Howe 1000-RLE Supplement

HoweCorporationPhone:1‐773‐235‐0200
Fax:1‐773‐235‐0269
1650NorthElstonAvenueWebsite:www.howecorp.com
Chicago,IL60642‐1585Email:[email protected]
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Rapid Freeze
®
IceFlaker
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Installation&ServiceManual
ForUsewithRemoteSingleCondensingUnit
1000‐RLE
2000‐RLE
3000‐RLE
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2
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ENGINEERINGGUIDELINES...................................................................................................................3
LocationRequirements...........................................................................................................................................................3
WaterSupplyRequirements....................................................................................................................................................3
DrainWaterPipingRequirements...........................................................................................................................................4
ElectricalRequirements...........................................................................................................................................................4
RefrigerationRequirements....................................................................................................................................................5
PipingTable............................................................................................................................................................................7
RefrigerantPipework..............................................................................................................................................................7
RefrigerantPipeworkInsulationRequirements.......................................................................................................................7
FIELDINSTALLATION............................................................................................................................8
SafetyInformationandGuidelines..........................................................................................................................................8
Inspection...............................................................................................................................................................................8
CondensingUnitRiggingandMounting...................................................................................................................................8
Piping......................................................................................................................................................................................9
LeakTesting............................................................................................................................................................................9
Evacuation.............................................................................................................................................................................10
FieldWiring............................................................................................................................................................................10
RefrigerantChargingInstructions...........................................................................................................................................11
InstallationChecklist..............................................................................................................................................................12
STARTUPANDOPERATION................................................................................................................13
WaterOperation....................................................................................................................................................................13
RefrigerationOperation.........................................................................................................................................................16
ElectricalOperation................................................................................................................................................................21
MechanicalOperation............................................................................................................................................................26
Start‐UpChecklist...................................................................................................................................................................30
MAINTENANCE..................................................................................................................................31
PreventativeMaintenanceSchedule......................................................................................................................................31
CleaningProcedure................................................................................................................................................................32
SanitizingProcedure...............................................................................................................................................................33
Lubrication.............................................................................................................................................................................34
WaterFiltration......................................................................................................................................................................35
TROUBLESHOOTING...........................................................................................................................37
APPENDIX..........................................................................................................................................40

EngineeringGuidelines
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3
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EngineeringGuidelines
LocationRequirements
HoweRapidFreezeIceFlakersaredesignedto
operateinambientroomtemperatures
between50°Fand100°F.
MinimumAmbient
Temperature
MaximumAmbient
Temperature
50°F100°F

TheIceFlakerwarrantyisvoidifitisinstalled
inambientroomtemperaturesbelow50°F.
TheIceFlakermustbelocatedaboveasanitary
sewerfloordrainhubortrenchdraintoensure
properdrainagetothefloor.Manydesigners
slopefloorstothesanitarysewerinletsto
managethesewetareas.
IfinstallingtheIceFlakerwithaHoweIceBin,
ensurethatthebinisadequatelysecuredtothe
floorsoastopreventtheassemblyfromtipping
whenempty.
WaterSupplyRequirements
ColdwatersupplytotheIceFlakermustbe
totallyseparateandunaffectedbyanylocalhot
watersupply.
Thiscoldwatersupplymustbewithintherange
of45°Fto90°F.
MinimumWater
SupplyTemp.
MaximumWater
SupplyTemp.
45°F90°F
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Thecoldwatersupplypressuremustbewithin
a20PSIGto60PSIGrange.
MinimumWater
Pressure
MaximumWater
Pressure
20PSIG60PSIG

StraightReverseOsmosis(RO)treatedwater
shouldneverbesuppliedtotheIceFlaker.
ROsystemtreatedwaterisaggressivetoward
metalsandplatedsurfaces.InadditionRO
waterwillaffectthelifeandintegrityofrubber
andplasticmaterialIceFlakercomponents.If
onlyROwaterisavailable,Post‐ROtreatment
mustbeprovidedtoraisepHandmineral
content.
Generally,filtrationofcoldsupplywateris
recommended.Howeoffersacompletelineof
replaceablecorecartridgefiltertreatment
systemsdesignedtoimproveicequalityand
extendthelifeoftheIceFlaker.
THEINFORMATIONFOUNDINTHISMANUALISINTENDEDFORUSEBYINDIVIDUALSPOSSESSING
EXPERIENCEDBACKGROUNDSINELECTRICAL,REFRIGERATIONANDMECHANICALREPAIRAND
MAINTENANCE.ANYATTEMPTTOREPAIRORALTERTHISEQUIPMENTMAYRESULTINPERSONAL
INJURYORPROPERTYDAMAGE.THEMANUFACTURERISNOTRESPONSIBLEFORTHEINTERPRETATION
OFTHEINFORMATIONCONTAINEDHEREIN,NORHASTHEMANUFACTURERASSUMEDANYLIABILITYIN
CONNECTIONWITHITSUSE.
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THEMANUFACTURERISNOTRESPONSIBLEFORANYLOSS,DAMAGEORINJURYCAUSEDASARESULT
OFEITHER(I)ANYREPAIRORREPLACEMENTTOTHEMANUFACTURER’SEQUIPMENTTHATISDONEBY
ATHIRDPARTYNOTPREVIOUSLYAPPROVEDBYTHEMANUFACTURER,OR(II)ANYREPAIRORSERVICE
WORKPERFORMEDONANYOFTHEMANUFACTURER’SEQUIPMENTWHICHDOESNOTSTRICTLY
FOLLOWTHEPROCEDURESSETFORTHHEREIN.
IMPORTANT

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4
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EngineeringGuidelines
Thisfiltrationwillalsoreducesupplywater
relatedserviceproblemsifchangedatleast
everysixmonthsordependinguponlocalwater
conditions.
Adedicated1/2”ODScoppercoldwatersupply
shouldbelocatedwithin4feetoftheIceFlaker
completewithhandshutoffvalve.
A3/8”ODcoppertubeshouldconnectthefield
installedshutoffvalvewiththeIceFlakerwater
inletconnectionlocatedattherearofthe
machine.
DrainWaterPipingRequirements
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TheDrainWaterPipingfigureaboveillustrates
therecommendedpipingtoafloorsanitary
sewerhubortrenchdrain.Thetwovertical
pipedropsshoulddrainwaterthroughan
indirectwaterconnectionwithan“AirGap”.
Codeauthoritieshavingjurisdictionmaydictate
otherindirectwaterconnectionrequirements.
Thefiguredepictstwoseparatedrainlines
whicharerequiredtoensuretheIceFlaker
doesnotinadvertentlyflowWaterSumpDrain
waterintotheIceBinorCartsintheeventofa
backuporanyothermalfunction.
ElectricalRequirements
Adedicated15amp,2pole,208‐230voltpower
supplyfromafieldfurnishedandinstalled
disconnectswitchisrequiredforeachIce
Flaker.
Adedicated3pole,208‐230voltpowersupply
fromafieldfurnishedandinstalleddisconnect
switchisrequiredforeachRemoteCondensing
Unit.Theamperageofthepowersupplycircuit
mustmatchtheselectedRemoteCondensing
UnitsuppliedbyHowewithrespectto
MinimumCircuitAmperage(MCA)and
MaximumOvercurrentProtectionDevice
(MOPD)nameplateinformation.
Atwoconductorcontrolcircuitisrequiredto
interconnecttheIceFlakerwiththeRemote
CondensingUnitinterlockingrelay.
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EngineeringGuidelines
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5
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RefrigerationRequirements
ModelRefrigerationRequirements*OptimumEvaporatorTemperature
1000‐RLE9,500BTU/hr0°F
2000‐RLE18,000BTU/hr‐5°F
3000‐RLE27,000BTU/hr‐5°F
*RefrigerationrequirementsarebasedonoperatingtheIceFlakerwith70°Fsupplywaterand90°Fambientairconditions.
Refrigerationrequirementsand/orcapacitywillvarywithtemperaturesoutsidetheseconditions.
HoweFurnishedCondensingUnits
Howefurnishedcondensingunitsareproperly
sizedforoutdoordesignambienttemperature
andsupplywatertemperatureconditions.
Thesecondensingunitsarefactoryequipped
withthefollowingaccessories:
LiquidLineFilter/DrierandSightGlass
SuctionFilter
SuctionAccumulator
OilSeparator
RefrigerantPump‐DownCycle
HeatedandInsulatedReceiver(except
forhighambientapplications)
DiscusCompressor
CondenserFanCyclingcontrol
Non‐AdjustableHeadPressureControl
Valve
FieldFurnishedCondensingUnits
Howeisnotresponsiblefortheperformanceof
fieldfurnishedcondensingunits.Howe
recommendsfieldfurnishedcondensingunits
besizedwithsufficientrefrigerationcapacityat
thelocaldesignoutdoorambienttemperature
includingenoughsystemcapacitytooffset
suctionlinepressurelosses.Howealso
recommendsfieldfurnishedcondensingunits
beatleastequippedwiththeaccessories
outlinedintheprevioussectiontoensure
successfuloperationoftheIceFlaker.
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6
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EngineeringGuidelines
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Figure1

EngineeringGuidelines
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7
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PipingTable
ModelLiquidLine*SuctionLine*SuctionRiser*
1000‐RLE3/8”ODS7/8”ODS3/4”ODS
2000‐RLE1/2"ODS1‐1/8”ODS7/8”ODS
3000‐RLE1/2"ODS1‐3/8”ODS1‐1/8”ODS
*Forrunsupto150feet.Iflonger,usenextlargerlinesize.
RefrigerantPipework
Howerecommendsthefieldrefrigerantpiping
beinstalledaccordingtotheSuggested
RefrigerantPipingDiagramshownonprevious
page.ThesepipesizesareforHFCrefrigerants
andarenotapplicabletoR‐744installationsor
secondaryrefrigerantapplications.
HowerecommendstheuseofharddrawnACR
typeLtubingwithrefrigerationgradewrought
copperlongradiuselbowsandfittingsonly.No
softdrawntubingshouldbeusedinthe
refrigerantpipeinstallation.
NofieldinstalledP‐typeoiltrapisrequiredat
thebaseofthesuctionrisersinceallIceFlakers
areinternallypipedwithasuctiontrapatthe
outletoftheevaporatorwithintheenclosure.
EvaporatorPressureRegulator(EPR)valves
mustbefieldinstalledwiththearrowcorrectly
pointinginthedirectionofflow.
Installationspecificationsshouldrequireall
refrigerantpipingshouldbejoinedwitha
suitablesilverbrazingalloywhilepurging
nitrogenthroughthepipingtopreventcopper
oxidationscalefromforminginsidethetubing.
ForclosecouplingIceFlakertoCondensing
Unit,useaminimumoftenfeettotalstraight
lengthofpipe.Minimizebendsandfittings.
SuctionLinetoincludeEPRandHeatExchanger.
RefrigerantPipeworkInsulation
Requirements
Fieldrefrigerantpipeworkshouldbeinsulated
withclosedcellflexibleelastomericfoam
thermalinsulationintendedforcold
applications.
Liquidlinesshouldbecoveredwith1/2”thick
andsuctionlineswith3/4”thickmaterial.
Theinsulationmaterialshouldbemoisture
vaporresistantwhencorrectlyinstalled
accordingtothemanufacturer’sinstructions.
ThefieldinstalledEvaporatorPressure
Regulator(EPR)valveandSuctionLineHeat
Exchangermustlikewisebeinsulated.Ifthese
systemcomponentsareleftun‐insulatedthey
become“thermalbridges”andunwanted
condensationandicewillformanddrip.
Allbuttjointsandseamsmustbeproperlyfield
fabricatedaccordingtotheinsulation
manufacturer’sfusingadhesiveinstructions.
Self‐adheringclosedcellfoaminsulationisalso
availableinrollsandcanbeusedtosupplement
theconventionaltubularmaterialsonirregular
shapes,EPRvalves,andcaps.
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8
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FieldInstallation
FieldInstallation
SafetyInformationandGuidelines
Onlyqualifiedservicetechniciansshould
attempttoinstall,service,ormaintaintheIce
Flaker.
Makesureallpowersourcesaredisconnected
beforeanyserviceworkisdonetotheIce
Flaker.
Allfieldwiringmustconformtothe
requirementsoftheequipmentandall
applicablelocalcodesandnationalcodes.
AlwaysrefertotheCondensingUnit
manufacturer’sinstallationmanualforfurther
specificationandguidance.
Inspection
Uponreceipt,checkallitemsagainstthebillof
ladingtomakesureallcratesandcartonsare
accountedfor.
Anyshortageordamagesshouldbereportedto
thedeliveringcarrier.Damagedmaterial
becomesthedeliveringcarrier’sresponsibility
andshouldnotbereturnedtothe
manufacturerunlesspriorapprovalisgiven.
Takecarenottodamageequipmentwhen
uncrating.
CondensingUnitRiggingand
Mounting
Riggingholesareprovidedonallunits.Caution
shouldbeexercisedwhenmovingtheseunits.
Topreventdamagetotheunithousingduring
rigging,cablesorchainsusedmustbeheld
apartbyspacerbars.Themountingplatformor
baseshouldbelevelandlocatedsoastopermit
freeaccessofsupplyair.
GroundMounting
Concreteslabraisedsixinchesaboveground
levelprovidesasuitablebase.Raisingthebase
abovegroundlevelprovidessomeprotection
fromgroundwaterandwind‐blownmatter.
Beforetighteningmountingbolts,rechecklevel
ofunit.Theunitshouldinallcasesbelocated
withaclearspaceinalldirectionsthatisata
minimum,equaltotheheightoftheunitabove
themountingsurface.Acondensingunit
mountedinacornerformedbytwowalls,may
resultindischargeairrecirculationwith
resultinglossofcapacity.
RoofMounting
Duetotheweightoftheunits,astructural
analysisbyaqualifiedengineermayberequired
beforemounting.Roofmountedunitsshould
beinstalledlevelonsteelchannelsoranI‐beam
framecapableofsupportingtheweightofthe
unit.
Access
Provideadequatespaceatthecompressorend
oftheunitforservicing.Provideadequate
spaceontheconnectionsidetopermitservice
ofcomponents.


FieldInstallation


9

Piping
TheIceFlakerhasbeenthoroughlycleanedand
dehydratedatthefactory.However,foreign
mattermayenterthesystembywayofthe
pipingtothecondensingunit.Therefore,care
mustbeusedduringinstallationofthepipingto
prevententranceofforeignmatter.
Installallrefrigerationsystemcomponentsin
accordancewithapplicablelocalandnational
codesandinconformancewithgoodpractice
requiredfortheproperoperationoftheIce
Flaker.
Therefrigerantpipesizeshouldbeselected
fromthePipingTable.Theinterconnectingpipe
sizeisnotnecessarilythesameasthestub‐out
onthecondensingunitortheIceFlaker.
Thefollowingproceduresshouldbefollowed:
1. Donotleaveunitsorpipingopentothe
atmosphereanylongerthanis
absolutelynecessary.
2. Useonlyrefrigerationgradecopper
tubing,properlysealedagainst
contamination.
3. Suctionlinesshouldslope1/4"per10
feettowardsthecompressor.
4. RefertotheSuggestedRefrigerant
PipingDiagram(p.6)forsuitableP‐type
oiltraplocationstoenhanceoilreturn
tothecompressor.
5. Whenbrazingrefrigerantlines,Dry
Nitrogenshouldbepassedthroughthe
lineatlowpressuretopreventscaling
andoxidationinsidethetubing.
6. Useonlyasuitablesilversolderalloyon
suctionandliquidlines.

LeakTesting
Afterallrefrigerantconnectionsaremade,the
entiresystemmustbeleaktested.
Thecompletesystemshouldbepressurizedto
nomorethan150psigwithrefrigerantanddry
nitrogen(ordryCO2).
Itisrecommendedthatthispressurebeheld
foraminimumof12hoursandthenrechecked.
Forasatisfactoryinstallation,thesystemmust
beleaktight.






10

FieldInstallation
Evacuation
Donotusetherefrigerationcompressorto
evacuatethesystem.Donotstartthe
compressorwhileitisinavacuum.
Agood,deepvacuumpumpshouldbe
connectedtoboththelowandhighside
evacuationvalveswithcoppertubeorhigh
vacuumhoses(1/4”IDminimum).
Ifthecompressorhasservicevalves,they
shouldremainclosed.
Adeepvacuumgaugecapableofregistering
pressureinmicronsshouldbeattachedtothe
systemforpressurereadings.
Ashutoffvalvebetweenthegaugeconnection
andvacuumpumpshouldbeprovidedtoallow
thesystempressuretobecheckedafter
evacuation.
Donotturnoffvacuumpumpwhenconnected
toanevacuatedsystembeforeclosingshutoff
valve.
Thevacuumpumpshouldbeoperateduntila
pressureof1,500micronsabsolutepressureis
reached–atwhichtimethevacuumshouldbe
brokenwiththerefrigeranttobeusedinthe
systemthroughadrieruntilthesystem
pressurerisesabove“0”psig.
Refrigerantusedduringevacuationcannotbe
vented.Reclaimallusedrefrigerant.
Repeatthisoperationasecondtime.
Openthecompressorservicevalvesand
evacuatetheentiresystemto500microns
absolutepressure.Raisethepressureto2psig
withtherefrigerantandremovethevacuum
pump.
FieldWiring
Allfieldwiringmustbeincompliancewithlocal
andnationalcodes.Useonlycopper
conductorsoftheappropriatesize.
1. Installdisconnect(notsuppliedby
factory).

2. Connect208‐230/1/60powertothe
twoblackwiresmarked“L1”and“L2”
inthejunctionboxontherearofthe
IceFlaker.

3. Inthejunctionboxtherearetwored
wiresmarked“A”and“B”.Remove
wirenut.

4. Connectthenormally‐openisolating
contactsfromtherelaymountedinthe
condensingunitto“A”and“B”.

5. LocateandconnectPhotoEyesensors
tothematchingpluginsidetheIce
Flakerenclosure(seep.24).







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