIGH SIDE PRESSURE CONTROLS SET YES PRESSURE CONTROLS SET AT: PSI

ADJUSTABLE HEAD PRESSURE VALVES (IF APPLICABLE) SET AND ADJUST TO: PSI

STANDARD FAN CYCLE CONTROLS NOT ADJUSTABLE AT 260PSI CUT IN AND 190PSI CUT OUT ARE FUNCTIONAL YES

ADJUSTABLE FAN CYCLE CONTROLS SET AND ADJUSTED TO:

#1 CUT IN: PSI CUT OUT: PSI





OIL SAFETY LEVEL CONTROL FUNCTIONAL YES COMPRESSOR CRANKCASE HEATERS ARE FUNCTIONAL YES

CONDENSER FAN MOTORS TEMPERATURE CONTROL (IF APPLICABLE) ADJUSTED TO:

RECEIVER HEATER ELEMENTS, TEMPERATURE CONTROL IF APPLICABLE ADJUSTED TO

HEAD PRESSURE, REGULATOR WATER VALVES ADJUSTED TO: PSI

WATER COOLED CONDENSERS EACH ISOLATION WATER VALVES (SUPPLY &RETURN) OPEN YES

WATER COOLED RACK BYPASS VALVE OPEN YES

WATER COOLED RACK MAIN ISOLATION WATER VALVES (SUPPLY &RETURN) OPEN YES

SUPPLY WATER STRAINER CLEANED/FLUSHED TO REMOVE DEBRIS 48-72 HOURS AFTER STARTUP YES

LOW SIDE PRESSURE CONTROLS FOR EACH SYSTEM ADJUSTED AND SET AT:

SYSTEM: CUT IN: CUT OUT: SYSTEM: CUT IN: CUT OUT:

PSI PSI PSI PSI

PSI PSI PSI PSI

PSI PSI PSI PSI

PSI PSI PSI PSI

PSI PSI PSI PSI

PSI PSI PSI PSI


HEAD PRESSURE READING FOR EACH SYSTEM AT THE RECEIVER LIQUID LINE

SYSTEM PSI SYSTEM PSI SYSTEM PSI

PSI PSI PSI

PSI PSI PSI

PSI PSI PSI

PSI PSI PSI

LOW SIDE PRESSURE FOR EACH SYSTEM AT THE COMPRESSORS SUCTION VALVES


PSI PSI PSI

PSI PSI PSI

PSI PSI PSI

PSI PSI PSI

DISCHARGE PRESSURE FOR EACH SYSTEM AT THE COMPRESSORS


PSI PSI PSI

PSI PSI PSI

PSI PSI PSI

PSI PSI PSI

LOW SIDE TEMPERATURE FOR EACH SYSTEM AT THE COMPRESSORS SUCTION VALVES

SYSTEM °F SYSTEM °F SYSTEM °F

°F °F °F

°F °F °F

°F °F °F

°F °F °F


HEAD PRESSURE TEMPERATURE FOR EACH SYSTEM AT THE RECEIVER LIQUID LINE


°F °F °F

°F °F °F

°F °F °F

°F °F °F

OFF CYCLE DEFROST, PUMP DOWN TIME CLOCK, (IF APPLICABLE) SET AT: WALK IN FREEZER, DEFROST TIMER SET FOR:

45 MINUTES DEFROST DURATION AT: (10AM -4PM-10PM-4AM) YES

OFF CYCLE DEFROST, PUMP DOWN NORMALLY OPEN LIQUID LINE SOLENOID CHECKED YES

STROBE LIGHT ALARM, CONTROL WIRES CONNECTED TO THE PANEL TERMINAL BLOCK YES

STROBE LIGHT ALARM, INSTALLED AND WIRED AT THE REQUESTED LOCATION YES

CONDENSER COILS, FINS FREE FROM ANY CONSTRUCTION DEBRIS AND DUST YES

CONDENSER FAN MOTORS ROTATION/ NOISE/ VIBRATION YES

FAN MOTORS, ANTI-WIND MILL (IF APPLICABLE) BEARING WHEEL/STRIKING ROD-GREASED YES

FAN MOTORS, MOUNTS CHECKED FOR TIGHTNESS AND VIBRATION YES

WALK IN FREEZER, CONTROL WIRES CONNECTED TO THE PANEL TERMINAL BLOCK YES


14.2 WALK-INS EVAPORATOR COIL

WALK IN COILS: LOCATED AND MOUNTED PER FLOOR PLAN YES WALK IN COILS: WIRED WITH SEAL TIGHT/WATER PROOF ON/OFF SWITCHES FOR FUTURE SERVICE AND KITCHEN OPERATION

YES WALK IN COILS: SUCTION PIPES, AT THE POINT OF CONNECTIONS, ARE ALL INSULATED INCLUDING ANY ISOLATION VALVES

YES

WALK IN COILS: MOUNTING RODS PENETRATION HOLES ARE SEALED FROM INSIDE AND OUTSIDE YES WALK IN BOXES: ALL PENETRATION HOLES INCLUDING REFRIGERATION LINES, ELECTRICAL CONDUITS, DRAIN LINES, FIRE SPRINKLERS, AND OTHERS ARE SEALED WITH SILICONE FROM INSIDE AND SPRAY FOAMED FROM OUTSIDE

YES

WALK IN COILS: DRAIN LINES INSTALLED WITH UNIONS FITTINGS AT THE POINT OF CONNECTION OF EACH DRAIN PAN

YES

WALK IN COILS: DRAIN LINES ARE PITCHED A MINIMUM ¼” PER FT YES

WALK IN COILS: DRAIN TRAPS ARE LOCATED OUTSIDE OF EACH BOX YES

WALK IN COILS: INSTALLED WITH SUCTION TRAP BEHIND EACH COIL AT THE BOTTOM OF THE RISER YES WALK IN COILS: LIQUID AND SUCTION REFRIGERATION LINES INSTALLED WITH ISOLATION VALVES LOCATED INSIDE THE BOXES IF SPECKED, AND MANDATORY ON ALL PARALLEL SYSTEMS

YES

FREEZER WALK IN COILS: DRAIN LINES INSULATED AND WRAPPED WITH HEATER ELEMENT YES

WALK IN COILS ARE WIRED TO MEET NATIONAL ELECTRICAL CODES AND LOCAL CODES YES FREEZER WALK IN COILS ARE WIRED FOLLOWING (KAIRAK SCHEMATIC) USING THE COLOR CODED WIRES AS NOTED

YES

TEMPERATURE CONTROLS SENSORS, LOCATED AT RETURN AIR OF EACH EVAPORATOR COIL UPPER SECTION YES WALK IN COOLERS: TEMPERATURE CONTROLS SETTINGS, (KAIRAK RECOMMENDED SETTINGS) FOR A STANDARD COOLER APPLICATION AT BELOW +40°F BOX TEMPERATURE ARE: 36°F SET POINT AND 4°F DIFFERENTIAL

YES

WALK IN COOLERS TEMPERATURE CONTROLS SETTINGS

SYSTEM: SET AT: DIFF AT: SYSTEM: SET AT: DIFF AT:

°F °F °F °F

°F °F °F °F

°F °F °F °F

°F °F °F °F

°F °F °F °F

°F °F °F °F


WALK IN FREEZERS TEMPERATURE CONTROLS SETTINGS (KAIRAK RECOMMENDED SETTINGS FOR A STANDARD FREEZER APPLICATION AT BELOW -10°F BOX TEMPERATURE ARE: -10°F SET POINT AND 5°F DIFFERENTIAL)

SYSTEM: SET AT: DIFF AT: SYSTEM: SET AT: DIFF AT:

°F °F °F °F

°F °F °F °F

°F °F °F °F

°F °F °F °F

°F °F °F °F

°F °F °F °F

WALK IN BOXES OPERATING TEMPERATURE AFTER 48 HOURS FROM START UP:


SUCTION LINES TEMPERATURE AT EACH EVAPORATOR COILS


SUPERHEAT CHECKED AND ADJUSTED IF NECESSARY AT EACH EVAPORATOR COIL



FREEZERS DRAIN LINE HEATER ELEMENTS, WIRES CONNECTED/ CHECKED/ RATED AT:

SYSTEM WATTS SYSTEM WATTS SYSTEM WATTS

FREEZERS COILS, DEFROST CONTROL WIRES ARE TERMINATED CORRECTLY YES

FREEZERS COILS, FANS CONTROL WIRES ARE TERMINATED CORRECTLY YES

FREEZERS COILS, DEFROST TERMINATION/ FAN DELAY SWITCHES CHECKED AND OPERATIONAL YES

FREEZER COILS, CHECK DEFROST INITIATION AFTER TURNING TIMER TO DEFROST YES FREEZER COILS, AFTER DEFROST INITIATION CONFIRM THAT COMPRESSOR PUMPED DOWN FIRST/ EVAPORATOR FAN MOTORS ARE OFF/ DEFROST HEATER ELEMENTS ARE ON

YES

FREEZER COILS, HEATER ELEMENTS ARE ALL WORKING DURING DEFROST AND RATED AT:

SYSTEM AMP SYSTEM AMP SYSTEM AMP

WALK IN COILS, SOLENOID VALVES OPERATIONAL, OPENING AND CLOSING YES WALK IN COOLERS, OFF CYCLE DEFROST TIMERS COILS ARE SET AT:

(LOCATED INSIDE THE EVAPORATOR) SYSTEM OFF AT OFF AT OFF AT OFF AT OFF AT OFF AT DURATION

: : : : : : :

: : : : : : :

: : : : : : :

: : : : : : :

: : : : : : :

WALK IN COILS, EVAPORATOR FAN MOTORS ARE RUNNING PROPERLY YES

WALK IN COILS, EVAPORATOR FAN MOTORS ROTATION/NOISE LEVEL/VIBRATION YES


WALK IN COILS, EVAPORATOR FAN MOTORS, MOUNTS AND BLADES CHECKED FOR TIGHTNESS AND VIBRATION YES

EVAPORATOR COIL:

SYSTEM # EVAPORATOR COIL MODEL/SERIAL NUMBER


14.3 FIXTURES PREP TABLES COLD RAILS UNDER-COUNTER

EQUIPMENT STANDS ALL OTHER ITEMS

SUCTION LINES AT POINT OF CONNECTIONS ARE ALL INSULATED INCLUDING ISOLATION VALVES YES LIQUID AND SUCTION REFRIGERATION LINES INSTALLED WITH ISOLATION VALVES LOCATED IN ACCESSIBLE AREA IF SPECKED, AND MANDATORY ON ALL PARALLEL SYSTEMS

YES

REFRIGERATION LINES AT THE POINT OF CONNECTIONS SECURED PROPERLY YES

SUCTION TRAPS INSTALLED AT THE BOTTOM OF THE RISER OF EACH POINT OF CONNECTIONS YES

WIRED CORRECTLY, MEET ELECTRICAL NATIONAL CODES/LOCAL CODES YES

SUPPLIED WITH PROPER REFRIGERATION CONTROLS AND ALL SET PER MANUFACTURER MANUAL YES

TEMPERATURE CONTROL INCLUDED AND SET PER MANUFACTURER MANUAL YES

SOLENOID VALVE AND COIL INCLUDED, CLOSING AND OPENING ON DEMAND YES

EXPANSION VALVES INCLUDED WITH MATCHING RACK REFRIGERANT TYPE YES

DEFROST TIMERS IF INCLUDED, SET PER EACH MANUFACTURER MANUAL YES ANY OTHERS/CUSTOM OR SPECIAL CONTROLS, LIST OF TYPE PER MANUFACTURER:

OPERATING TEMPERATURE AFTER 48 HOURS FROM START UP:


EVAPORATORS FAN MOTORS ARE ALL RUNNING PROPERLY AND CHECKED YES


CONDENSATION DRAIN LINES ARE PIPED AND INSTALLED WHERE NEEDED YES

CONDENSATE EVAPORATOR PANS ARE OPERATIONAL IF PROVIDED YES

SYSTEM FIXTURE DESCRIPTION MODEL SERIAL # MFG


14.4 INSTALLTION/PIPING

INSTALLER TO APPLY THE STANDARD REFRIGERATION PIPING PRACTICE YES REFRIGERATION PIPES INSULATION, IF EXPOSED TO THE ELEMENTS (OUTDOORS) MUST BE WATERPROOF, COVERED TO PROTECT AGAINST RAIN/UV/HEAT

YES

SUCTION LINE INSULATED WITH PROPER THICKNESS - MINIMUM ¾” THICK WALL YES SUCTION LINE INSULATION THICKNESS CHOSEN BY REFRIGERATION CONTRACTOR:

MEDIUM TEMP SYSTEMS

INCHES LOW TEMP

SYSTEMS INCHES

PIPES INSULATION USED, MEET LOCAL STANDARD/ CONTRACT AND GC SPECK YES

PIPES INSULATION, PLENUM RATED AND LISTED YES

PIPES INSULATION, GLUED TOGETHER AT THE CONNECTION JOINTS YES

PIPES INSULATION, AFTER 48 HOURS OF STARTUP NO CONDENSATION OR SATURATION YES

SUCTION LINES SLOPED ½” FOR EVERY 10FT TOWARDS THE COMPRESSORS REMOTE RACK YES

SUCTION P TRAPS AT THE BOTTOM OF EACH RISER YES

SUCTION P TRAPS AT LEAST EVERY 10FT OF THE EACH RISER YES

LIST THE LONGEST RISER AT THIS PROJECT: SYSTEM / FEET

INVERTED SUCTION TRAPS ON TOP OF THE RISERS YES

SUCTION DOUBLE RISERS WHERE REQUIRED FOLLOW (RECOMMENDED LINE SIZES CHART) YES

SUCTION LINE BRANCHES T OFF AT THE TOP OF EACH MAIN HEADER (12 CLOCK) YES

REFRIGERATION PIPES SIZED PER RECOMMENDED PIPE SIZES CHART YES

REFRIGERATION PIPES ARE ONLY COPPER DEHYDRATED/ LISTED FOR REFRIGERATION GRADE YES

ONLY LONG RADIUS ELBOWS ARE USED YES

MINIMUM 15% SILVER SOLDER ALLOY USED YES

DRY NITROGEN PASSED THROUGH WHEN BRAZING THE LINES YES

ISOLATION VALVES ARE INSTALLED AND PROVIDED BY INSTALLER FOR PARALLEL SYSTEMS YES

PARALLEL SYSTEMS, ISOLATION VALVES ARE INSTALLED ON BRANCHES OFF THE MAIN HEADER YES

PARALLEL SYSTEMS, ISOLATION VALVES ARE INSTALLED ON ALL WALK IN COILS YES PARALLEL SYSTEMS, ISOLATION VALVES ARE INSTALLED ON ALL FIXTURES/REACH IN/PREP TABLES/UNDER COUNTERS/OR ANY OTHERS

YES

ISOLATION VALVES ARE ALL PROPERLY INSULATED YES REFRIGERATION LINES PRESSURIZED WITH NITROGEN AT 300PSI FOR AT LEAST 48HOURS BEFORE CONNECTING TO THE RACK AND EQUIPMENTS

YES


REFRIGERATION LINES, PRESSURIZED AT 300PSI FOR AT LEAST: DAYS YES

REFRIGERATION LINES, GAUGES TEMPORARY INSTALLED TO VERIFY HOLDING PRESSURE YES REFRIGERATION LINES, HOLDING PRESSURE IS APPROVED AND CONFIRMED BY:

INSTALLER GENERAL CONTRACTOR CUSTOMER OR DEALER BUILDING OR CITY INSPECTOR REFRIGERATION LINES, FLUSHED OUT AT THE LOWEST ENDS WITH HIGH PRESSURE NITROGEN AFTER CONFIRMING THE PRESSURE TEST AND BEFORE CONNECTING TO ANY EQUIPMENT

YES

PARALLEL SYSTEMS, REFRIGERATION LINES MAIN HEADERS SIZES AND DISTANCE SYSTEM

NUMBER HORIZONTAL SIZE VERTICAL SIZE

HORIZONTAL LINE DISTANCE

VERTICAL LINE DISTANCE

OVERALL DISTANCE

FT FT FT

FT FT FT

FT FT FT

FT FT FT

INDIVIDUAL CIRCUIT COMPRESSORS, REFRIGERATION LINE SIZES AND DISTANCE SYSTEM

NUMBER HORIZONTAL SIZE VERTICAL SIZE

HORIZONTAL LINE DISTANCE

VERTICAL LINE DISTANCE

OVERALL DISTANCE

FT FT FT

FT FT FT

FT FT FT

FT FT FT

FT FT FT

FT FT FT

FT FT FT

FT FT FT

FT FT FT

FT FT FT

FT FT FT

FT FT FT

REFRIGERATION PIPING PLAN /ROUTE, MARKED UP WITH LINE SIZES, SAVED AND DOCUMENTED AT THE SITE YES REFRIGERATION PIPING PLAN/ROUTE, COPIES PROVIDED TO:

GC KAIRAK CUSTOMER OR DEALER LOCATION MAINTENANCE/ SERVICE COMPANY


PROPER SUPPORT FOR ALL OVERHEAD REFRIGERATION PIPES YES

OVERHEAD REFRIGERATION PIPES, SUPPORTED USING PROPER HANGERS/UNISTRUT/CLAMPS YES

OVERHEAD REFRIGERATION PIPES, NOT SUPPORTED OR SECURED ON OTHER TRADES EQUIPMENTS YES OVERHEAD REFRIGERATION PIPES, SUCTION LINES ARE FULLY INSULATED AND NO OPENINGS FOR CLAMPING PURPOSES

YES OVERHEAD REFRIGERATION PIPES, HORIZONTAL RUN SITTING ON A CUSHIONED SUPPORT OR SADDLE/ SLEEVES, TO PROTECT INSULATION FROM BEING CRUSHED

YES

OVERHEAD REFRIGERATION PIPES, COPPER NOT IN CONTACT WITH ANY OTHER METAL MATERIAL YES

OVERHEAD REFRIGERATION PIPES, LABELED PER RACK SYSTEM IDENTIFICATIONS YES

OVERHEAD REFRIGERATION PIPES, ALL WALL PENETRATIONS SEALED/FOAMED OR PER LOCATION SPECK YES

REFRIGERATION LINES INSIDE WALLS INSULATED AND RAN INSIDE PROTECTED SLEEVES YES

PULL BOXES PROVIDED FOR REFRIGERATION LINES LOCATED INSIDE WALLS YES

SOFT COPPER ARE ONLY USED IF IT’S NECESSARY, UNDERGROUND/ TOUGH WALL LOCATIONS YES

UNDERGROUND REFRIGERATION LINES ARE FULLY INSULATED AND INSIDE SLEEVES YES

UNDERGROUND REFRIGERATION LINES, SLEEVES ENDS ARE FOAMED/SEALED/WATER PROOFED YES

FOR ALL EQUIPMENTS CONNECTED TO THE RACK; LABELED FOLLOWING SYSTEMS IDENTIFICATIONS YES PICTURES ARE TAKEN FOR THE ENTIRE INSTALLATION PROJECT, INCLUDING RACK LOCATION / OVERHEAD PIPES/WALK IN COILS/FIXTURES/POINTS OF CONNECTIONS

YES

NOTES:

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