KeepRite Parallel User manual

CONTENTS
Page
General Safety............................................................................................................................
Inspection..................................................................................................................................
Handling, Placement and Installation...........................................................................................
Vibration Isolation.......................................................................................................................
Ventilation..................................................................................................................................
Electrical Information..................................................................................................................
Refrigerant Piping.......................................................................................................................
System Accessories....................................................................................................................
Leak Testing...............................................................................................................................
Evacuation and Dehydration.........................................................................................................
Line Insulation.............................................................................................................................
Refrigerant Charging....................................................................................................................
Compressor Oils..........................................................................................................................
System Start-Up Checklist............................................................................................................
Pressure Controls........................................................................................................................
Low Temperature Room Pull-Down...............................................................................................
Checking Superheat.....................................................................................................................
System Operational Checklist.......................................................................................................
System Troubleshooting..............................................................................................................
Customer Instructions.................................................................................................................
Maintenance Program.................................................................................................................
Service Parts Availability.............................................................................................................
Equipment Start-Up Information...................................................................................................
Product Support Resources.........................................................................................................
“As Built” Service Parts List.........................................................................................................
Parallel Compressor Systems
Installation and Maintenance
Manual
Air, Water and Remote Models
Hermetic, Semi-Hermetic and
Scroll Compressors
!
WARNING: Only a qualied refrigeration mechanic who is familiar with refrigeration systems and
components, including all controls, should perform the installation and start-up of the system.
Bulletin K90-KPCS-IM-2
Part # 1090001
PRODUCT SUPPORT
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BACK
18/04/22

K90-KPCS-IM-2 18/04/22
- 2 -
Inspect all equipment before unpacking for visible signs of
damage or loss. Check shipping list against material received to
ensure shipment is complete.
IMPORTANT: Remember, you, the consignee, must make any
claim necessary against the transportation company. Shipping
damage or missing parts, when discovered at the outset, will
prevent later unnecessary and costly delays. If damage or loss
during transport is evident, make claim to carrier, as this will be
their responsibility, not that of the manufacturer.
Should carton be damaged, but damage to equipment is not
obvious, a claim should be led for “concealed damage” with the
carrier.
IMPORTANT: Check the electrical ratings on the unit to make sure
they correspond to those ordered and to electrical power avail-
able at the job site. Save all shipping papers, tags, and instruction
sheets for reference by installer and owner.
NOTE: Accessories such as drier cores, run-in lters for oil sepa-
rator, mounting pads etc. may be packaged in a separate carton.
Be sure that you receive all items.
Only a qualied refrigeration mechanic who is familiar with refrigeration systems and components, including all controls, should
perform the installation and start-up of the system. To avoid potential injury, use care when working around coil surfaces (if
applicable) or sharp edges of metal cabinets. All piping and electrical wiring should be installed in accordance with all applicable
codes, ordinances and local by-laws.
IMPORTANT SAFETY NOTE
Always disconnect and lock off the main power supply on any system that will be worked on to avoid accidental start up of the
equipment.
WARNING
GENERAL SAFETY
INSPECTION

K90-KPCS-IM-2 18/04/22
- 3 -
IMPORTANT: When selecting a location for the condensing unit,
consideration should be given to some of the following:
(a) Loading capacity of the oor or roof. Check building
codes for weight distribution requirements.
(b) Distance to suitable electrical supply.
(c) Distance to the evaporator.
(d) Adequate air circulation and ventilation.
(e) Close proximity to water source and oor drains
(water-cooled units)
(f) Accessibility for maintenance.
(g) Local building codes.
(h) Adjacent buildings relative to noise levels.
(i) Wishes of the end user / owner.
When all of the above points have been considered and a specic
location chosen, it is advisable to obtain written approval of this
location from the building and/or condensing unit owner. This
may be a means of avoiding disagreement and expense at a later
date.
A fully qualied and properly equipped crew with the necessary
tackle and rigging should be engaged to locate the condensing
unit in position. When lifting the unit, spreader bars and chang
gear should be used to prevent damage.
SPECIAL NOTE FOR LARGE PARALLEL RACK UNITS: Parallel
rack units are large and heavy pieces of mechanical equipment
and must be handled as such. A fully qualied and properly
equipped crew with the necessary tackle and rigging should be
engaged to locate the condensing unit into location. Spreader
bars should be used to prevent damage to the sides of the unit.
Do not sling directly around the base of unit. The unit should
be placed on a base, which is level and even.
HANDLING, PLACEMENT AND INSTALLATION
REFRIGERATION
Brantford, Ontario, Canada.
DRAWING. NUMBER SIZE
SHT of
CHANGE
SCALE
DATE
DRW. BY
APPR. BY MAT'L
PART NAME
ECO NO.
PRODUCT
BY LTRDATE
NATIONAL REFRIGERATION AND AIR
CONDITIONING PRODUCTS INC.
THIRD ANGLE PROJECTI ON
2. ALL DIM.'S ARE OUTSIDE DIM.'S UNLE SS SPECIFIED
1. FOR STANDARD TOLERANCES REFE R TO DOCUMENT # EN-311
3. HEADER BODY ENDS ARE SEALED SHUT UNLESS SPECIFIED
4. BREAK DIRECTIONS ARE RELATIVE TO PAPER PLANE
SYMMETRICAL LINE
C
L
5. SYMBOLS
BREAK / CREASE LINE
C
DCREASE DIRECTION
None
02/03/2022
PER BOM
D
RACK OD
1111057-NR074799A
AG JOB NR074799 RACK A
LIFTING POINTS
Racks are large, heavey mechanical equipment and must be handled as such.
A fully qualified and properly equipped crew with necessary rigging should be
engaged to set the Rack into position. Lifting lugs have been provided along
the base frame c-channels for attaching lifting slings. Spreader bars and lifting
slings should be sized and positioned so that the lifting forces are evenly and
and more vertically applied.
REFRIGERATION
Brantford, Ontario, Canada.
DRAWING. NUMBER SIZE
SHT of
CHANGE
SCALE
DATE
DRW. BY
APPR. BY MAT'L
PART NAME
ECO NO.
PRODUCT
BY LTRDATE
NATIONAL REFRIGERATION AND AIR
CONDITIONING PRODUCTS INC.
THIRD ANGLE PROJECTI ON
2. ALL DIM.'S ARE OUTSIDE DIM.'S UNLESS SPECIFIED
1. FOR STANDARD TOLERANCES REFE R TO DOCUMENT # EN-311
3. HEADER BODY ENDS ARE SEALED SHUT UNLESS SPECIFIED
4. BREAK DIRECTIONS ARE RELATIVE TO PAPER PLANE
SYMMETRICAL LINE
C
L
5. SYMBOLS
BREAK / CREASE LINE
C
DCREASE DIRECTION
None
02/03/2022
PER BOM
D
RACK OD
1111057-NR074799C
AG JOB NR074799 RACK B
LIFTING POINTS
Racks are large, heavey mechanical equipment and must be handled as such.
A fully qualified and properly equipped crew with necessary rigging should be
engaged to set the Rack into position. Lifting lugs have been provided along
the base frame c-channels for attaching lifting slings. Spreader bars and lifting
slings should be sized and positioned so that the lifting forces are evenly and
and more vertically applied.
REFRIGERATION
Brantford, Ontario, Canada.
DRAWING. NUMBER SIZE
SHT of
CHANGE
SCALE
DATE
DRW. BY
APPR. BY MAT'L
PART NAME
ECO NO.
PRODUCT
BY LTRDATE
NATIONAL REFRIGERATION AND AIR
CONDITIONING PRODUCTS INC.
THIRD ANGLE PROJECTION
2. ALL DIM.'S ARE OUTSIDE DIM.'S UNLESS SPECIFIED
1. FOR STANDARD TOLERANCES REFER T O DOCUMENT # EN-311
3. HEADER BODY ENDS ARE SEALED SHUT UNLE SS SPECIFIED
4. BREAK DIRECTIONS ARE RELATIVE TO PA PER PLANE
SYMMETRICAL LINE
C
L
5. SYMBOLS
BREAK / CREASE LINE
C
DCREASE DIRECTION
None
1
1
01/01/2007
D
For outdoor Racks, welded structural-steel lifting lugs have been provided in strategic locations along the base frames to allow
units to be lifted as level as possible. Attach lifting slings to the lifting lugs provided. Spreader bars must be used so that the
lifting forces are applied vertically and damage to the cabinet doesn’t occur. Spreader bars and lifting slings should be posi-
tioned so that the lifting forces are evenly and more vertically applied on the unit.
Indoor Racks, Trees and other indoor units aren’t provided with lifting lugs.
Strap lifting cables onto the top corners of the frame, and position the cables
so the lifting forces are evenly distributed across the unit.

K90-KPCS-IM-2 18/04/22
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The unit should be placed on a base, which is level and even.
Units should be lagged to sleepers or support base. Place unit
where it will not be subject to damage by trafc or ooding.
On critical installations where noise is liable to be transmitted
through the oor structure, vibration isolators should be installed.
Isolators should be installed under mounting base and spaced out
evenly to support the unit.
SPECIAL NOTE FOR LARGE PARALLEL RACK UNITS: Vibration
isolation pads should be put under the rack. Refer to the sketch
below for typical isolator locations.
DO NOT USE THE SHIPPING SKID (IF APPLICABLE) AS A
PERMANENT BASE.
The unit should be positioned to allow adequate space for per-
forming service work.
On units equipped with rigid mounted compressors, check the
compressor mounting bolts to insure they have not vibrated loose
during shipping.
VIBRATION ISOLATION
REFRIGERATION
Brantford, Ontario, Canada.
DRAWING. NUMBER SIZE
SHT of
CHANGE
SCALE
DATE
DRW. BY
APPR. BY MAT'L
PART NAME
ECO NO.
PRODUCT
BY LTRDATE
NATIONAL REFRIGERATION AND AIR
CONDITIONING PRODUCTS INC.
THIRD ANGLE PROJECTION
2. ALL DIM.'S ARE OUTSIDE DIM.'S UNLESS SPECIFIED
1. FOR STANDARD TOLERANCES REFER T O DOCUMENT # EN-311
3. HEADER BODY ENDS ARE SEALED SHUT UNLE SS SPECIFIED
4. BREAK DIRECTIONS ARE RELATIVE TO PA PER PLANE
SYMMETRICAL LINE
C
L
5. SYMBOLS
BREAK / CREASE LINE
C
DCREASE DIRECTION
None
1
1
01/01/2007
D
For Link+ units, heavy gauge welded lifting lugs have been provided in strategic locations along the base frames to allow units to be
lifted as level as possible. Use the lugs at the compressor end always, and nd the lugs toward the opposite end that allow for the
most level lift.
Spreader bars must be used when lifting so that lifting
forces are applied vertically and damage to the cabinet
and coil casing doesn’t occur.
Warning: under no circumstances should the
holes along the top edge of the condenser coil be
used to lift an entire unit (Damage to the unit will result).
In the rare circumstance that the condenser coil needs to be separated from the unit, the backer
plates can be removed from these holes and the coil section can be lifted off.
All heavy gauge side gussets must remain in place for any coil servicing removal.
HANDLING, PLACEMENT AND INSTALLATION (cont’d)

K90-KPCS-IM-2 18/04/22
- 5 -
VENTILATION REQUIREMENTS
INDOOR UNITS: If the unit is to be located in the machine room,
adequate ventilation air must be provided to avoid an excessive
temperature rise in the machine room. To allow for peak summer
temperatures a maximum rise of 10°F is recommended.
In case of compressors with remote condensers, approx. 10% of
the total heat rejected is given off by compressor and associated
piping. The correct formula for calculating the ventilation require-
ment for indoor parallel compressor unit is:
CFM =
The air intake should be positioned so that air passes over the
units. All State, Local and National codes should be followed.
This ventilation is only for the parallel compressor system. Ad-
ditional ventilation must be taken in to account after considering
other heat loads of the building.
10% of THR (BTU/HR)
10 (°F)
ELECTRICAL INFORMATION
All wiring and connections to the unit must be made in accordance with national as well as local electrical codes and by-laws.
WARNING
Electrical wiring should be sized in accordance with the minimum
circuit ampacity (MCA) shown on the unit nameplate and appli-
cable electrical codes. The unit power connections are approved
for copper wire only.
Connect the eld power supply through a properly sized branch
circuit protection disconnect switch. The entering service fuse
must not exceed the maximum overcurrent protection (MOP)
value on the unit data plate.
Field connected control circuit wires are terminated directly at the
control circuit terminal block in accordance with the appropriate
wiring diagram.
Voltage at the unit terminals must not vary more than the allow-
able variation during start-up and while under full load. If the volt-
age is normal at the supply with the compressor not running and
drops considerably when the switch is closed and the motor is
trying to start, there is a high resistance due to undersized wires
or faulty connections. Voltage drop between inoperative and full
load must not exceed 3% of line voltage. In addition, the phase
imbalance at the motor terminals should be within 2% on three
phase units.
Refer to the wiring diagrams shipped with the unit for wiring ar-
rangements.
60 Hz Supply
Power Allowable Variation
115-1-60 103-127 V
208/230-1-60 197-254 V
208/230-3-60 187-254 V
460-3-60 414-506 V
575-3-60 518-632 V
50 Hz Supply
Power Allowable Variation
100-1-50 90-110 V
200/220-1-50 190-242 V
200/220-3-50 180-242 V
380/400-3-50 342-440 V
Any deviation or change to the electrical components or wiring as supplied on the original equipment, or noncompliance with the volt-
age and phase balance requirements without written authorization will void the warranty.
WARNING

K90-KPCS-IM-2 18/04/22
- 6 -
Piping practice and line sizing charts as recommended by
A.S.H.R.A.E. or other reputable refrigeration standards must be
followed to ensure minimum pressure drop and correct oil return.
An inert gas such as dry nitrogen should be passed through the
piping during welding or brazing operations. This reduces or
eliminates oxidation of the copper and formation of scale inside
the piping. For specic piping requirements refer to your local
distributor or sales representative.
Correct line sizing is most critical because of the several factors
involved:
(a) Minimum pressure drop to ensure efcient
compressor performance.
(b) Sufcient gas velocity to maintain proper oil return
to the compressor under all load conditions.
(c) Elimination of conditions on multiple evaporators
whereby oil may log in an idle evaporator.
Suction Line: Suction lines should be sized on the basis of a
maximum total pressure drop equivalent to a 2°F (1.1°C) change
in saturated temperature. At 40°F (4.4°C) suction temperature,
this is approximately 3 psig (20.7 kPa) for R-22. At -20°F (-28.9°C)
suction temperature, this is approximately 1.3 psig (9.0 kPa) for
R-404A.
At the temperatures encountered in the condenser, receiver and
liquid line a certain amount of oil is always being circulated with
the refrigerant through the system by the compressor. However,
at the evaporator temperature, and with the refrigerant in a
vapor state, the oil and refrigerant separate. This oil can only be
returned to the compressor by gravity or by entrainment in the
suction gas. Roof installations leave no alternative but by entrain-
ment for oil return, so suction gas velocity and correct line sizing
to maintain this velocity are imperative. Care must be taken not to
oversize the suction line in the desire for maximum performance.
Gas velocity in vertical suction lines must not be less than 1,000
fpm (5 m/s) and preferably 1,250 to 1,500 fpm (6 to 8 m/s).
Important: A suction trap must be installed at the base of all
suction risers of four (4) feet or more in order to trap oil and allow
entrainment in the suction gas.
Appropriate line sizing practices must be used throughout the installation of the refrigeration system.
REFRIGERATION GRADE COPPER TUBING MUST BE USED FOR PIPING SYSTEMS.
IMPORTANT PIPING NOTE
All local codes must be observed in the installation of refrigerant piping.
WARNING
REFRIGERANT PIPING
TYPICAL SUCTION P-TRAP

K90-KPCS-IM-2 18/04/22
- 7 -
Refrigerant
Liquid Line Rise in Feet
10' 15' 20' 25' 30'
PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F
R134a 4.9 2.0 7.4 2.9 9.8 4.1 12.3 5.2 14.7 6.3
R22 4.8 1.6 7.3 2.3 9.7 3.1 12.1 3.8 14.5 4.7
R404A R507 4.1 1.1 6.1 1.6 8.2 2.1 10.2 2.7 12.2 3.3
R407AR407A R407C R448AR448A R449AR449A 4.3 1.4 6.5 2.1 8.7 2.8 10.8 3.5 12.8 4.1
Refrigerant
Liquid Line Rise in Feet
40' 50' 75' 100'
PSIG °F PSIG °F PSIG °F PSIG °F
R134a 19.7 8.8 24.6 11.0 36.8 17.0 49.1 23.7
R22 19.4 6.2 24.2 8.0 36.3 12.1 48.4 16.5
R404A R507 16.3 14.1 20.4 5.6 30.6 8.3 40.8 11.8
R407AR407A R407C R448AR448A R449AR449A 17.82 5.5 21.82 7 32.82 11 43.82 14
Based on 110°F liquid temperature at bottom of riser.
Pressure Loss of Liquid Refrigerant in Liquid Line Risers
If steps of capacity control are supplied on a compressor, provisions must be made for oil return by sizing suction risers to maintain
adequate gas velocities at reduced refrigerant ow.
IMPORTANT PIPING NOTE
REFRIGERANT PIPING (cont’d)
IMPORTANT: All suction lines outside of the refrigerated space
must be insulated.
During the lower capacity running mode (compressor capacity
control energized) oil will collect in the elbow or at U-bend below
pipe “B”. This will divert the gas and oil to ow up the smaller pipe
“A” at a higher velocity.
Liquid Line: Horizontal liquid lines should be sized on a basis of
a maximum pressure drop equivalent to a 2°F (1.1°C) drop in the
sub-cooling temperature. If the lines must travel up vertically then
adequate sub-cooling must be provided to overcome the vertical
liquid head pressures. A head of two feet of liquid refrigerant is
approximately equivalent to 1 psig (6.9 kPa). Liquid line velocities
should not exceed 300 fpm (1.52 m/s). This will prevent possible
liquid hammering when the solenoid valve closes
IMPORTANT: When brazing service valves or any components that may be damaged by heat, manufacturer’s installation instructions
must be followed. Wrapping components with a wet cloth will help to prevent damage from heat.

K90-KPCS-IM-2 18/04/22
- 8 -
SYSTEM ACCESSORIES
Some of the important components of a parallel compressor
system are as follows:
1. The Coalescent Type Oil Separator has an extremely ne and
efcient lter. This lters particles down to 0.3 microns in size,
which can easily pass through other lters and dryers in the sys-
tem. Because of this nature, the initial lter has a tendency to get
clogged quickly.
After an initial run of 24 to 48 hrs, the lter should be replaced
with a new one.
2. An Inlet Pressure Regulator and Outlet Pressure Regulator are
used for head pressure control under low ambient temperature
conditions.
3. (Optional) Oil Level Control is used to regulate oil ow back to
the compressor crankcase and maintain a minimum oil level. The
oil level control is adjustable between ½ sight glass and ¼ sight
glass. Do not adjust beyond 10 turns down from the top stop or the
control may be damaged.
In addition, the Oil Pressure Differential Valve is installed on the
oil feed line. The valve maintains the pressure of the oil to the
compressor crankcase at 10-25 psi higher than crankcase pres-
sure. Without the valve, the oil level control would overfeed the
compressor. The valve setting is adjusted at the factory (20 psi).
4. (Optional) OMB Electronic Oil Level Control is used to regu-
late oil ow back to the compressor crankcase and maintain a
minimum oil level. Offers alarm and status lights as well as safety
lockout features.
5. (Optional) Each compressor may have a Phase/Voltage Monitor
for protection against phase loss (single phasing), phase reversal
(improper sequence), high voltage and low voltage (brownouts).
6. (Optional) A microprocessor Refrigeration Controller controls
the refrigeration system including compressors and system
evaporators. Separate output relay boards are mounted on each
condenser (or at compressors) to control fan cycling and split
circuiting. Refrigeration controller may require eld program-
ming to perform major functions as per available data. All the set
points should be reviewed by customer and need to be reset as
per actual requirements. An optional modem could be provided.
7. (Optional) A Refrigerant Leak Detector (sniffer type) is recom-
mended. It may be mounted (or shipped separately) on the unit.
This leak detector can detect leaks in the machine room area
close to its sensor location. An IRLD (Infra Red Leak Detection
System) is recommended for higher sensitivity of leak detection.
When conventional leak detection methods are employed using HCFC or CFC tracer gas, all of the tracer gas must be reclaimed and
disposed of in a proper manner.
IMPORTANT ENVIRONMENTAL NOTE
A proper refrigerant leak detector must be employed and monitored at all times in the machine room where the parallel compressor
system is installed. An effective monitoring and quick response is necessary to avoid any prolonged leakage of refrigerant.
Manufacturer will not be responsible for any refrigerant loss and its environmental impact from the system.
IMPORTANT ENVIRONMENTAL NOTE / WARNING
LEAK TESTING
IMPORTANT: All system piping, including the parallel compressor
unit and accessories should be thoroughly tested for leaks
prior to start up and charging. The system should be initially
pressurized to a maximum of 150 psig (1136 kPa) with dry
nitrogen to ensure that the system is free of major leaks. With the
system free of major leaks, a more detailed leak check should be
performed. It is recommended that an electronic leak detector be
used when checking for leaks because of its greater sensitivity
to small leaks. As a further check it is recommended that this
pressure be held for a minimum of 12 hours and then rechecked.
Follow the recommendations of the leak detector manufacturer
for the procedure. The system must be leak free for satisfactory
operation.

K90-KPCS-IM-2 18/04/22
- 9 -
EVACUATION AND DEHYDRATION
When the system is completely free of refrigerant leaks, an
evacuation of the entire system should be completed by using a
“high vacuum” pump. This evacuation, if completed correctly, will
ensure long life for the system as well as elimination of moisture
and non-condensable gas problems. Moisture problems causing
compressor failure will void warranty. Follow the recommended
procedure carefully.
Use only a “high vacuum” pump capable of drawing a vacuum of
100 microns. Change the vacuum pump oil frequently. Gauges or
vacuum measuring instruments should be suitable to measure
conditions at any stage of the process in order to give the
operator indications of progress. For specic recommendations,
refer to the vacuum pump supplier for these instruments.
Copper jumper lines should be used to interconnect both high
and low-pressure sides of the system. These lines should be at
least 3/8” O.D. in order to handle the light density vapor at high
vacuum obtained at completion of operation. Lines smaller than
3/8” O.D. will slow down the process considerably as well as
make nal system vacuum questionable. Double evacuation with
a “sweeping” of dry nitrogen is recommended. First evacuation
should be to at least 1,500 micron. When this point is reached,
break the vacuum with refrigerant or dry nitrogen to melt any
moisture, which may have frozen during the rst vacuum stage.
Reclaim any tracer gas from the system and re-evacuate to a nal
vacuum of at least 500 microns. With this degree of evacuation,
all moisture and non-condensables should be removed from the
entire system.
Do not use the refrigeration compressor to evacuate the system. Never start the compressor or perform a megger insulation test while
the system is in a vacuum.
CAUTION

K90-KPCS-IM-2 18/04/22
- 10 -
LINE INSULATION
After the nal system leak test is complete, it is important that
all refrigerant lines exposed to high ambient conditions must be
insulated to reduce the heat pick-up and prevent the formation
of ash gas in the liquid lines. Suction lines should be insulated
with 3/4 inch wall insulation, Armstrong “Armaex” or equal.
To prevent rupture due to condensate re-freezing, all suction
vibration eliminators on low temperature systems MUST BE
COMPLETELY INSULATED. Liquid lines exposed to high ambient
temperatures should be insulated with 1/2 inch wall insulation
or better. Any insulation that is to be located in an outdoor
environment should be protected from UV exposure to prevent
deterioration of the insulating value.
REFRIGERANT CHARGING
Condensing units must be charged only with the refrigerant for
which they were designed. The type of refrigerant to be used is
specied on the name plate of the unit. Installing a liquid line
drier between the service gauge and the liquid service port when
charging a unit will ensure the refrigerant supplied to the system
is clean and dry. This is especially important when charging a
low temperature system. Blend type refrigerants (400 series,
i.e. R404A) must not be vapor charged unless the cylinder is
completely emptied into the system.
Weigh the refrigerant drum before and after charging in order to
keep an accurate record of the weight of refrigerant put into the
system.
Overcharging a system can result in poor system performance, personal injury and / or compressor damage. DO NOT charge strictly
by the holding capacity of the receiver. DO NOT assume that bubbles in a sight glass, when located at the condensing unit, indicates
the system is undercharged.
IMPORTANT REFRIGERANT CHARGING NOTE
Note: To estimate the total system requirement, refer to the
manufacturer’s evaporator and condensing unit specications on
typical operating charges and include the amount for the liquid
lines. Allow an extra 10% to 15% safety factor.
Break the vacuum by charging liquid refrigerant into the receiver
side only.
If charging to the “bubble” method (observing liquid line sight
glass), always use a sight glass located directly before the TXV
(thermostatic expansion valve) for the nal indicator.
On units that use an adjustable ooded condenser pressure-
regulating valve, the controls should be re-adjusted to the
following pressures:
185 psig (1377 kPa) for R-22
200 psig (1480 kPa) for R-404A
Refer to manufacturer’s installation instructions for further
details.

K90-KPCS-IM-2 18/04/22
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COMPRESSOR OILS
Check to see that the oil level is 1/8 to 1/3 up on the compressor
sight glass on compressors so equipped before starting the
compressor and after 15 to 20 minutes of operation.
CAUTION: Oil levels should not be allowed to go above the centre
or 1/2 of the sight glass. Excessive oil levels in the compressor
can result in excessive compressor noise, higher power
consumption or internal compressor damage.
DO NOT re-use drained oil that has been exposed to the
atmosphere.
DO NOT re-ll, at any one time more than a total of 110 % of the
compressor’s factory specied charge. Allow time for some of the
oil to circulate into the system.
R-12 R-22, R-502
Copeland Ultra 22CC
AAP
Mobil EAL ARTIC 22 CC A A P
ICI (Virginia KMP)
Emkarate RL 32CF
A A P
Thermal Zone 22CC A A P
Witco Suniso 3GS P P PM
Texaco Capella WF32 P P PM
Calumet RO15 (Witco) P P PM
Witco LP-200* P P
Penreco*
Sontex 200-LT
Shritene
P P
Copeland Ultra 200 A A PM
Shreve Zerol 200 TD A A PM
Soltex AB200A A A PM
Thermal Zone 200 A A PM
Shell 22-12 A A P
Witco R-195-0 A A P
Legend P = Preferred Lubricant Choice M = Mixture of Mineral Oil and AlkylBenzene
* BR, QR and Scroll A/C applications (AB) with 50 % AB.
NOT
ACCEPTABLE
POE's
A/B M/O
Mix
NOT
ACCEPTABLE
A = Acceptable Alternative
Refrigeration Oils - Copeland Semi-Hermetic Reciprocating Compressors
A/B
NOT
ACCEPTABLE
NOT
ACCEPTABLE
Mineral
Oils
Lubricant Type
Traditional Refrigerants
Interims
R-401A, R-401B, R402A,
R-408A, R409A (MP-39,
MP-66, HP-80, FX-10, FX-
56)
HFC's
R-134a, R-404A, R-
507, R-407C, R-
410A

K90-KPCS-IM-2 18/04/22
- 12 -
Bitzer Semi-Hermetic Reciprocating Compressors: 2KC-05.2(Y) to 6F-50.2(Y)
Lubricant Type
(H)CFC R22
Interim Blends
R-401A, R-401B, R-402A,
R-408A, R-409A,
(MP-39, MP-66,
HP-80, FX-10, FX56)
HFC's
R134a
R404A R507
R407AR407A R407C
R448AR448A R449AR449A
Polyol Ester
ICI (Virgina KMP) Emkarate RL32S A* P
Mobil EAL Arctic 32 A* P
Castrol Icematic SW32 A* P
Mineral Oils
Suniso 3GS A
Not Acceptable
Suniso 4GS A
Capella Oil WF32 A
Capella Oil WF68 A
Esso Zerice R68 A
Alkyl Benzene
Zerol 150 P
Not Acceptable
Zerol 300 P
Icematic 2284 P
Esso Zerice S46 P
Esso Zerice S68 P
A/B M/O
Mix
Shell Clavus SD 2212 P Not Acceptable
Esso Zerice R46 A
Legend: P = Preferred A= Acceptable Alternative
- Compressor with “Y” designation are factory charged with polyolester oil
* NOTE: When operating (H)CFC with ester oils the quantity of refrigerant dissolved in the oil is more than doubled as compared with
conventional lubricants. Special care should be taken. Refer to Bitzer Technical Bulletin KT-510-2, section 5 for additional information.
COMPRESSOR OILS (cont’d)
Refrigeration Oils--Carlyle Semi-Hermetic Reciprocating Compressors:
06D/E and 06CC
HFC's
R-134a, R-404A,
R-507, R-407C
Totaline P903-1001,1701 A
Castrol E68 A
ICI Emkerarate RL68H A
CPI CP-2916S A
CPI Solest 68 A
BP Marine Enersyn MP-S68 A
Witco Suniso 3GS A
Totaline P903-2001 A
Texaco Capella Oil WFI-32-150 A
IGI Cryol -150 A
Shrieve Zerol-150 A
A = Approved
Some restrictions may apply.For further information consult Carlyle factory or Carlyle web site.
Mineral/Alkyl
Benzene
Not Approved
Lubricant Type
(H)CFC R-22
Polyol Ester
Not Approved
Due to the extreme hygroscopic (moisture absorbing) characteristics of Polyol Ester (POE) oils, systems MUST NEVER be left open
to the atmosphere for any extended period of time. Simply pulling a deep vacuum on the system during the evacuation and dehydra-
tion procedure WILL NOT remove moisture that is absorbed into POE oils.

K90-KPCS-IM-2 18/04/22
- 13 -
SYSTEM START-UP CHECK LIST
Only a qualied refrigeration mechanic who is familiar with compressor performance and the function and adjustment of all controls
and components should start up the compressor. Finishing up work on the installations should be planned so that a qualied mechanic
IMPORTANT START-UP NOTE
Before any refrigeration system is started, the following items should be checked:
Before any refrigeration system is started, the following items should be checked:
(1) Check that the wiring diagrams, instructions, bulletins etc. are read and attached to the unit for future reference.
(2) Check that all electrical and refrigeration connections are tight.
(3) Check compressor crankcase oil level (if equipped with sight glass). It should be from 1/8 to 1/2 full in the sight glass.
(4) Ensure that compressor shipping spacers (spring mounted compressors) or hold down nut (solid mounted compressors are
properly in place.
(5) Check that the compressor discharge and suction shut-off valves are open.
(6) Ensure that the high and low pressure controls (see table below), pressure regulating valves, oil pressure safety controls and
any other safety controls are adjusted properly.
(7) Check all motors, fans and pump bearings in the condenser and evaporator. If they are the types that require oil or grease,
make sure that this is attended to in accordance with the tag, which will be attached. Fan blades and pumps should be checked
for correct rotation, tightness and alignment. Air should be drawn through the condenser (air cooled condensing unit models).
(8) Electric and hot gas evaporator fan motors should be temporarily wired for continuous operation until the room temperature
has stabilized.
(9) Observe the system pressures during the charging and initial operation process. DO NOT add oil while the system is low on
refrigerant charge unless the oil level is dangerously low.
(10) Continue to charge the system until it has enough charge for proper operation. DO NOT OVERCHARGE THE SYSTEM. Note that
bubbles in the sight glass may not necessarily mean a shortage of refrigerant. It could be caused by a restriction.
After the system is started, pay attention to the following:
(1) DO NOT leave the system unattended until the system has reached its normal operating condition and the oil charge has
properly adjusted itself to maintain the proper level in the sight glass.
(2) Compressor performance, and that of all of the moving components, should be watched carefully throughout the rst operating
cycle and then checked periodically during the rst day of operation.
Three phase scroll compressors must be checked for correct rotation. During the initial start up, observe the suction and discharge
gauges to ensure the suction pressure drops and the discharge pressure rises.
WARNING
Extreme care must be used when starting compressors for the rst time after the system has been charged. During this time liquid
refrigerant may have migrated to the compressor crankcase, creating a condition that could cause the compressor damage due to
slugging. Energizing a crankcase heater (if so equipped) 24 hours prior to start-up is recommended. If the compressor is not equipped
with a crankcase heater, directing a 500 watt heat lamp or other safe heat source on the lower shell or crankcase of the compressor
for approximately thirty minutes is recommended unless machine room is at above 65°F for at least 24 hrs prior to startup.
CAUTION

K90-KPCS-IM-2 18/04/22
- 14 -
Low Pressure Control Settings
Minimum
Temperature °F *
R134a R22 R404A R507 R407AR407A R407C
R448AR448A R449AR449A
Cut-in (PSIG) Cut-out
(PSIG) Cut-in (PSIG) Cut-out (PSIG) Cut-in (PSIG) Cut-out (PSIG)
Cut-in
(PSIG) Cut-out (PSIG)
50 35 5 70 20 85 30 65 20
40 25 5 55 20 70 30 50 20
30 17 5 40 20 50 30 35 20
20 12 0 30 10 40 20 25 5
10 7 0 20 0 30 10 15 0
0 5 0 15 0 20 5 10 0
-10 - - 15 0 15 0 10 0
-20 - - 10 0 10 0 7 0
-30 - - 10 0 6 0 7 0
* The coldest Temperature of either the xture or outdoor ambient.
High Pressure Control Settings
Refrigerant Maximum Cut-out (PSIG)
Air-Cooled Units Water Cooled Units
R134a 250 200
R22 350 315
R407AR407A R407C R448AR448A R449AR449A 400 315
LOW TEMPERATURE ROOM PULL-DOWN
It can take up to two weeks to properly start-up and pull-down a
large freezer. Large freezers should be pull-down to temperature
in stages. Too fast a pull-down can cause structural problems in
pre-fabricated rooms and will damage (crack) concrete oors.
Reduce room temperature by 10 to 15°F (5.6 to 8.4°C) per day.
Hold this temperature for 24 to 48 hours at 35°F (1.7 °C) and
again at 25°F (-3.9 °C). Monitor the amount of defrost water
during this pull down stage.
Once the room is pulled down to temperature, expect frost on the
compressor end bell and any exposed suction line. A lack of frost
in these areas probably indicates too high of suction superheat.
Reduce defrost frequency to 30 minutes every 6 hours if possible.
Adjust the defrost termination (and time clock) so that the coil
and drain pan are COMPLETELY free of frost / ice at termination.
Too short of a defrost cycle will allow residual ice to grow. Too
long of a defrost will allow the coil(s) to steam at the end of
the cycle. The steam will condense and freeze fans, fan guards
and create frosting on the ceiling of the room. The evaporator
fan delay must allow any condensate left on the coil surface to
refreeze before the fans start.
SYSTEM START-UP CHECK LIST (cont’d)

K90-KPCS-IM-2 18/04/22
- 15 -
CHECKING SUPERHEAT
To obtain maximum system capacity and insure trouble free operation it is necessary to check both the compressor and evaporator
superheat.
IMPORTANT SYSTEM BALANCING NOTE
Compressor suction superheat must be checked. To check the superheat at the compressor the following steps should be followed:
(1) Measure the suction pressure at the suction service valve of the compressor. Determine the saturated
temperature corresponding to this pressure from a “Pressure- Temperature” chart.
(2) Measure the suction temperature of the suction line about 6 inches (15 cm) back from the compressor suction
valve using an accurate thermometer.
(3) Subtract the saturated temperature (from step 1) from the actual suction line temperature (from step 2). This
difference is the actual superheat at the compressor.
System capacity decreases as the suction superheat increases. For maximum system capacity, the suction superheat should be kept
as low as is practical. The superheat at the compressor should range within 20 to 45 °F (11.2 to 25.2 °C) Superheat.
NOTE: Too low of a suction superheat can result in liquid being returned to the compressor. This can cause dilution of the oil and
eventually cause failure of the bearings and rings through wash out as well as liquid slugging.
NOTE: Too high of a suction superheat will cause excessive discharge temperatures which cause a break down of the oil and will result
in piston ring wear, piston and cylinder wall damage.
If adjustment to the suction superheat is required, it should be done either by adjusting the thermostatic expansion valve at the
evaporator, the use of liquid to suction heat exchanger or suitable use of suction line insulation.
Compressor Superheat
Once the refrigerated space is at its design temperature or close to design temperature, the evaporator superheat must be checked. To
check the suction superheat at the evaporator the following steps should be followed:
(1) Measure the suction pressure in the suction line at the bulb location by either,
(a) A gauge in the external equalizer line will indicate the pressure directly and accurately.
(b) A gauge directly in the suction line near the evaporator or directly in the suction header will sufce.
(2) Measure the temperature of the suction line at the point where the thermostatic expansion valve bulb is
clamped to the suction line.
(3) Convert the pressure obtained in step 1 above to a saturated evaporator temperature from a “Pressure-
Temperature” chart.
(4) Subtract the saturated temperature (from step 1) from the actual suction line temperature (from step 2). This
difference is the actual superheat at the evaporator.
The superheat at the evaporator should be a minimum of 6 to 10 °F (3.4 to 5.6 °C) for systems with a 10 °F (5.6 °C) design TD
(temperature difference) to a maximum of 12 to 15 °F (6.7 to 8.4 °C) for systems with a higher operating TD.
Low temperature applications (freezers) should be set at superheats of 4 to 6 °F (2.2 to 3.4 °C).
TD = Box temperature – evaporating temperature.
Evaporator Superheat

K90-KPCS-IM-2 18/04/22
- 16 -
When the system has been running trouble free for an extended time (two weeks or more) and design conditions are satised, the
following check list should be followed:
(1) Check that compressor discharge and suction pressures are operating within the allowable design limits for the
compressor. If not, take the necessary corrective action.
(2) Check the liquid line sight glass and expansion valve operation. If there is an indication that the system is low on
refrigerant, thoroughly check the system for leaks before adding refrigerant.
(3) Check the level of the oil in the compressor sight glass (if so equipped). Add oil as necessary.
(4) The thermostatic expansion valve must be checked for proper superheat settings. The sensing bulb must have
positive contact with the suction line and should be insulated. Valves operating at a high superheat setting results
in low refrigeration capacity. Low superheat settings can cause liquid slugging and compressor bearing washout.
(Refer to the section on compressor and evaporator superheats)
(5) Check the voltage and amperage readings at the compressor terminals. Voltage reading must be within the
recommended guidelines. Normal operating amperages can be much lower than the compressor nameplate
values.
(6) To check the high pressure control setting it is necessary to build up the head pressure to the cut-out point of
the control. This can be done by stopping the condenser fan(s) (air cooled condensing units) or pump and
watching the pressure rise on a high pressure gauge to make sure the high pressure control is operating at the
setting.
(7) Check the low pressure settings by throttling the compressor shut-off valve and allowing the compressor to
pump down. This operation must be done with extreme caution to avoid too sudden a reduction in crankcase
pressure, which will cause oil slugging and possible damage to the compressor valves. Close the valve a turn a
a time while watching the compound gauge for change and allowing time for the crankcase pressure to equalize
with the pressure control bellows pressure. The slower the pressure is reduced, the more accurate will be the
check on the pressure control setting.
(8) Recheck all safety and operating controls for proper operation and adjust as necessary.
(9) Check defrost controls for initiation and termination settings, and the length of defrost period. Set the fail
safe on the time clock at the length of defrost plus 25 %.
(10) If the system is equipped with winter head pressure controls (fan cycling or ooded valves), check for operation.
(11) Fill in the Service Log in the back of this Installation Manual.
SYSTEM OPERATIONAL CHECK LIST

K90-KPCS-IM-2 18/04/22
- 17 -
The following System Troubleshooting Guide lists the most common types of malfunctions encountered with refrigeration systems.
These simple troubleshooting techniques can save time and money minimizing unnecessary downtime and end-user dissatisfaction.
Contact the factory or your local sales representative for further information or assistance.
SYSTEM TROUBLESHOOTING
System Troubleshooting Guide
Condensing Unit Problem Possible Causes
Compressor will not run. Does not try to start. 1. Main power switch open.
2. Fuse blown or tripped circuit breaker.
3. Thermal overloads tripped.
4. Defective contactor or coil.
5. System shut down by safety devices.
6. Open thermostat or control. No cooling required.
7. Liquid line solenoid will not open.
8. Loose wiring.
Compressor hums, but will not start. 1. Improperly wired.
2. Low line voltage.
3. Loose wiring.
4. Defective start or run capacitor.
5. Defective start relay.
6. Motor windings damaged.
7. Internal compressor mechanical damage.
Compressor starts, but trips on overload protector. 1. Improperly wired.
2. Low line voltage.
3. Loose wiring.
4. Defective start or run capacitor.
5. Defective start relay.
6. Excessive suction or discharge pressure.
7. Tight bearings or mechanical damage in compressor.
8. Defective overload protector.
9. Motor windings damaged.
10.Overcharged system.
11.Shortage of refrigerant.
12.Suction or discharge pressure too high.
13.Inadequate ventilation.
14.Operating system beyond design conditions.
Compressor short cycles. 1.Low pressure control differential set too low.
2.Shortage of refrigerant.
3.Low airow at evaporator(s).
4.Discharge pressure too high.
5.Compressor internal discharge valves leaking.
6.Incorrect unit selection (oversized).
Contact welded stuck 1.Short cycling.
Compressor noisy or vibrating. 1.Flood back of refrigerant.
2.Improper piping support on the suction or discharge lines.
3.Broken or worn internal compressor parts.
4.Incorrect oil level.
5.Scroll compressor rotating in reverse (three phase).
6.Improper mounting on unit base.
Continues on next page >>>

K90-KPCS-IM-2 18/04/22
- 18 -
System Troubleshooting Guide Continued
Condensing Unit Problem Possible Causes
Discharge pressure too high. 1.Non-condensables in the system.
2.System overcharged with refrigerant.
3.Discharge service valve partially closed.
4.Condenser fan not running.
5.Dirty condenser coil.(air-cooled condensers)
6.Dirty tubes. .(water-cooled condensers)
7.Defective or improperly set water regulating valve.
(water-cooled condensers)
8.Defective or improperly set ooded head pressure control.
Discharge pressure too low. 1.Low suction pressure.
2.Cold ambient air.
3.Suction service valve partially closed.
4.Shortage of refrigerant.
5.Defective or improperly set water regulating valve.
(water-cooled condensers)
6.Defective or improperly set ooded head pressure control.
Suction pressure too high. 1.Excessive load.
2.Compressor internal valves broken.
3.Incorrect unit selection (undersized).
4.Improper TXV bulb charge.
Suction pressure too low. 1.Shortage of refrigerant.
2.Evaporator dirty or iced up.
3.Clogged liquid line lter drier.
4.Clogged suction line lter or compressor suction strainers.
5.Expansion valve malfunctioning.
6.Condensing temperature too low.
7.Improper TX valve selection.
8.Evaporator distributor feed problems.
Low or no oil pressure. 1.Low oil level. (trapped oil in evaporator or suction line)
2.Clogged suction oil strainer.
3.Excessive liquid refrigerant in the crankcase.
4.Worn oil pump.
5.Oil pump reversing gear sticking in the wrong position.
6.Worn bearings.
7.Loose tting on oil line.
8.Pump housing gasket leaking.
Compressor loses oil. 1.Refrigerant leak.
2.Short cycling.
3.Excessive compressor ring blowby.
4.Refrigerant ood back.
5.Improper piping or traps.
6.Trapped oil in evaporator.
Compressor runs continuously 1.Excessive load.
2.Too low of a system thermostat setting or defective thermostat.
3.Shortage of refrigerant.
4.Leaking compressor internal valves.
5.Malfunctioning liquid line solenoid.
6.Incorrect unit selection (undersized).
SYSTEM TROUBLESHOOTING (cont’d)
Continues on next page >>>

K90-KPCS-IM-2 18/04/22
- 19 -
System Troubleshooting Guide Continued
Condensing Unit Problem Possible Causes
Room temperature too high. 1.Defective room thermostat or improper differential / setting.
2.Malfunctioning liquid line solenoid valve.
3.Insufcient air across evaporator coil (iced up coil, product
blocking evaporator, fan blade / motor problem).
4.Improper evaporator superheat (low refrigerant charge,
plugged TXV strainer, poor TXV bulb contact, incorrect
TXV setting).
5.Malfunctioning condensing unit.
Room temperature too low. 1.Defective room thermostat or improper differential / setting.
2.Malfunctioning liquid line solenoid valve.
Ice accumulating on ceiling. 1.Defrost on too long (improper setting / defective termination
thermostat, improper setting / defective time clock).
2.Too many defrosts per day.
3.Fans not delayed after defrost (improper setting / defective
fan delay thermostat).
Evaporator coil not clear of ice after defrost. 1.Defrost on too short (improper setting / defective
termination thermostat, improper setting / defective time clock).
2.Electric heaters defective / miswired / low voltage.
3.Not enough defrosts per day.
4.Air defrost evaporator operating at too low of temperature
(require electric defrost).
5.Defective / miswired interlock at compressor contactor.
6.Defective defrost contactor or coil.
Ice building up in drain pan. 1.Improper slope in pan.
2.Blocked drain line (unheated , not insulated).
3.Electric heater in drain pan defective / miswired / low voltage).
4.Not enough defrosts per day.
5.Lack of or improper P-trap in drain line.
Evaporator fans will not operate. 1.Main power switch open.
2.Fuse blown or tripped circuit breaker.
3.Defective contactor or coil.
4.Room temperature too high (fan delay thermostat open).
5.Fan delay thermostat improper setting / defective.
6.Defective fan motor (low voltage / tripped on thermal overload).
7.Defective time clock.
8.Normal mode during defrost cycle (electric defrost type evaporator).
SYSTEM TROUBLESHOOTING (cont’d)
Before any components are changed on the refrigeration system, the cause of the failure must be identied. Further problems will exist
unless the true cause or problem is identied and corrected.
IMPORTANT TROUBLESHOOTING NOTE

K90-KPCS-IM-2 18/04/22
- 20 -
Completely ll in System Start-Up Worksheets located at the back
of this Installation and Maintenance Manual. This document
should be left with the equipment for future reference.
Give the owner / end user instructions on normal operation
of the system. Explain electrical characteristics, location of
disconnect switches as well as other safety precautions. Advise
on keeping equipment area clean and free of debris. If system
has operational features, point these out to the operator.
CUSTOMER INSTRUCTIONS
In order to ensure that the refrigeration system runs trouble free for many years, a follow-up maintenance program (consisting of a
minimum of two inspections per year) should be set up. A qualied refrigeration service mechanic should carry out this semi-annual
inspection. The main power supply must be disconnected and locked off to avoid accidental start up of the equipment.
(1) Check electrical components and tighten any loose connections.
(2) Check all wiring and electrical insulators.
(3) Check contactors to ensure proper operation and contact point for wear.
(4) Check that fan motors (if applicable) are operational, ensure fan blades are tight and all mounting bolts are tight.
(5) Check oil and refrigerant levels in the system.
(6) Ensure that the condenser surface (if applicable) is cleaned and free of dirt and debris.
(7) Check the operation of the control system. Make certain that all of the safety controls are operational and
functioning properly.
(8) Check all refrigeration piping. Make sure that all mechanical joints and are nuts are tight.
MAINTENANCE PROGRAM
Genuine replacement service parts should be used whenever
possible. Refer to the Service Parts List on the back cover of this
Installation and Maintenance Manual or attached to the unit.
Parts may be obtained by contacting your local sales
representative or authorized distributor.
SERVICE PARTS AVAILABILITY