INSTALLATION, OPERATION AND MAINTENANCE MANUAL

INSTALLATION,

OPERATION AND

MAINTENANCE

MANUAL

Publication No. IOM 108.2

February, 2007

TABLE OF CONTENTS

INSPECTION

INSTALLATION

LOCATING CONDENSING UNITS

LOCATING UNIT COOLERS

UNIT COOLER MINIMUM DISTANCES

FIELD WIRING

REFRIGERANT PIPING

LEAK TESTING

EVACUATION

CHARGING & START-UP

GENERAL MAINTENANCE

TYPICAL FIELD WIRING DIAGRAMS

HIGH SIERRA SEQUENCE OF OPERATIONS

TROUBLE SHOOTING GUIDE

REPLACEMENT PARTS

PAGE

2

6

6

7

5

5

2

3

4

7

8

9

11-12

13-16

221 S. BERRY ST., BREA, CA. 92821 TEL (714) 529-1935 www.russellcoil.com

FAX (714) 529-7203

INSPECTION

When the equipment is received, check the quantity of cartons and crates against the bill of lading.

· Inspect all containers for visible damage.

· Report any damage or shortages to the freight company immediately.

· It is the customer's responsibility to file a freight claim.

· Check the unit name plates to verify that the voltage and phase is correct before installation.

Installation and maintenance should be performed by qualified personnel who are familiar with local codes and regulations. Installers should have previous experience with this type of equipment.

CAUTION: Avoid contact with sharp edges and coil surfaces.

INSTALLATION

LOCATING CONDENSING UNITS

Condensing unit - Minimum clearances

Drawing 1

Discharge air

A

B

CONDENSING UNIT

Intake air

C

Table 1

Minimum

HP Dimensions (in)

A B C

1/2 - 2 60 24 36

3 - 6 72 24 36

8 - 15 72 30 48

20 - 40 48 48 48

B

PLAN VIEW

Do not locate condensing units so that they are bordered on three or more sides by tall obstructions. Condensing units should be positioned so that the airflow through the condenser is the same as the prevailing winds. If strong variable winds are common, a wind deflector should be used on the discharge side of the unit. Be certain that there is adequate room around the unit for regular inspection and service. For multiple unit sites, do not locate units where the air discharge from one condensing unit will enter into the air intake of other units.

Roof mounted condensing units should be located above supporting walls, over storage areas or spaces not sensitive to noise or vibration. They must be adequately supported.

Pad mounted condensing units should be installed a minimum of 4 inches above ground level, away from windows, doors and other areas where noise may be a problem. All units must be level when mounted.

2

CONDENSING UNIT INSTALLATION (continued.)

Condensing units with spring mounted compressors are shipped with retainers under the compressor feet to prevent damage during shipment. For Copeland H and K body compressors, remove the retainers and loosen the mounting nut to allow 1/16” clearance between the nut and rubber spacer. For 3HP and larger units, the mounting nuts must be removed to insert the rubber spacer. Insert the rubber spacer over the mounting studs, replace the nut and tighten to within 1/16” of the spacer. DO NOT TIGHTEN THE NUTS

AGAINST THE SPACER OR FOOT.

Units with iso-pad mounted compressors are shipped with the mounting nuts tight. These should be checked to make certain that they have not loosened during shipment.

LOCATING AND MOUNTING UNIT COOLERS

Determine the best location for the unit in the walk-in cooler or freezer. Consider the air pattern required to cover the entire space. For High Sierra Systems with two unit coolers, locate the unit coolers so that the piping runs from the suction and liquid line tees are equal in size and length.

Do not restrict the inlet or outlet air stream. Place the unit cooler as far as possible from

any door openings. Direct the discharge air stream towards the door whenever possible.

This will help to prevent warm, moist air from being drawn into the coil (Drawings 2, 3 and

Table 2). Adequate clearances should be maintained around the unit cooler to allow for proper airflow through the unit and for regular maintenance and service to be preformed.

For all Hot Gas defrost unit coolers, ensure that the drain pan is in contact with the Hot Gas drain pan loop after installation. If the drain pan is removed for any reason, verify that it has

physical contact with the defrost loop when replaced.

The drain line should be pitched a minimum of 4" per foot to allow proper drainage and should exit the room as quickly as possible. Do not reduce the drain line size. Do not locate line bends, elbows or drain traps within the refrigerated space. All drain lines must be

trapped outside of the enclosure where the temperature is never below 35 degrees. Drain lines should run to an open drain and should never be attached directly to a sewage or waste line. Drain lines must be protected from possible freezing. Freezer units must have copper drain lines that are heated and insulated.

Remove all packaging materials before lifting the unit into position. Be certain that the unit is not sitting on the drain fitting or refrigerant connections. All-Temp units should be hung using

5/16" minimum diameter, stainless steel support rods or fasteners at all hanging slots. Use minimum 3/8" hanger rods for Inter-Temp and Ultra-Temp models.

Tighten all fasteners securely. All units must be positioned level, flush with the ceiling and all gaps must be properly caulked. Allow minimum clearances on all sides of the unit cooler(s) as indicated in Table 2 (next page).

3

Recommended Minimum Dimensions

Table 2

Unit cooler

Height

Air intake* Side clearance clearance

H

15

19

1 x H

15

19

1 x H

15

19

25

32

50

25

32

50

25

32

50

* Absolute minimum Distance

** 15’ is adequate clearance for these models

Dimensions are in inches.

Air discharge Unit to clearance

2 x H floor

5 x H

30

38

75

95

50

64

100

125

160

180**

Drawing 2 obstruction free area

Air H*

5 x H* 12" min.

door

Slope Drain line 4" per foot and trap.

Drawing 3

H*

H*

Back Wall

2 x H* H*

Alternate

Door

Location

5 x H*

Keep air discharge area free from obstruction

Door

4

Air

Discharge

Front Wall

Alternate

Door

Location

FIELD WIRING

All field wiring must be done in compliance with local and national electrical codes. Use only properly sized Copper conductors. A system wiring diagram is located inside the condensing unit control box. Wire components as indicated on the diagram. The equipment nameplates are marked with electrical characteristics. All field wiring should enter the equipment through electrical conduit bushings. Note: All units must be grounded.

Before applying power to the units, check all connections to ensure they have not come loose during shipment. Be certain that the power is disconnected before tightening any electrical

connections. Disconnect switches and evaporator branch circuit protection are supplied by the equipment installer and must conform to governing electrical codes. Air defrost systems are wired so that the evaporator fans run continuously. For electric defrost and High Sierra systems, the evaporator fans are cycled off during the defrost and re-cooling period.

Electric defrost unit coolers are supplied with a temperature sensing defrost termination switch that will end the defrost at a preset coil temperature. (Recommended time clock settings for electric defrost are 2 defrosts per day, with a twenty minute fail safe setting. Adjust according to job site conditions. Fewest possible defrosts for the shortest possible duration are desirable.)

A high limit control is provided to prevent overheating if there is a component failure. A fan delay control is installed to allow the water condensate on the fins to freeze before the evaporator fan motors start. A pumpdown cycle is mandatory for all systems.

For both Sierra and High Sierra systems, a liquid line solenoid is factory installed and wired to each unit cooler terminal board (multiple evap systems receive multiple solenoid valves). Follow the system wiring diagram (provided in the condensing unit). Connection to TB1-44 must be made to assure proper pumpdown function. The room thermostat is mounted on the unit cooler for single evaporator systems and supplied loose for multiple evaporator systems. Follow the system wiring diagram supplied in the condensing unit.

REFRIGERANT PIPING

Condensing units and unit coolers are thoroughly cleaned and dehydrated at the factory. Use only ACR (refrigeration grade) tubing that is dehydrated and sealed. Only use WROT Copper fittings, cast fittings are a source of refrigerant leaks. All liquid and suction elbows must be long radius types for minimum pressure drop. Refrigerant lines must be properly supported to prevent vibration and breakage. Tube clamps should have a gasketed liner to prevent abrasion of the tubing. Sierra and High Sierra must not exceed more then a 100’ refrigerant line run.

Install all piping and components in accordance with local and national codes. Make refrigerant connections by using only hard or Silver bearing solder such as Silfos, Stay-Silv or higher Silver content brazing material. Slowly purge dry nitrogen through the tubing while brazing to prevent the formation of Copper oxide scale.

LIQUID LINE

Refer to the current ASHRAE Refrigeration Systems and Applications Handbook for assistance in determining appropriate liquid line sizes.

Horizontal and vertical liquid lines are normally the same diameter. However, pressure loss due to vertical lift may lead to flash gas that can inhibit proper TXV (and system) performance if not properly accounted for. Under sizing the liquid line can result in flash gas while over sizing the liquid line will unnecessarily increase the system charge requirement.

Sierra and High Sierra condensing units include Russell’s patented finned receiver ® , which is integrated into the air-cooled condenser. This finned receiver ® also acts as an efficient liquid sub-cooler. An additional liquid to suction heat exchanger is not normally required. The liquid line must be insulated to obtain the maximum benefits of the subcooled liquid.

5

SUCTION LINES

The suction line and it’s components must be carefully selected and installed. The suction line must be sized to maintain a balance of adequate refrigerant velocity, to allow for good oil return, and a low pressure drop that will prevent excessive capacity loss. The optimal line size will result in a reasonable refrigerant velocity and a minimum pressure drop. Total suction line pressure loss should not exceed 2 o F equivalent loss. For best system performance, the suction line should be insulated.

Suction line risers should be no larger in diameter than the horizontal pipe run. Refer to the current ASHRAE Refrigeration Systems and Applications Handbook for correct suction line and riser sizing. Horizontal suction line runs should slope in the direction of flow, 1 inch per ten feet of length. All suction lines should be insulated as soon as they exit the refrigerated space. Install a 1/4-inch schrader fitting near the evaporator outlet to assist in accurate superheat readings. All suction line risers should be trapped to facilitate oil return. Additional

P-Traps are required for every 15 feet of elevation. Oil traps should be the same diameter as the suction line riser that it attaches to.

MULTIPLE EVAPORATOR PIPING

High Sierra systems involving multiple evaporators require that piping runs be of equal length to each evaporator. The line runs must be of equivelent length from the bull-head tees to each unit cooler. This will ensure proper distributon of hot gas to each unit cooler during the defrost cycle. Reference the drawing below for further clarification.

Evaporator

TXV

Liquid

Sol. Valve

Check

Valves

Drain Pan Circuit

Evaporator

Check Valve

TXV

Liquid

Sol. Valve

Check

Valves

Drain Pan Circuit

Check Valve

Condensing Unit

Fan Cyle

Control

Set: 90c.i.

60c.o.

Reversing

Valve

Power

Supply

Insulation

Compressor

Bi-Flow

Liquid Filter

Liquid

Shutoff

Valve

Suction Filter

Size For Total System Capacity

Size for one evaporator capacity.

Must be equal length or equivelent pressure drop.

Tee must be oriented to split hot gas defrost.

Defrost

Termination

Set: 250c.i.

200c.o.

Check

Valve

Relief

Valve

TXV

Sight

Glass

Condenser Coil

LEAK TESTING

After all refrigerant connections are made, add the proper system refrigerant until the pressure is 25 to 35 PSI. Then pressurize with dry nitrogen up to 120 PSI. Always use a pressure reducing regulator. Wait 30 minutes for the refrigerant to reach all parts of the system. Use an electronic leak detector to inspect all connections and system components. Repair any leaks that are found and re-check until all leaks are eliminated. Leave the system pressurized over night. Once the system is tight, it must be evacuated before charging.

6

EVACUATION

Proper installation procedures must include a deep evacuation of the system. A clean/dry system is essential when charging refrigerant. Open all service valves. The high vacuum method is the most effective procedure for assuring a clean and dry system. It requires the use of a two-stage high vacuum pump, an electronic high-vacuum gauge and 3/8" minimum

OD copper tubing. Use a high vacuum sealant on all lines and connections. Clean and dry

DEEP VACUUM OIL is essential for proper system evacuation.

This step is required FOR SIERRA/HIGH SIERRA SYSTEMS:

Evacuation access fitting:

AREA 1: From the compressor service valve (including the compressor head) through the condenser up to the liquid line module; Connecting to the port on the compressor discharge valve gets this area.

AREA 2: From the liquid line module to the liquid line solenoid; connecting to the liquid line “King” valve port gets this area on Sierra system. The connection will not properly evacuate area 1, above, since evacuation would have to be pulled through the check valve in the module, which will have about 1 PSI restriction. However, on High Sierra systems a pressure tap at the connection for the terminator pressure control evacuates the liquid line since this connection is downstream of the module.

AREA 3 : From the liquid line solenoid to the compressor (including the crankcase) connecting to the suction service port gets this area.

The need for this clarification has arisen from the fact that some systems have experienced high head pressure because non-condensables were left in the system when these procedures were not followed.

All systems - continued

Connect the vacuum lines to both the high and low-pressure sides of the system. Run the vacuum pump until the gauge reaches 500 microns for newly installed systems. With the pump still running, shut off the high vacuum line valve. The vacuum gauge should not exceed

(1500 microns or less ) after two minutes once the pump is closed off, though the pressure will increase slightly even on the most leak-free system. Open the compressor service valves and pull a continuous vacuum for a minimum of 4 hours. Pulling the vacuum overnight is highly recommended (mandatory for 5 HP systems and larger). Do not allow the system to stand at high vacuum without the vacuum pump operating. Do not start the compressor while the system is under a vacuum.

CHARGING

Both Sierra and High Sierra systems are designed to operate with minimum refrigerant charge and minimum head pressures. - Low head pressures are normal at low ambient conditions.

Make the charging line connection with a hose that is purged of air, through a filter drier.

Break the vacuum with the proper system refrigerant. Charge liquid refrigerant into the high side of the system. This should enable the system to operate. Add refrigerant charge as necessary to achieve a clear sight glass with the system close to normal operating condition, whether it is winter or summer. Ambient temperature is not relevant to the charging procedure.

IMPORTANT! Sierra and High Sierra systems are critical charge systems.

Be careful, DO NOT OVERCHARGE!

7

CHARGING continuation...

Refrigerant can be added most rapidly by introducing liquid directly into the liquid line down stream of the liquid line valve. Close the liquid line intermittently and add refrigerant directly into the port on the side of the liquid line valve until the sight glass is clear.

NOTE: Some new refrigerants require liquid charging only.

Be extra diligent not to log liquid in the accumulator, if one is present in the system. An accumulator is not recommended for Sierra or High Sierra systems. They can negatively impact the charging procedure of these systems. Liquid build-up in the accumulator may result from improper charging. Once in the accumulator the refrigerant returns very slowly.

Depending on how much is accumulated, how much frost is on the accumulator (frost acts as an insulator so the refrigerant boils off slower), ambient temperature, etc..., this excess refrigerant can cause significant problems.

START UP

Install gauges on the system to check both high and low pressures. Using the gauges, verify that the low-pressure control is properly set (3 PSI cut out, 15 PSI cut in).

Pump down the system by closing the liquid line solenoid and the service valve to verify that there is no objectionable increase in head pressure.

Be certain that the fan cycling control is properly adjusted. At the correct setting the cut-out setting should be 30 PSI above the design suction pressure. The cut-in setting should be 30

PSI above the cut out pressure.

THIS STEP IS REQUIRED FOR HIGH SIERRA ONLY

Move the high side gauge to the defrost termination schrader valve on the suction line and start a defrost cycle. Verify that the defrost terminates at 250 PSI, adjust the termination control if necessary. Set the time clock defrost fail-safe to

A MAXIMUM OF 10 MINUTES

and an initial setting of 2 defrosts per day.

Check the evaporator superheat after the system has run long enough to reach a balanced state. Low temperature systems normally operate most efficiently at a superheat settings that range from 6 to 8 degrees at design room temperature. Medium temperature rooms normally operate from 8 to 10 degree evaporator superheat. Adjust expansion valves only if necessary.

GENERAL MAINTENANCE

Disconnect all electrical power to the unit before inspecting or cleaning. Unit coolers and condensing units should be checked periodically and cleaned of all dirt or grease accumulation.

Fan blades and guards may require more frequent cleaning. Remove debris from the condenser coil using a brush or vacuum cleaner. All fan motors are life lubricated and do not require periodic oiling. Do not use ammonia or other cleaning agents that are corrosive or react with Copper or Aluminum.

If the liquid line filter is replaced High Sierra system, it must be replaced with a Bi-Flow filter.

8

TYPICAL FIELD WIRING DIAGRAMS

HIGH SIERRA COUNTER FLOW DEFROST

Condensing unit Condensing unit

Legend (all diagrams)

— — Field wiring

TB1 - Terminal block # 1

TB2 - Terminal block # 2

C6 - Heater contactor

LLS - Liquid line solenoid

EF - Evaporator fan motor(s)

T’stat - Room thermostat

DT - Defrost Termination

FD - Fan Delay Control

Single unit cooler

1 Phase motor(s)

SIERRA SYSTEMS

Condensing unit

2 unit coolers

1 Phase motors

Condensing unit

Air Defrost

Systems

Condensing unit

Electric Defrost

Single unit cooler

1 phase motors

1 phase heaters

Condensing unit

Electric Defrost

Single unit cooler

1 phase motors

3 phase heaters

*See page 5 for wiring instructions.

9

Electric Defrost

Two unit coolers

1 phase motors

1 phase heaters

HIGH SIERRA - Sequence of operation.

Refrigeration cycle

The High Sierra counter flow defrost system is unique in design. It operates like most conventional systems during the refrigeration cycle. As cooling is called for, the compressor, condenser fan(s), evaporator fans and liquid line solenoid valve are all energized.

Refrigerant vapor exits the compressor discharge port, moves through the High Sierra reversing valve and into the air-cooled condenser. As ambient air flows through the condenser, the refrigerant vapor gives up it's heat, becomes liquid and moves through the patented Sierra Finned

Receiver ® and liquid sub-cooler.

The sub-cooled liquid refrigerant exits the sub-cooler, passing through the High Sierra check valve

/ TXV valve assembly, leaving the condensing unit via a bi-flow liquid filter.

The liquid refrigerant enters the evaporator, flowing through a factory mounted solenoid valve. It passes through the expansion valve to be boiled off in the coil, providing cooling for the box. The vaporized refrigerant returns through the suction line, the reversing valve and suction filter into the compressor suction port.

As with any normal pump-down system, when the room temperature satisfies the thermostat, it deenergizes the liquid line solenoid, causing the system to pump down and cycle off.

Counter flow defrost cycle

The defrost timer initiates the counter flow defrost cycle. The number of defrost cycles is set by the installer. (The recommended frequency is one to two defrosts per day with the fail safe override set at 10 minutes. A normal defrost cycle lasts from 3 to 7 minutes.)

Upon the signal from the defrost timer, the reversing valve switches modes and the evaporator fan motors are turned off. The liquid line solenoid remains energized.

The direction of refrigerant flow is now reversed, as are the functions of the evaporator and condenser. The reversing valve diverts the compressor discharge through, what was formerly the suction line, back towards the evaporator. A suction line check valve, (factory mounted), routes the discharge gas through the evaporator drain pan circuit and into the coil tubes, thus providing the heat source for the counter flow defrost.

The evaporator, now acting as the condenser, converts the discharge gas into liquid, releasing large amounts of heat, defrosting the coil(s) very quickly.

The liquid refrigerant then exits the coil through the distributor, and the factory mounted TXV bypass check valve. It moves through the liquid line, the bi-flow liquid filter, through the condenser

TX valve and into the system condenser (now acting as the evaporator). The liquid refrigerant is then boiled off and returned to the compressor as suction gas, passing first through the reversing valve and suction filter.

The defrost cycle is ended when the system pressure reaches the termination point at the defrost control (located in the condensing unit). The installer must verify that the coil clears completely of

all frost and ice. If the defrost cycle terminates before all frost has been completely removed from the coil, the defrost termination pressure control setting may be increased incrementally until the coil defrosts properly (maximum setting 300 psi). The recommended defrost termination setting is

250 psi with a 50 psi differential.

10

Counterflow defrost cycle - continued

After the refrigeration cycle resumes, the evaporator fan motors remain off during the cool down period (never less than two minutes). This allows all condensate to drain before the fan motors are energized, thus preventing water from blowing off the coil and into the room.

Notes:

1. The condensing unit pressure relief valve is provided to regulate potential excessive pressures that may develop in the liquid line during extended shut down periods. It does not come into play during the refrigeration or defrost cycles.

2. The condensing unit TX valve is factory set and should not be field adjusted.

3. The evaporator fan delay control is located in the condensing unit control panel.

High Sierra Piping

Diagram 4

Diagram 5

11

Typical High Sierra replacement parts- Low Temp. Models*

Comp. Cond. Unit Rev. Valve Strainer Cond. Unit Liquid Filter Condenser Low Pres.

High Pres.

Fan Cycle

Type Model No.

PART# PART#

RHH100L44 21012 123277001

RHH165L44 21012 123277001

RHH215L44 21012 123277001

RHH315L44 21012 123277001

RHS075L44 21012 123277001

RHS100L44 21012 123277001

RHS150L44 21012 123277001

RHS200L44 21012 123277001

RHS250L44 21012 123277001

RHS300L44 21012 123277001

RHD300L44 16506 123277002

RHD400L44 16506 123277002

RHD500L44 16506 123277002

TXV (c.u.)

SBFSE-AA-Z

SBFSE-A-Z

SBFSE-B-Z

SBFSE-C-Z

SBFSE-AA-Z

SBFSE-A-Z

SBFSE-A-Z

SBFSE-B-Z

SBFSE-B-Z

SBFSE-C-Z

SBFSE-C-Z

EBSSE-6-Z

EBSSE-6-Z

PART# 230V Motor Blade Control Control Control

104471048 102540004 119103001 24464232 204464208 204464002

104471049 102540004 119103001 24464232 204464208 204464002

104471049 102540004 119103001 24464232 204464208 204464002

104471046 102540004 119103001 24464232 204464208 204464002

104471048 102540004 119103001 24464232 204464208 204464002

104471048 102540004 119103001 24464232 204464208 204464002

104471049 102540004 119103001 24464232 204464208 204464002

104471049 102540004 119103001 24464232 204464208 204464002

104471046 102540004 119103001 24464232 204464208 204464002

104471046 102540004 119103001 24464232 204464208 204464002

104471046 201006007 213266000 24464232 204464208 204464002

104471047 201006007 213266000 24464232 204464208 204464002

104471047 201006007 213266000 24464232 204464208 204464002

RHO200L44 21012 123277001

RHO250L44 21012 123277001

RHO300L44 21012 123277001

RHO301L44 21012 123277001

RHO400L44 21012 123277001

RHO500L44 16506 123277002

RHO600L44 16506 123277002

SBFSE-A-Z

SBFSE-B-Z

SBFSE-B-Z

SBFSE-C-Z

SBFSE-C-Z

EBSSE-6-Z

EBSSE-6-Z

104471049 201006007 213266000 24464232 204464208 204464002

104471046 201006007 213266000 24464232 204464208 204464002

104471046 201006007 213266000 24464232 204464208 204464002

104471046 201006007 213266000 24464232 204464208 204464002

104471047 201006007 213266000 24464232 204464208 204464002

104471047 201006007 213266000 24464232 204464208 204464002

104471047 201006007 213266000 24464232 204464208 204464002

DHD5L44

DHD6L44

DHD8L44

DHD9L44

DHD10L44

DHD12L44

DHD15L44

DHO6L44

21054 123277003 EBSSE-6-Z 104471047 205051004 213266000 204464041 Hi/Lo Combo 204464002

21054 123277003 EBSSE-7 1/2-Z 104471047 205051004 213266000 204464041 Hi/Lo Combo 204464002

21054 123277003 EBSSE-10-Z

21054 123277003 EBSSE-10-Z

21000 123277004 EBSSE-13-Z

21000 123277004 EBSSE-13-Z

21000 123277004 EBSSE-13-Z

16506 123277002 EBSSE-6-Z

104471066 205051004 213266000 204464041 Hi/Lo Combo

104471066 205051004 213266000 204464041 Hi/Lo Combo

104471066 205051004 213266000 204464041 Hi/Lo Combo

104471066 205051004 213266000 204464041 Hi/Lo Combo

104471193 205051004 213266000 204464041 Hi/Lo Combo

104471066 205051004 213266000 204464041 Hi/Lo Combo

204464002

204464002

204464002

204464002

204464002

204464002

DHO8L44

DHO10L44

DHO13L44

VHD15L44

VHD22L44

VHD27L44

VHD30L44

VHD44L44

VHD54L44

VHD60L44

21054 123277003 EBSSE-6-Z

21054 123277003 EBSSE-10-Z

104471066 205051004 213266000 204464041 Hi/Lo Combo 204464002

104471066 205051004 213266000 204464041 Hi/Lo Combo 204464002

21054 123277003 EBSSE-10-Z 104471066 205051004 213266000 204464041 Hi/Lo Combo 204464002

21049

21049

21055

21055

123277005

123277005

123277005

123277005

OSE-21-Z

OSE-21-Z

OSE-30-Z

OSE-30-Z

104471021

†

104471021

†

104471021

†

104471021

†

21055

21056

21056

123277005

Factory

OSE-45-Z 104471022

†

Contact (2) 104471022

†

(2) OSE-30-Z 104471022

†

110204000 210385000 204464041 Hi/Lo Combo

110204000 210385000 204464041 Hi/Lo Combo

110204000 210385000 204464041 Hi/Lo Combo

110204000 210385000 204464041 Hi/Lo Combo

110204000 210385000 204464041 Hi/Lo Combo

110204000 210385000 204464041 Hi/Lo Combo

110204000 210385000 204464041 Hi/Lo Combo

204464002

204464002

204464002

204464002

204464002

204464002

204464002

* Parts may vary based upon specific operating conditions.

† V-Series filter is not Bi-Flow Design. Part number is for replaceable core filter (shell only). Core Part# 14471034 (may require more than one core)

Russell Part #

21065

21066

21067

21068

21070

21072

21073

21074

21075

21076

21077

21079

21080

21063

204464020

104799015

204464004

104799020

104799010

Description

Rebuild kit for Russell Part#16506




O-Ring Kit for Russell Part# 21012

O-Ring Kit for Russell Part#16506






PILOT ASSY/MANIFOLD for Russell Part# 21054



HIGH SIERRA Defrost Termination Control

HIGH SIERRA Evap Fan Delay Control

HIGH SIERRA Condensing Unit Fan Cycle Control

HIGH SIERRA RELAYS R1 & R2 (Same number for each)

HIGH SIERRA Defrost Timer

12

Comp.

Type

Model

Number

Typical High Sierra replacement parts - R-Series Medium Temp. Models*

Reversing Rev. Valve

Valve Strainer

Cond. Unit

TXV

Repl. Core Condenser

Liquid Filter 230V Motor Blade

Low Pres. High Pres.

Control Control

RHH075H22 21012 123277001 SBFVE-AA-C 104471048 102540004 119103001 24464232 204464208

RHH100H22 21012 123277001 SBFVE-A-C 104471048 102540004 119103001 24464232 204464208

RHH151H22 21012 123277001 SBFVE-A-C 104471049 102540004 119103001 24464232 204464208

RHH201H22 21012 123277001 SBFVE-B-C 104471049 102540004 119103001 24464232 204464208

RHH251H22 21012 123277001 SBFVE-B-C 104471046 102540004 119103001 24464232 204464208

RHH301H22 21012 123277001 SBFVE-C-C 104471046 102540004 119103001 24464232 204464208

RHH401H22 21012 123277001 SBFVE-C-C 104471047 205051004 213266000 24464232 204464208

RHH500H22 21012 123277001 SBFVE-C-C 104471047 205051004 213266000 24464232 204464208

RHH050M44 21012 123277001 SBFSE-A-C 104471048 102540004 119103001 24464232 204464208

RHH075M44 21012 123277001 SBFSE-A-C 104471048 102540004 119103001 24464232 204464208

RHH101M44 21012 123277001 SBFSE-B-C 104471048 102540004 119103001 24464232 204464208

RHH150M44 21012 123277001 SBFSE-B-C 104471049 102540004 119103001 24464232 204464208

RHH201M44 21012 123277001 SBFSE-C-C 104471049 102540004 119103001 24464232 204464208

RHH300M44 21012 123277001 SBFSE-C-C 104471046 102540004 119103001 24464232 204464208

RHH400M44 16506 123277002 EBSSE-6-C 104471047 205051004 213266000 24464232 204464208

RHS050H22 21012 123277001 SBFVE-AA-C 104471048 102540004 119103001 24464232 204464208

RHS075H22 21012 123277001 SBFVE-AA-C 104471048 102540004 119103001 24464232 204464208

RHS100H22 21012 123277001 SBFVE-A-C 104471048 102540004 119103001 24464232 204464208

RHS150H22 21012 123277001 SBFVE-A-C 104471049 102540004 119103001 24464232 204464208

RHS200H22 21012 123277001 SBFVE-B-C 104471049 102540004 119103001 24464232 204464208

RHS300H22 21012 123277001 SBFVE-C-C 104471046 102540004 119103001 24464232 204464208

RHS400H22 21012 123277001 SBFVE-C-C 104471047 205051004 213266000 24464232 204464208

RHS050M44 21012 123277001 SBFSE-A-C 104471048 102540004 119103001 24464232 204464208

RHS100M44 21012 123277001 SBFSE-A-C 104471048 102540004 119103001 24464232 204464208

RHS200M44 21012 123277001 SBFSE-B-C 104471049 102540004 119103001 24464232 204464208

RHS300M44 21012 123277001 SBFSE-C-C 104471046 102540004 119103001 24464232 204464208

RHS400M44 16506 123277002 EBSSE-6-C 104471047 205051004 213266000 24464232 204464208

RHO200M44 21012 123277001 SBFSE-C-C 104471049 205051004 213266000 24464232 204464208

RHO250M44 21012 123277001 SBFSE-C-C 104471046 205051004 213266000 24464232 204464208

RHO300M44 21012 123277001 SBFSE-C-C 104471046 205051004 213266000 24464232 204464208

RHO301M44 16506 123277002 EBSSE-6-C 104471046 205051004 213266000 24464232 204464208

RHO400M44 16506 123277002 EBSSE-6-C 104471047 205051004 213266000 24464232 204464208

RHO500M44 16506 123277002 EBSSE-6-C 104471047 205051004 213266000 24464232 204464208

RHO600M44 21054 123277003 EBSSE-6-C 104471047 205051004 213266000 24464232 204464208

RHO650M44 21000 123277004 EBSSE-7 1/2-C 104471066 205051004 213266000 24464232 204464208

* Parts selection may vary based upon specific operating conditions.

Medium Temp models are only available for warm ambient locations.

13

Comp.

Type

Typical High Sierra replacement parts- D-Series and V-Series Medium Temp. Models*

Model

Number

DHD5H22

DHD7H22

DHD8H22

DHD10H22

DHD12H22

DHD5M44

DHD6M44

DHD7M44

DHD8M44

DHD10M44

DHD12M44

DHO6M44

DHO7M44

DHO8M44

DHO10M44

DHO13M44

Reversing

Valve

16506

21054

21054

21054

21000

21054

21054

21054

21000

21000

21049

16506

21054

21054

21000

21000

Rev. Valve

Strainer

123277002

123277003

123277003

123277003

123277004

123277003

123277003

123277003

123277004

123277004

123277005

123277002

123277003

123277003

123277004

123277004

Cond. Unit

TXV

Bi-Flo

†

Liquid Filter

Condenser

230V Motor Blade

Low Pres.

Control

High Pres.

Control

Fan Cycle

Control

EBSVE-8-C 104471066 205051004 213266000 204464041 Hi/Lo Combo 204464002





EBSSE-10-C 104471066 205051004 213266000 204464041 Hi/Lo Combo 204464002






EBSSE-7 1/2-C 104471047 205051004 213266000 204464041 Hi/Lo Combo 204464002





VHD15H22

VHD20H22

VHD25H22

VHD30H22

VHD35H22

VHD40H22

VHD50H22

VHD60H22

VHD70H22

VHD80H22

VHD15M44

VHD20M44

VHD25M44

VHD30M44

VHD35M44

VHD40M44

VHD50M44

VHD60M44

VHD70M44

21000

21049

21049

21049

21055

21055

21055

21056

21056

21057

21049

21049

21055

21055

21055

21056

21056

21056

21057

123277004

123277005

123277005

123277005

EBSVE-20-C 104471021

†

EBSVE-20-C 104471021

†

OVE-30-C

OVE-30-C

104471021

†

104471022

†

123277005

123277005

OVE-40-C

OVE-40-C

104471031

†

104471031

†

123277005 (2) OVE-30-C 104471031

†

Contact Factory (2) OVE-30-C 104471032

†


†


†

123277005

123277005

123277005

123277005

123277005

Contact Factory

Contact Factory

Contact Factory

OSE-21-C

OSE-21-C

OSE-30-C

OSE-30-C

OSE-30-C

OSE-35-C

OSE-45-C

OSE-45-C

104471021

†

104471021

†

104471021

†

104471022

†

104471031

†

104471031

†

104471031

†

104471032

†

Contact Factory (2) OSE-30-C 104471033

†

Contact Factory (2) OSE-35-C 104471033

†

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

110204000

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

210385000 204464041 Hi/Lo Combo 204464002

VHD80M44 21057 110204000 210385000 204464041 Hi/Lo Combo 204464002

* Parts selection may vary based upon specific operating conditions.

† V-Series filter is not Bi-Flow Design. Part number is for replaceable core filter (shell only). Core Part# 14471034 (may require more than one core)

Medium Temp models are only available for warm ambient locations.

14

MODEL NUMBER

ALL MODELS

ALL MODELS

ALL MODELS

ALL MODELS

ALL MODELS (OPTIONAL)

ALL "AE" MODELS

ALL "AE" MODELS

1 - 6 FAN AE MODELS

AE14-37B, AE16-36B,

AE16-41B, AE16-46B

AE24-72B, AE24-85B,

AE26-92B

AE26-60B, AE26-75B

AE34-105B, AE36-120B,

AE36-140B

AE44-140B, AE46-164B,

AE46-185B

AE54-180B, AE56-210B

AE64-215B, AE66-245B,

AE66-280B

ALL-TEMP²B - MODELS AA, AE (AFTER APRIL, 2004 )

MOTOR, SHADED POLE, 1/20 HP, 1550 RPM, 115 V.

MOTOR, SHADED POLE, 1/20 HP, 1550 RPM, 208-230 V.

MOTOR, SHADED POLE, 1/20 HP, 1550 RPM, 460 V.

PART NUM.

102540003

102540004

102540005

FAN GUARD, PLASTIC, BLACK, 12"

FAN GUARD, WIRE, EPOXY COATED, BLACK, 12"

MOTOR MOUNT

MOTOR, PSC, 1/20 HP, 1550 RPM, 115 V., (3 MFD CAPACITOR NOT INCL.)

MOTOR, PSC, 1/20 HP, 1550 RPM, 230 V., (2 MFD CAPACITOR NOT INCL.)

CAPACITOR, 3 MFD, FOR 1/20 115 V. PSC MOTOR

CAPACITOR, 2 MFD, FOR 1/20 230 V. PSC MOTOR

DEFROST CONTROL, DEFROST TERMINATION, (TIMER RESET) 2 WIRE

DEFROST CONTROL, FAN DELAY, 2 WIRE

HEATER SAFETY SWITCH, 2 WIRE

DEFROST HEATER, CORE, 500 WATTS, 26-1/4" LENGTH, 208-230/460 V.

119647000

201006011

21062000

108178001

108178002

202163010

202163009

103079010

103079009

103079003

206240006

DEFROST HEATER, DRAIN PAN, 500 WATTS, 21" LENGTH, 208-230/460 V.

200172042


206240008


200172044


206240007


200172043


206240009


200172045


206240010


200172046

DEFROST HEATER, CORE, 2500 WATTS, 97-3/4" LENGTH, 208-230 V.

206240011


200172047


206240012

DEFROST HEATER, DRAIN PAN, 3000 WATTS, 111" LENGTH, 208-230/460 V. 200172048

1 FAN AA, & AE MODELS

AA28-76B, -97B, -122B,

ALL-TEMP²B - HINGED END PANEL UNITS (AFTER APRIL, 2004 )

VENTURI, 20" LENGTH

AA26-70B, -87B, AE26-60B,

AE26-75B

AA28-106B, -134B, AA26-115B

AE26-92B, AE24-85B

3 FAN AA & AE MODELS

4 FAN AA & AE MODELS*



1 FAN AA, & AE MODELS

AA28-76B, -97B, -122B,

AA26-70B, -87B, AE26-60B,

AE26-75B

AA28-106B, -134B, AA26-115B

AE26-92B, AE24-85B

3 FAN AA & AE MODELS




SHORT

LONG

ACF Model 1 Fan Evaps

ACF Model 2 Fan (Short) Evaps

ACF Model 2 Fan (Long) Evaps




VENTURI, 34" LENGTH

VENTURI, 38" LENGTH

VENTURI, 56" LENGTH

VENTURI, 74" LENGTH

VENTURI, 92" LENGTH

VENTURI, 110" LENGTH

DRAIN PAN, 27" LENGTH







HINGED END PANEL

HINGED END PANEL

Hot Gas Drain Pan Assembly w/ loop






15

8519104

8519241

8519242

8519243

8519244

8519245

8519246

8519592

8519593

8519594

8519595

8519596

8519597

8519598

8518612

8518613

12297800

12297900

12298000

12298100

12298200

12298300

High Sierra Systems

Additional Service, Installation and Trouble Shooting Tips

In the event of freezing drain pan Problems: Check the following

1. Verify that the unit cooler has been installed in a way insuring the drain pan is slightly pitched towards the drain connection. This will provide positive drainage of the condensate.

2. The surface of the drain pan must be touching the Hot Gas drain pan tubes, located in the bottom of the unit cooler. Later model units have the drain pan loops welded to the drain pan.

3. The High Sierra system has a time initiated and pressure terminated defrost. The pressure switch is factory set at 250# Cut In pressure and 200# Cut Out pressure. If the 250 pound setting does not clear the coil, the setting may be raised to a higher pressure, but no higher than 300 pounds (use high pressure gauge for this check). The time clock should have a maximum of (3) three defrosts per 24 hours. (We suggest the clock be set for 1 to 2 defrosts per 24 hours). The time clock fail safe should be set at 10 minutes maximum. 1 to 2 defrosts per 24 hours will ensure a longer defrost, 3-5 minutes in length.

4. The evaporator fans should have a two minute delay after defrost. This control is located in the condensing unit control panel. If the delay setting is less than two minutes, it should be corrected.

5. Check drain pan for straightness, if warped, the pan may have to be replaced.

6. Check the Hot Gas Loop, it should be straight and must make contact with the drain pan.

7. Evaporator Drain lines must be installed with copper tubing, wrapped with heat tape, insulated and trapped. The trap should be located outside of the freezer.

8. Superheat setting must be checked, 8°F @ coil, 20°F to 40°F at the compressor.

9. Refrigerant charge, charge to clear sight glass after room is within 10° of desired temperature.

DO NOT OVER CHARGE.

10. Check the expansion valve bulb on the outdoor unit, it must be clamped tightly in the proper location.

11. Fan Cycling control, Fan on at 90 psi. off at 60 psi.

Russell High Sierra System Data Sheet

Date: ____________ Contractor: ______________________________

High Sierra C.U. Model #_____________________ Serial # ____________________

Evaporator Coil Model #______________________ Serial # ____________________

1. Discharge pressure before defrost _________lbs.

After defrost _______________ lbs.

2. Suction pressure before defrost _________ lbs.

3. Superheat @ Coil before defrost _________ °F

After defrost _______________ lbs.

After defrost_______________°F

4. Compressor Superheat before defrost _________°F After defrost_______________°F

5. Sight glass condition before _________ after defrost___________ (clear or bubbles)

6. Suction Temperature reading across reversing valve IN__________ OUT__________

7. How long did the defrost last _____ Time clock fail safe setting ______

8. What was the defrost termination pressure ___________ lbs.

9. How many defrosts per day__________

10.Coil condition after defrost _____________________________

11. Condenser fan cycling control: Cut in ________ Cut Out ________

12. Fan Delay setting (should be no less than 2 minutes in duration) _____________ www.russellcoil.com

221 S. BERRY ST. BREA, CA. 92822-1030 TEL. (714) 529-1935 FAX (714) 529-7203

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

INSTALLATION,

OPERATION AND

MAINTENANCE

MANUAL

TABLE OF CONTENTS

INSPECTION

INSTALLATION

LOCATING CONDENSING UNITS

IMPORTANT! Sierra and High Sierra systems are critical charge systems.

Be careful, DO NOT OVERCHARGE!

A MAXIMUM OF 10 MINUTES

High Sierra Systems

Russell High Sierra System Data Sheet

Related manuals

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

INSTALLATION,

OPERATION AND

MAINTENANCE

MANUAL

TABLE OF CONTENTS

INSPECTION

INSTALLATION

LOCATING CONDENSING UNITS

IMPORTANT! Sierra and High Sierra systems are critical charge systems.

Be careful, DO NOT OVERCHARGE!

A MAXIMUM OF 10 MINUTES

High Sierra Systems

Russell High Sierra System Data Sheet

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