View TSR40A_1263043.PDF datasheet online --- IC-ON-LINE

Datasheet File OCR Text:

eqr, sqr, lqr, tsr & txr series chiller remote air cooled condenser installation guidelines manual
table of contents installation guidelines manual..................... ................................................... ..........................................1 foreword ........................................... ................................................... ................................................... .............1 installation ....................................... ................................................... ................................................... ............1 r eceiving ................................................... ................................................... ................................................... ......1 r igging , h andling , and l ocating e quipment ................................................... ................................................... .1 i nterconnecting r efrigerant p iping ................................................... ................................................... ............2 c ompressor p hasing ................................................... ................................................... ......................................2 refrigeration piping design........................ ................................................... ...............................................2 g eneral d esign c onsiderations ................................................... ................................................... ....................2 d etermining e quivalent l ine l ength ................................................... ................................................... .............2 table 1 - equivalent lengths (in feet)............. ................................................... .................................................2 l iquid l ine s izing ................................................... ................................................... .............................................2 figure 1 - condenser located with no elevation diff erence ............................................. ................................4 figure 2 - condenser located above chiller unit .... ................................................... .......................................4 figure 3 - condenser located below chiller unit.... ................................................... ........................................4 table 2 - liquid line sizes (continued) ............ ................................................... ...............................................6 table 2 - liquid line sizes (continued) ............ ................................................... ...............................................7 d ischarge (h ot g as ) l ine s izing ................................................... ................................................... ....................8 figure 4 - double discharge riser .................. ................................................... ................................................8 table 3 - horizontal or downflow discharge line siz es (inches od) ..................................... ...........................8 table 4 - upflow discharge line sizes (inches od) .. ................................................... .....................................9 calculating system refrigerant and oil charge ...... ................................................... ...................10 table 5 - refrigerant charge (lbs. of hcfc-22 per c ircuit)............................................ ................................10 table 6 - field piping charge ...................... ................................................... ..................................................1 0 o il c harge d etermination ................................................... ................................................... ............................10 s etting c ondenser f an c ontrols ................................................... ................................................... ...............10 table 7 - condenser fan control pressure settings .. ................................................... ..................................11 drawings........................................... ................................................... ................................................... .............11
1 foreword the intent of this manual is to serve as a guide fo r placing your remote condenser in service and operating and maintaining it properly. improper installation can lead to poor equipment performance or severe equipment damage. failure to follow the enclosed installatio n instructions may result in damage that will not be covered by your warranty. it is extremely important that a qualified refrigeration installation contractor perform all i nstallation line sizing and piping. please supply these instru ctions to your authorized refrigeration contractor. this man ual is supplemented as required to accommodate any special items that may have been provided for a specific application. the written information contained in t his manual, as well as various drawings, are intended t o be general in nature. the schematics included in this manual are typical only. actual schematics are included in the electrical enclosure of the remote condenser and sh ould be referred to for troubleshooting and servicing of the unit. additional copies of wiring diagrams are available upon request. we strive to maintain an accurate record o f all equipment during the course of its useful life. whi le every effort is made to standardize the design features o f these condensers, the various options may make it necessa ry to rearrange some of the components; therefore, some o f the general drawings in this manual may differ from you r specific unit. specific references to current applicable codes, ordinances, and other local laws pertaining to the use and operation of this equipment are avoided due to thei r ever- changing nature. there is no substitute for common sense and good operating practices when placing any mechanical equipment into operation. we encourage a ll personnel to familiarize themselves with this manua l's contents. failure to do so may unnecessarily prolon g equipment down time. the condenser is designed for use with chemical refrigerants for heat transfer purposes. this chemi cal is sealed and tested in a pressurized system containin g asme coded vessels; however, refrigerant gas can be released if there is a system failure. refrigerant gas can cause toxic fumes if it is exposed to fire. these u nits must be placed in a well-ventilated area, especially if open flames are present. failure to follow these instructions could result i n a hazardous condition. the standard refrigerant used in these units is a hydrochloro-fluorocarbon (hcfc) tr ade named r-22. the epa has enacted laws regarding the handling of refrigerants and eventual phase-out of hcfc refrigerants. hcfc refrigerant production will cont inue until january 1, 2010 for new equipment and until j anuary 1, 2020 for service purposes. customers are advised to immediately implement a refrigerant management program including a survey of all equipment to docu ment the type and quantity of refrigerant in each machin e. all refrigeration service technicians must be certified by an epa approved organization. it is recommended that good piping practices are followed and that the informat ion in this manual is adhered to. we cannot be held respon sible for liabilities created by substandard piping metho ds and installation practices external to the chiller or condenser(s). we trust your equipment will have a long and useful life. if you should have any questions, please contact our customer service department specifying the serial number and model number of the unit as indicated on the nameplate. installation receiving each unit is shipped with a holding charge of nitro gen. before accepting delivery, check the condenser to e nsure the coils are still full of the nitrogen holding ch arge and check the entire unit for visible damage. if damag e is evident, it should be properly documented on the de livery receipt and the box or crate should be immediately removed to allow for detailed inspection of the uni t. check for broken refrigerant lines, oil leaks, damaged co ntrols, or any other major component torn loose from its mount ing point. any sign of damage should be recorded and a claim filed immediately with the shipping company. in order to expedite payment for damages it is importa nt to record and document damage. an excellent way to do this is by taking pictures. our customer service department will provide assistance with the prepara tion and filing of your claims, including arranging for an estimate and quotation on repairs. rigging, handling, and locating equipment the condenser coil should be pressurized to 350 psi (2413 kpa) with dry nitrogen gas and leak-checked p rior to rigging. this will ensure no coil damage has occur red after the unit left the factory. the condenser is shipped with the legs removed. the legs must be mounted to the condenser using the provided nuts, bolts and washer s. proper rigging methods must be followed to prevent damage to components. avoid impact loading caused by sudden jerking when lifting or lowering the condens er. use pads where abrasive surface contact is anticipa ted. ! caution: under no circumstances should the condenser manifolds, control panel or return bends of the condenser coil be used for lifting or moving the condenser. the condenser is designed for outdoor use. a primar y concern when designing your unit was serviceability ; therefore, the condenser should be located in an accessible area. the unit must be installed on a f irm, level base no closer than their width from walls or other condensers. avoid locations near exhaust fans, plu mbing vents, flues or chimneys. mounting legs should be securely fastened at their base to the steel or con crete of the supporting structure. for units mounted on a r oof structure, the steel support base holding the conde nser should be elevated above the roof and attached to t he building.
2 interconnecting refrigerant piping the chiller unit is shipped with a full charge of o il, excluding the additional charge for field piping, a nd a refrigerant holding charge. the chiller is designe d for use only with the air-cooled condenser provided with th e unit. the following section covers the required piping be tween the chiller and the provided air-cooled condenser. the chiller may consist of multiple evaporators, compressors, liquid line solenoid valves, expansion valves, sight glasses, filter driers, and receivers . if the chiller is designed to operate in lower ambient air temperatures, the chiller may also contain head pre ssure control valves. the discharge and liquid lines leav ing the chiller are capped. these line sizes do not necessa rily reflect the actual line sizes required for the pipi ng between the chiller and the air-cooled condenser. the inst alling contractor need only provide the interconnecting pi ping between the chiller and the air-cooled condenser. refrigerant piping size and piping design has a sig nificant effect on system performance and reliability. refe r to the refrigeration line sizing section of this manual to ensure the refrigerant piping is properly sized and that t he piping runs are properly laid out. all piping should conf orm to the applicable local and state codes. use refrigerant grade copper tubing only and isolate the refrigeration li nes from building structures to prevent transfer of vibratio n. do not use a saw to remove end caps. this might allow cop per chips to contaminate the system. use a tube cutter or heat to remove the caps. when sweating copper join ts it is important to flow dry nitrogen through the syste m prior to charging with refrigerant. this prevents scale formation and the possible formation of an explosive mixture of hcfc-22 and air. this will also prevent the format ion of toxic phosgene gas, which occurs when hcfc-22 is exposed to open flame. soft solders are not to be used. for copper-to-copper joints use a phos-copper solde r with 6% to 8% silver content. a high silver content bra zing rod must be used for copper-to-brass or copper-to-steel joints. only use oxy-acetylene brazing. compressor phasing during manufacturing, chillers with remote condense rs are put through a limited testing program since the condenser is not connected to the chiller. when the refriger ation circuit is constructed at the factory, it is capped and sealed at the remote condenser connections to prevent contamination. because of this, the refrigeration c ircuit cannot be run and the compressor cannot be tested f or proper phasing. after the refrigerant piping is co nnected to the remote condenser and the circuit is properly charged, check the phasing of the compressor to mak e sure there is proper rotation. the compressor may need to be re-wired to have proper phasing. refrigeration piping design the system can be configured in any of the primary arrangements as shown in figures 1, 2 and 3. the configuration and its associated elevation, along w ith the total distance between the chiller and the air-cool ed condenser are important factors in determining the liquid line and discharge line sizes. this will also affe ct the field refrigerant and oil charges. consequently, there a re physical limits that must not be violated if the sy stem is to operate as designed. general design considerations 1. the total distance between the chiller and the a ir- cooled condenser must not exceed 200 actual feet (61 meters) or 300 equivalent feet (91 meters). 2. liquid line risers must not exceed 15 feet (5 me ters) in height from the condenser liquid line connection . (see figure 4). 3. discharge line risers cannot exceed an elevation difference greater than 100 actual feet (31 meters) without a minimum of 2% efficiency decrease. determining equivalent line length to determine the appropriate size for field install ed liquid and discharge lines, it is first necessary to estab lish the equivalent length of pipe for each line. the equiv alent length is the actual friction loss from the linear run of pipe plus the added friction loss of elbows, valves, etc . table 1 shows the equivalent length of pipe for various non ferrous valves and fittings. follow these steps when calcu lating line size: 1. start with an initial approximation of equivalent l ength by assuming that the equivalent length of pipe is 1 .5 times the actual pipe length. 2. refer to tables 2 and 3 for a first approximation o f line size. 3. check the line size by calculating the actual equivalent length. note: when calculating the equivalent length, do no t include piping of the chiller unit. only field piping must be considered. table 1 - equivalent lengths (in feet) line size od (inches) angle valve short radius el long radius el 3/8 24 4 2.8 1/2 24 4.7 3.2 5/8 25 5.7 3.9 3/4 25 6.5 4.5 7/8 28 7.8 5.3 1-1/8 29 2.7 1.9 1-3/8 33 3.2 2.2 1-5/8 34 3.8 2.6 2-1/8 39 5.2 3.4 2-5/8 44 6.5 4.2 liquid line sizing the liquid line diameter should be as small as poss ible while maintaining acceptable pressure drop. this i s necessary to minimize refrigerant charge. the tota l length between the chiller unit and the air-cooled condens er must not exceed 200 actual feet (61 meters) or 300 equiv alent feet (91 meters). liquid line risers in the system will require an ad ditional 0.5 psig (3.5 kpa) pressure drop per foot (31 cm) o f vertical rise. when it is necessary to have a liqu id line riser, make the vertical run immediately after the condenser before any additional restrictions. the liquid line risers must not exceed 15 feet (5 meters) in h eight
3 from the condenser liquid line connection (see figu re 3). the liquid line does not have to be pitched. liquid lines are not typically insulated. however, if the lines are exposed to solar heat gain or temperature s exceeding 110 f (43c), sub-cooling may be effecte d. in these situations, insulate the liquid lines.
4 figure 1 - condenser located with no elevation diff erence unit chiller figure 2 - condenser located above chiller unit figure 3 - condenser located below chiller unit chiller unit 15 ft max. note: liquid line sizing for each chiller capacity is shown in table 2. line sizing shown in table 2 is listed per circuit and applies where leaving water temperature (lwt) is 40f (4.4 c) or higher. for applications where the lwt is be low 40f (4.4c), size lines using the ashrae refrigeration handbook or other su itable design guide. unit see figure 4 for double riser construction. chiller
5 table 2 - liquid line sizes 3 ton circuit 5 ton circuit liquid line size (inch od) liquid line size (inch od) total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet 25 1/2 1/2 1/2 1/2 25 1/2 1/2 1/2 3/4 50 1/2 1/2 1/2 1/2 50 1/2 1/2 5/8 3/4 75 1/2 1/2 1/2 1/2 75 1/2 1/2 5/8 3/4 100 1/2 1/2 1/2 1/2 100 1/2 1/2 5/8 3/4 125 1/2 1/2 1/2 1/2 125 1/2 5/8 5/8 3/4 150 1/2 1/2 1/2 1/2 150 1/2 5/8 3/4 3/4 175 1/2 1/2 1/2 1/2 175 5/8 5/8 3/4 3/4 200 1/2 1/2 1/2 1/2 200 5/8 5/8 3/4 3/4 225 1/2 1/2 1/2 1/2 225 5/8 5/8 3/4 3/4 250 1/2 1/2 1/2 1/2 250 5/8 5/8 3/4 3/4 275 1/2 1/2 1/2 1/2 275 5/8 5/8 3/4 3/4 300 1/2 1/2 1/2 1/2 300 5/8 5/8 3/4 3/4 7.5 ton circuit 10 ton circuit liquid line size (inch od) liquid line size (inch od) total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet 25 5/8 5/8 5/8 7/8 25 3/4 3/4 3/4 3/4 50 5/8 5/8 5/8 7/8 50 3/4 3/4 3/4 3/4 75 5/8 5/8 5/8 7/8 75 3/4 3/4 3/4 3/4 100 5/8 5/8 5/8 7/8 100 3/4 3/4 3/4 7/8 125 5/8 5/8 3/4 7/8 125 3/4 3/4 3/4 7/8 150 5/8 5/8 3/4 7/8 150 3/4 3/4 3/4 7/8 175 5/8 5/8 3/4 7/8 175 3/4 3/4 3/4 7/8 200 5/8 5/8 3/4 7/8 200 3/4 3/4 3/4 1 1/8 225 5/8 3/4 3/4 7/8 225 3/4 3/4 3/4 1 1/8 250 5/8 3/4 3/4 7/8 250 3/4 3/4 7/8 1 1/8 275 5/8 3/4 3/4 7/8 275 3/4 3/4 7/8 1 1/8 300 5/8 3/4 3/4 7/8 300 3/4 3/4 7/8 1 1/8 15 ton circuit 20 ton circuit liquid line size (inch od) liquid line size (inch od) total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet 25 7/8 7/8 7/8 7/8 25 7/8 7/8 7/8 1 3/8 50 7/8 7/8 7/8 7/8 50 7/8 7/8 7/8 1 3/8 75 7/8 7/8 7/8 7/8 75 7/8 7/8 7/8 1 3/8 100 7/8 7/8 7/8 1 1/8 100 7/8 7/8 7/8 1 3/8 125 7/8 7/8 7/8 1 1/8 125 7/8 7/8 1 1/8 1 3/8 150 7/8 7/8 7/8 1 1/8 150 7/8 7/8 1 1/8 1 3/8 175 7/8 7/8 7/8 1 1/8 175 7/8 7/8 1 1/8 1 3/8 200 7/8 7/8 7/8 1 1/8 200 7/8 1 1/8 1 1/8 1 3/8 225 7/8 7/8 7/8 1 1/8 225 7/8 1 1/8 1 1/8 1 3/8 250 7/8 7/8 1-1/8 1 1/8 250 7/8 1 1/8 1 1/8 1 3/8 275 7/8 7/8 1-1/8 1 1/8 275 1-1/8 1 1/8 1 1/8 1 3/8 300 7/8 7/8 1-1/8 1 1/8 300 1-1/8 1 1/8 1 1/8 1 3/8
6 table 2 - liquid line sizes (continued) 25 ton circuit 30 ton circuit liquid line size (inch od) liquid line size (inch od) total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet 25 1 1/8 1 1/8 1 1/8 1 3/8 25 1 1/8 1 1/8 1 1/8 1 1 /8 50 1 1/8 1 1/8 1 1/8 1 3/8 50 1 1/8 1 1/8 1 1/8 1 1 /8 75 1 1/8 1 1/8 1 1/8 1 3/8 75 1 1/8 1 1/8 1 1/8 1 1 /8 100 1 1/8 1 1/8 1 1/8 1 3/8 100 1 1/8 1 1/8 1 1/8 1 3/8 125 1 1/8 1 1/8 1 1/8 1 3/8 125 1 1/8 1 1/8 1 1/8 1 3/8 150 1 1/8 1 1/8 1 1/8 1 3/8 150 1 1/8 1 1/8 1 1/8 1 3/8 175 1 1/8 1 1/8 1 1/8 1 3/8 175 1 1/8 1 1/8 1 1/8 1 3/8 200 1 1/8 1 1/8 1 1/8 1 3/8 200 1 1/8 1 1/8 1 1/8 1 3/8 225 1 1/8 1 1/8 1 1/8 1 3/8 225 1 1/8 1 1/8 1 1/8 1 3/8 250 1 1/8 1 1/8 1 1/8 1 3/8 250 1 1/8 1 1/8 1 3/8 1 5/8 275 1 1/8 1 1/8 1 1/8 1 3/8 275 1 1/8 1 1/8 1 3/8 1 5/8 300 1 1/8 1 1/8 1 1/8 1 3/8 300 1 1/8 1 1/8 1 3/8 1 5/8 35 ton circuit 40 ton circuit liquid line size (inch od) liquid line size (inch od) total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet 25 1 1/8 1 1/8 1 1/8 1 1/8 25 1 1/8 1 1/8 1 1/8 1 5 /8 50 1 1/8 1 1/8 1 1/8 1 1/8 50 1 1/8 1 1/8 1 1/8 1 5 /8 75 1 1/8 1 1/8 1 1/8 1 3/8 75 1 1/8 1 1/8 1 1/8 1 5 /8 100 1 1/8 1 1/8 1 1/8 1 3/8 100 1 1/8 1 1/8 1 3/8 1 5/8 125 1 1/8 1 1/8 1 1/8 1 3/8 125 1 1/8 1 1/8 1 3/8 1 5/8 150 1 1/8 1 1/8 1 1/8 1 3/8 150 1 1/8 1 1/8 1 3/8 1 5/8 175 1 1/8 1 1/8 1 1/8 1 3/8 175 1 1/8 1 1/8 1 3/8 1 5/8 200 1 1/8 1 1/8 1 1/8 1 5/8 200 1 1/8 1 3/8 1 3/8 1 5/8 225 1 1/8 1 1/8 1 3/8 1 5/8 225 1 1/8 1 3/8 1 3/8 1 5/8 250 1 1/8 1 1/8 1 3/8 1 5/8 250 1 1/8 1 3/8 1 5/8 1 5/8 275 1 1/8 1 1/8 1 3/8 1 5/8 275 1 3/8 1 3/8 1 5/8 1 5/8 300 1 1/8 1 1/8 1 3/8 1 5/8 300 1 3/8 1 3/8 1 5/8 1 5/8 45 ton circuit 50 ton circuit liquid line size (inch od) liquid line size (inch od) total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet 25 1 1/8 1 1/8 1 1/8 2 1/8 25 1 1/8 1 1/8 1 5/8 2 1 /8 50 1 1/8 1 1/8 1 3/8 2 1/8 50 1 1/8 1 1/8 2 1/8 2 1 /8 75 1 1/8 1 1/8 1 3/8 2 1/8 75 1 1/8 1 3/8 2 1/8 2 1 /8 100 1 1/8 1 1/8 1 3/8 2 1/8 100 1 1/8 1 3/8 2 1/8 2 1/8 125 1 1/8 1 3/8 1 5/8 2 1/8 125 1 1/8 1 3/8 2 1/8 2 1/8 150 1 1/8 1 3/8 1 5/8 2 1/8 150 1 3/8 1 3/8 2 1/8 2 1/8 175 1 1/8 1 3/8 1 5/8 2 1/8 175 1 3/8 1 3/8 2 1/8 2 1/8 200 1 3/8 1 3/8 1 5/8 2 1/8 200 1 3/8 1 5/8 2 1/8 2 1/8 225 1 3/8 1 3/8 1 5/8 2 1/8 225 1 3/8 1 5/8 2 1/8 2 1/8 250 1 3/8 1 3/8 1 5/8 2 1/8 250 1 3/8 1 5/8 2 1/8 2 1/8 275 1 3/8 1 3/8 1 5/8 2 1/8 275 1 3/8 1 5/8 2 1/8 2 1/8 300 1 3/8 1 3/8 1 5/8 2 1/8 300 1 3/8 1 5/8 2 1/8 2 1/8
7 table 2 - liquid line sizes (continued) 60 ton circuit 70 ton circuit liquid line size (inch od) liquid line size (inch od) total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet 25 1 3/8 1 3/8 1 3/8 2 1/8 25 1-5/8 1-5/8 1-5/8 2-1 /8 50 1 3/8 1 3/8 1 3/8 2 1/8 50 1-5/8 1-5/8 1-5/8 2-1 /8 75 1 3/8 1 3/8 1 3/8 2 1/8 75 1-5/8 1-5/8 1-5/8 2-1 /8 100 1 3/8 1 3/8 1 3/8 2 1/8 100 1-5/8 1-5/8 1-5/8 2 -1/8 125 1 3/8 1 3/8 1 3/8 2 1/8 125 1-5/8 1-5/8 1-5/8 2 -1/8 150 1 3/8 1 3/8 1 5/8 2 1/8 150 1-5/8 1-5/8 1-5/8 2 -1/8 175 1 3/8 1 3/8 1 5/8 2 1/8 175 1-5/8 1-5/8 1-5/8 2 -1/8 200 1 3/8 1 3/8 1 5/8 2 1/8 200 1-5/8 1-5/8 1-5/8 2 -1/8 225 1 3/8 1 3/8 1 5/8 2 1/8 225 1-5/8 1-5/8 1-5/8 2 -1/8 250 1 3/8 1 3/8 1 5/8 2 1/8 250 1-5/8 1-5/8 1-5/8 2 -1/8 275 1 3/8 1 5/8 1 5/8 2 1/8 275 1-5/8 1-5/8 1-5/8 2 -1/8 300 1 3/8 1 5/8 1 5/8 2 1/8 300 1-5/8 1-5/8 1-5/8 2 -1/8 80 ton circuit 90 ton circuit liquid line size (inch od) liquid line size (inch od) total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet 25 1-5/8 1-5/8 1-5/8 2-1/8 25 1-5/8 1-5/8 1-5/8 2-1 /8 50 1-5/8 1-5/8 1-5/8 2-1/8 50 1-5/8 1-5/8 1-5/8 2-1 /8 75 1-5/8 1-5/8 1-5/8 2-1/8 75 1-5/8 1-5/8 1-5/8 2-1 /8 100 1-5/8 1-5/8 1-5/8 2-1/8 100 1-5/8 1-5/8 1-5/8 2 -1/8 125 1-5/8 1-5/8 1-5/8 2-1/8 125 1-5/8 1-5/8 1-5/8 2 -1/8 150 1-5/8 1-5/8 1-5/8 2-1/8 150 1-5/8 1-5/8 1-5/8 2 -1/8 175 1-5/8 1-5/8 1-5/8 2-1/8 175 1-5/8 1-5/8 1-5/8 2 -1/8 200 1-5/8 1-5/8 1-5/8 2-1/8 200 1-5/8 1-5/8 1-5/8 2 -1/8 225 1-5/8 1-5/8 1-5/8 2-1/8 225 1-5/8 1-5/8 1-5/8 2 -1/8 250 1-5/8 1-5/8 1-5/8 2-1/8 250 1-5/8 1-5/8 1-5/8 2 -1/8 275 1-5/8 1-5/8 1-5/8 2-1/8 275 1-5/8 1-5/8 2-1/8 2 -1/8 300 1-5/8 1-5/8 1-5/8 2-1/8 300 1-5/8 1-5/8 2-1/8 2 -1/8 100 ton circuit liquid line size (inch od) total equivalent length (ft) horizontal or downflow upflow 1 to 5 feet upflow 6 to 10 feet upflow 11 to 15 feet 25 1-5/8 1-5/8 1-5/8 2-1/8 50 1-5/8 1-5/8 1-5/8 2-1/8 75 1-5/8 1-5/8 1-5/8 2-1/8 100 1-5/8 1-5/8 1-5/8 2-1/8 125 1-5/8 1-5/8 1-5/8 2-1/8 150 1-5/8 1-5/8 1-5/8 2-1/8 175 1-5/8 1-5/8 2-1/8 2-1/8 200 1-5/8 1-5/8 2-1/8 2-1/8 225 1-5/8 1-5/8 2-1/8 2-1/8 250 1-5/8 1-5/8 2-1/8 2-1/8 275 1-5/8 1-5/8 2-1/8 2-5/8 300 1-5/8 1-5/8 2-1/8 2-5/8
8 discharge (hot gas) line sizing discharge line size is based on the velocity needed to obtain sufficient oil return. line length and rest rictions should be minimized to reduce pressure drop and maximize capacity. the discharge lines should pitch downward, in the direction of the hot gas flow, at the rate of ? inc h (1.25 cm) per each 10 foot (3 meter) of horizontal run. if the chiller unit is below condenser, loop the discharge line to at least 1 inch (2.5 cm) above the top of the conde nser. a pressure tap valve should be installed at the conde nser to facilitate measuring pressure for service. if the chiller is below the condenser, consideration must be taken in the design of the discharge gas riser. all of our chil lers have unloading capabilities via hot gas bypass or compre ssor unloading; therefore, they all require a double dis charge riser for proper oil management. an example of the double discharge line construction is shown in figu re 4. refer to table 3 to determine the size of the doubl e discharge line riser. if the riser exceeds 25 feet (8 meters) in vertical height, the double discharge riser shou ld be repeated for each 25 foot (8 meter) of rise. figure 4 - double discharge riser condenser pitch to a b reducing tee chiller from street elbows 45 degree street elbow 90 degree note: discharge line sizing for each chiller capaci ty is shown in table 3. line sizing shown in table 3 is listed per circuit and applies where leaving water temperature (lwt) i s 40f (4.4c) or higher. for applications where lwt is b elow 40f (4.4c), size lines using the ashrae refrigeration handbook, or other suitable design guide. table 3 - horizontal or downflow discharge line siz es (inches od) total equivalent length (ft) circuit tons 25 50 75 100 125 150 175 200 225 250 275 300 3 5/8 5/8 3/4 3/4 3/4 3/4 7/8 7/8 7/8 7/8 7/8 7/8 5 3/4 7/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1 -1/8 1-1/8 1-1/8 7.5 7/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1 /8 1-3/8 1-3/8 1-3/8 10 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1- 3/8 1-3/8 1-3/8 1-3/8 15 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 20 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 25 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 30 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 35 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 40 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 45 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 50 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-5/8 60 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 70 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 80 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 90 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 100 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8
9 table 4 - upflow discharge line sizes (inches od) total equivalent length (ft) circuit tons 25 50 75 100 125 150 175 200 225 250 275 300 a-3/8 a-3/8 a-3/8 a-3/8 a-3/8 a-3/8 a-3/8 a-3/8 a-3 /8 a-3/8 a-3/8 a-3/8 3 b-1/2 b-1/2 b-5/8 b-5/8 b-5/8 b-5/8 b-3/4 b-3/4 b-3 /4 b-3/4 b-3/4 b-3/4 a-3/8 a-3/8 a-3/8 a-3/8 a-3/8 a-3/8 a-3/8 a-3/8 a-3 /8 a-3/8 a-3/8 a-3/8 5 b-5/8 b-3/4 b-3/4 b-7/8 b-7/8 b-7/8 b-7/8 b-7/8 b-7 /8 b-7/8 b-7/8 b-7/8 a-1/2 a-1/2 a-1/2 a-1/2 a-1/2 a-1/2 a-1/2 a-1/2 a-1 /2 a-1/2 a-1/2 a-1/2 7.5 b-5/8 b-5/8 b-7/8 b-7/8 b-7/8 b-7/8 b-7/8 b-7/8 b-7 /8 b-1-1/8 b-1-1/8 b-1-1/8 a-1/2 a-1/2 a-1/2 a-1/2 a-1/2 a-1/2 a-1/2 a-1/2 a-1 /2 a-1/2 a-1/2 a-1/2 10 b-5/8 b-7/8 b-7/8 b-7/8 b-1-1/8 b-1-1/8 b-1-1/8 b-1 -1/8 b-1-1/8 b-1-1/8 b-1-1/8 b-1-1/8 a-5/8 a-5/8 a-5/8 a-5/8 a-5/8 a-5/8 a-5/8 a-5/8 a-5 /8 a-5/8 a-5/8 a-5/8 15 b-7/8 b-7/8 b-7/8 b-1-1/8 b-1-1/8 b-1-1/8 b-1-1/8 b -1-1/8 b-1-1/8 b-1-3/8 b-1-3/8 b-1-3/8 a-5/8 a-5/8 a-5/8 a-5/8 a-5/8 a-5/8 a-5/8 a-5/8 a-5 /8 a-5/8 a-5/8 a-5/8 20 b-7/8 b-1-1/8 b-1-1/8 b-1-1/8 b-1-1/8 b-1-3/8 b-1-3/8 b-1-3/8 b-1 -3/8 b-1-3/8 b-1-3/8 b-1-3/8 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3 /4 a-3/4 a-3/4 a-3/4 25 b-1-1/8 b-1-1/8 b-1-3/8 b-1-3/8 b-1-3/8 b-1-3/8 b-1-5/8 b-1-5/8 b-1 -5/8 b-1-5/8 b-1-5/8 b-1-5/8 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3 /4 a-3/4 a-3/4 a-3/4 30 b-1-1/8 b-1-1/8 b-1-3/8 b-1-3/8 b-1-3/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1 -5/8 b-1-5/8 b-1-5/8 b-1-5/8 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3/4 a-3 /4 a-3/4 a-3/4 a-3/4 35 b-1-1/8 b-1-3/8 b-1-3/8 b-1-3/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1 -5/8 b-1-5/8 b-1-5/8 b-1-5/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7 /8 a-7/8 a-7/8 a-7/8 40 b-1-3/8 b-1-3/8 b-1-3/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1 -5/8 b-1-5/8 b-1-5/8 b-1-5/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7 /8 a-7/8 a-7/8 a-7/8 45 b-1-3/8 b-1-3/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1 -5/8 b-1-5/8 b-2-1/8 b-2-1/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7/8 a-7 /8 a-7/8 a-7/8 a-7/8 50 b-1-3/8 b-1-3/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-2 -1/8 b-2-1/8 b-2-1/8 b-2-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1 -1/8 a-1-1/8 a-1-1/8 a-1-1/8 60 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-2-1/8 b-2 -1/8 b-2-1/8 b-2-1/8 b-2-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1 -1/8 a-1-1/8 a-1-1/8 a-1-1/8 70 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-1-5/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2 -1/8 b-2-1/8 b-2-1/8 b-2-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1 -1/8 a-1-1/8 a-1-1/8 a-1-1/8 80 b-1-5/8 b-1-5/8 b-1-5/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2 -1/8 b-2-1/8 b-2-1/8 b-2-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1 -1/8 a-1-1/8 a-1-1/8 a-1-1/8 90 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2 -1/8 b-2-1/8 b-2-1/8 b-2-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1-1/8 a-1 -1/8 a-1-1/8 a-1-1/8 a-1-1/8 100 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2-1/8 b-2 -1/8 b-2-1/8 b-2-1/8 b-2-1/8
10 calculating system refrigerant and oil charge the approximate amount of the refrigerant charge required by the system can be determined by using t ables 1 and 2. to verify the system charge, run the syst em and check the liquid line sight glasses. to determine the approximate charge, first refer to table 5 and establish the required charge for the condenser and chiller. values given in table 5 are per circuit. then refer to table 6 to determine the charge required for the field- installed piping per circuit. the approximate charg e per circuit is therefore the sum of the values from tab les 5 and 6. table 5 - refrigerant charge (lbs. of hcfc-22 per c ircuit) combined charge for remote condenser and chiller minimum design ambient - f chiller model 60 50 40 30 20 10 0 -10 -20 eq2r3 9 9 10 11 12 13 13 13 14 sq2r5 10 10 12 14 15 16 16 17 17 lq2r8 13 13 15 17 19 20 21 21 22 lq2r10 18 19 22 25 27 29 30 31 32 lq2r15 25 25 25 26 31 34 36 38 40 lq2r20 30 30 30 32 37 41 44 47 49 lq2r25 51 51 51 52 52 58 63 67 71 lq2r30 51 51 51 51 51 51 55 55 65 lq2r35 70 70 70 70 70 70 76 76 88 lq2r40 80 80 80 80 80 80 80 88 94 tsr20a 19 19 23 25 27 29 30 31 32 tsr30a 25 25 25 26 30 33 36 37 39 txr40 36 36 36 37 37 40 44 46 49 TSR40A 44 44 45 46 51 55 58 61 63 txr50 74 74 74 74 74 74 80 80 94 tsr50a 45 45 45 45 45 50 54 57 59 txr60 89 89 89 89 89 89 89 99 105 tsr60a 51 51 51 53 60 65 69 73 75 txr70 59 59 59 60 61 68 74 80 84 txr85 107 107 108 108 108 119 127 134 140 tsr80a 59 59 60 60 60 68 74 80 84 tsr100a 60 60 60 61 61 68 75 80 84 txr80 72 72 72 73 73 81 87 92 97 txr100 147 147 147 147 147 147 160 160 188 txr105 147 147 147 147 147 147 160 160 188 txr120 178 178 178 178 178 178 178 197 210 txr140 118 118 119 120 121 136 148 159 168 txr170 214 214 215 216 217 237 254 268 279 txr200 294 294 294 294 294 294 319 319 376 table 6 - field piping charge line size od (inches) discharge line lbs. of hcfc-22 liquid line lbs. of hcfc-22 3/8 - 4 1/2 - 8 5/8 1 12 3/4 1 17 7/8 2 24 1-1/8 3 40 1-3/8 4 61 1-5/8 6 86 2-1/8 10 150 2-5/8 14 231 3-1/8 20 330 3-5/8 27 445 4-1/8 35 580 note: the amounts of refrigerant listed in table 2 are based on 100 feet (31 meters) of pipe. actual amounts wi ll be in direct proportion to the actual length of the pipin g. oil charge determination the chiller is factory charged with the amount of o il required by the chiller only and not the total syst em. refer to the manual that came with the chiller to determi ne the type of oil used. the amount of oil required is de pendent upon the amount of refrigerant that is added to the system for the field-installed piping. calculate the amount of oil to be added, using the following formula: pints of oil = lbs. of r-22 added / 100 oil level should be checked after the chiller has r un for 15 minutes. setting condenser fan controls depending on the number of condenser fans present i n the condenser there will be different fan cycling p ressure control settings requirements. it is important tha t these setting be correct in order to maintain proper capa city control and operation of the system. each refriger ant circuit has a separate head pressure control circui t. the proper pressure settings are shown in table 7.
11 table 7 - condenser fan control pressure settings number of fan stages 1 2 3 4 5 6 set point 180 180 180 180 180 180 differential 40 40 40 40 40 40 fan on 220 220 220 220 220 220 stage 1 fan off 180 180 180 180 180 180 offset 30 30 10 10 10 differential 40 40 40 40 40 fan on 250 250 230 230 230 stage 2 fan off 210 210 190 190 190 offset 50 20 20 20 differential 40 40 40 40 fan on 270 240 240 240 stage 3 fan off 230 200 200 200 offset 30 30 30 differential 40 40 40 fan on 250 250 250 stage 4 fan off 210 210 210 offset 40 40 differential 40 40 fan on 260 260 stage 5 fan off 220 220 offset 50 differential 40 fan on 270 stage 6 fan off 230 note: dual circuit condensers have two separate hea d- pressure controls circuits. drawings we have prepared a custom set of drawings for your unit and placed them inside the shipping box or control panel prior to shipment. please refer to these drawings when troubleshooting, servicing and installing the unit. if you cannot find these drawings or wish to have addition al copies sent, please contact our customer service department and reference the serial number of your unit. the drawings included in this manual are typical on ly and may not represent the actual unit purchased.
notes
notes
thermal care, inc. sales department service departm ent parts department 7720 north lehigh ave. phone (847) 966-2260 phone ( 847) 966-2636 phone (847) 966-8560 niles, il 60714-3491 fax (847) 966-9358 fax (847) 9 66-2906 fax (847) 966-6065 www.thermalcare.com email info@thermalcare.com emai l service@thermalcare.com form 9-100.12

▲Up To Search▲

Price & Availability of TSR40A

	To Download TSR40A Datasheet File
If you can't view the Datasheet, Please click here to try to view without PDF Reader .