—— $160-500 IOM/NOV 93 Frick Fite ‘SERVICE MANUAL - Section 160, Replaces: 160-500 IOMMAY 87, Dist 3, 3a, 3b, 3e Installation - Operation - Maintenance PACKAGED REFRIGERANT RECIRCULATION UNITS THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE IN- STRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER OP- ERATION OF THE UNIT.PACKAGED REFRIGERANT RECIRCULATION UNITS INSTALLATION ~ OPERATION ~ MAINTENANCE PREFACE “This manual hasbeen prepared to acquaint the owner and serviceman swith the INSTALLATION, OPERATION and MAINTENANCE oro: ‘lures 9 recommended by Frick Company for FRICK PACKAGED REFRIGERANT RECIRCULATION UNITS, It is most important that these units be properly applied to an ade fquetely controled refrigeration system, Your authorized Frick Company representative should be consulted for his expert quidance in thes determination. Proper performance and continued satisfaction with vhese units is CORRECT INSTALLATION PROPER OPERATION REGULAR, SYSTEMATIC MAINTENANCE To assure correct installation and applietion, the equipment must be propery seloted and connected to a properly designed and in 5160-500 10M Page steiea system. The Engineering pions, piping leyouts, ete. must be Setalled in acsordance with the best praties and local odes, such fs thoee outlined in ASHRAE literature, JOB SITE INSPECTION Immediately upon arrival examine all crates, boxes and exposed tompenent surfaces for GemegeUnpsck al toms and check agains. Shipping ists for any possible shortage. Examine all items for ‘damage in transit ‘TRANSIT DAMAGE CLAIMS All claims must be made by consignee. This isan 1CC requirement. Reauest immediate inspection bythe agent ofthe cari and be sure ‘the proper elim forme are executed. Contact Frick Company, Sales Administration Depertment, in Wovnesboro, PA to report damage or shortage claims. INSTALLATION ‘The intermediate base, between logs, is not designed to carry the weight of tne unit on rollers of other single point support Handle the unit by overhead suspension. It may be “walked into positon by elevation applied dirsctly under a support leg providing the turning force 1s equally applied at both ends, Love! the unit lengthways on the top of the accumulator erossways by keeping the level contol column in 2 vertical plane,” Use small pleces Of flat ion to 4 thickness of about one inch under each Foot, fdjusted for proper level and equal load. "Then grout under each Make all pipe connections in accordance with applicable, codes. Note that the antrance of the return lina from the ‘evaporators into the accumulator is at a 45° angie from the Nerttcal and st the center of the accumulator near the outlet, Connection to the comprassor. This might appear contrary to ‘900d practice, bul internal structure provides for vapor re- moval from near the ends and safely away trom the evaporator returns To leak test field connections, isolate the pumps and pres- Cerise tho unit to 122 peig may (Noto: aalaty values ate Sct at 150 psig) I higher test pressures are required, remove the Salety valves temporary But do not exceed 150 psig test bressure The dual safety valve asembly should be set with the valve stem turmed in and seated tightly. This takes the safety vale farthest from the exposed end of the valve stem out of service. The pur pos being to, provide the maximum length of clean valve stem land avoid stem packing damage for future ume. [Always return stem to this postion sfter replacing safety valve [After the final testing of the pining, relieve the test pressure and Feplace the safety valves, if any were removed ELECTRICAL CONNECTIONS ‘These refrigerant recirculation units may be supplied with or ‘nithout a wired control center assembly shown on page 10. THE PUMP SHOULD NOT BE OPERATED WHEN ‘THE UNIT IS VOID OF LIQUID REFRIGERANT. 11 the control center is supplied by others, the scheme of con- {rol as shown on the Frick wiring diagram must be used. PIPING Piping should be so designea and supported that regardless of temperature conditions there is no pipe strain applied to the pump OPERATION Liauio FEED SETTINGS Incividual feed settings at the evaporators should be made by attaching « surface temperate thermometer to the outlet of the fvaporator, Open the feed regulating vave 1/8 turn. After 8 3 10 Siminute delay eheek evaporator outlet temperature. Repeat this Drocedure until the evaporator outlet temperature corresponds to the suction presure of the accumulator. At this point the feed ‘ate is correct and no further acjusment is required Carefully wateh the pump discharge pressure gauge (installed by thers} As each feed regulating valve js opened @ change in the Sting of the PRY toy be required” Al, obworve and regulate The modulating quid supply volve to the purmoing sccumulator as Foquiras. It fs suggested that'8 smal ight be attached to the minals of the liqult supply solenoid valve for the purpose of in- eating whan the solenetd is eneraized. Time the seconds of ight on ‘nd light oft Reguate the hand et modulating va fora timing of 75% light-on. This insures relatively even liquid supply. Note “The lights supplied with the optional contro contr Each evaporator in the system must be adjusted ss outlined shove. DO NOT FEED ANY MORE LIQUID THAN REQUIRED O"OBTAIN SATURATED REFRIGERANT TEMPERATURE AT THE OUTLET OF EACH EVAPORATOR, Initiah setting of these hang regulated feed valves may be made evaporator load levels Tose than maximum. It may be necessst6080010 Page sey i make further adusimaet at pa fae level. One sit nae oye tvs, the manual feed valve should be wild oF maior problem i cececutation syste am excessive tet 9 ony one cvaparsion, which Men robe the Feed 12 ep. Frotare at high tevel Orerfeeding a any evaaorator ll Rot Sraveve its pertgnmanee beeause the excsave twtr phaee Toa i tie raparator sil “sererate a enGaBGhe peseaure: crop iN the Saparatar O1L DRAINING ‘Aa ol! sparing device is supplied on cach package recirulation et. Management sf this drama e suggested 3& folous: Use a 2 betch ditloe bocouse ha shautea Musi. retina te avery before teroval ai the oll. Open the valve asked” Vent Them gen the wave marked “Drain” Thisra wale nee be Open for several minutes oly Tse aloes the dain wah. Tie ot igen tthe i zparater couenn wil grey be OMT and ny HOR! On the outer surface 0! che mil separator will aappear, Then ope the ‘rains fort tee ewes Feb Repeat the shose daily Unt wi noticed that when rating. the ‘edicats that the ol! spars is about ane-nat full of oa. Allow thw sstrgeront ta evaporate ad befary rein orain the ail aking Noto that in many systems. the suction pressure may be below aimespheric pressure. thus the oil will not be reravatie. syaters of low suchon pressure, proceed as follows Cbsene the meting o! tw frost are when about ® melted close Ine vent valve, The remaining sefngorant will naw Build 2 ull ‘Siant oresaure s0 that the oul wil draia Feely alter all-of the frost © melted PUMPSELECTION Cnty one pump may be gamsted at atime. Hf operation of the Sondby pure, i said, progaad a follans: Open the ie (alve on the gandoy gains Tho discharge valve shauid coer oat hace to acute shat “l fully open. Ture the Mode Select Ssuteh 20 the OFF postion to stou the main purr. Change te ump Select switen fram mai Ee slaaxy. Turn the Made Select tween fo the Auro postin ww stort the Sandby pump far a snhast the pomp. thaws ne madener of equity permit M10 oerow in the Auta: Move coniityivly. The pomp ahh has fieew siat_down siould nave the init ap wah load arc the sor rae oer PACKAGED REFRIGERANT RECIRCULATION UNITS INSTALLATION — OPERATION ~ MAINTENANCE PUN® SUCTION STRAINER (OPTIONAL) After the system tat Been ip operation for oparanimnatty 2 — 4 herr, ar afer the apsteth hat been Geter 0 be cleat remawe the qump suction arene enmall the spacer gc, and conte ening LEVEL CONTROL COLUMN ker instalation ofthe quid level pabe, te level swishes Soule be rated 1" te sbwetc refuge 1 Level 1 tine olay tneraies shutting ot comaeega, leing 00 flan, is usio to canta! hig level epnettons A nigh vet Sans sauncing Une FairLo tevel aiacra The hig level rely site Should be set at the desired pereentae of probe that would ineheate righ vs! conditions. The range kred sts the per centage? of drop i9 Heel roquired to. caute the relay £0 Oe Serge. 2, Levol 2 tiuid tees contra, apan an close the saleroic trolling the linus tas io: the west The salenoid wil fe wid to the ve! unt! the sion paroantage 0" the pre 1 scat sat te ec te aa Tall below De fange uercesioge wet By the Level 2 range knob “Te gonaness ope at the Hm ar ul) Towa restore ame quia Fees Settings 09 92" 3 2. Lev 3, bay level relay, etaiaes On law vel coneions et the Level 3 relay bros a Ive! carl'ong ate met, then am diye sound, compreaot shuts of but the solenoid reais ‘oper to alla lina led (eet ito the ves, Level 1. 2 and 3 kobe calibrate tr length Lamp tt whom ela teeneegue 20 — 100 of prone “Rang: 4. 2 and 3 knobs ~ calibrated fran 2 — 108 vepesse ting te amount of wars hat Car Take piace inthe bevel befare the ay teh is energie aga. ‘ Calioeating screws “era!” and "ull" ave set in the factory before Gupmen, and oly wrder special teumtances sroule these be (rete in the es + ndiatensorcontanest tllpeobe Sag (EVEL CONTADL Lou veveL ERO CALINAT HAVEL CONTROL COLUMN RELAY UNIT vere WE ACH PCH LDPACKAGED REFRIGERANT RECIRCULATION UNITS 5160500 10m INSTALLATION — OPERATION ~ MAINTENANCE Pome 5 eer we wae en “ae Cu Bea scanned iN Spot dee Bw rRICK Soar Fig 2. PRR Une PIPING SCHEMATIC ‘SLOPE BECAUSE OF TWO PHASE FLOW Shing ies SENSI eomreeie eae sess g —| Bates ann ee, ihe | seetimieead meat coats Eoiie, [iaaniereranta eaten SMORCRET A ata ateo Sees ine matte HORS RE hut ue Hees Silene” ro. -oape ort SONOMA netagan5160500 10m Page 6 PACKAGED REFRIGERANT RECIRCULATION UNITS INSTALLATION - OPERATION — MAINTENANCE ACCUMULAT: PENEL MAINTENANCE ‘TROUBLESHOOTING LEVEL CONTROL COLUMN Probable Causes Cure Symptom lame da no ight on conections 3nd 4 Restore correct voltage. "No indication on tha meter, signal amos ight up, Connections 1 and 2 are defective lr prabe not connected Make «good connection, Meter indicates #t00 low eve “Too much oil in the electrode standbipe (only it NH), Drain off she standing ‘Meter indicates toa high or sessing eeewrage (probe) ie | 10 love, must be mtn, | ‘checs the probe inmuteing fetstance with 9 "Moggen,” elective, replace the electrode, Meter doesnot indicate eve aiterences, Poor connestion between standpipe and vray: he sto valve(s are closed or the Saangetions are clogged (ol, (Cheek the valve postion clean the ‘connections between veel and Eandpipe Meter indicates hig lve foniy vr low temperature pplication Etectrode standoipe is not causing high level IF THE LEVEL DOES NOT YIELD SATISFACTORY RESULTS, FOLLOW THIS PROCEDURE. Chvch to we ther probe and controller are marked for correct 3, If above steps check out, then check the retrigeraing conditions. ‘esgrany ane that the controll ig matked for te correct sss oath being use. (Cluck sh salting resistance of the measuring electrode using or The rault must be infinite, 4. Finally, check the standaibe's positioning relative 10 lig hol ing vera t ‘when vest approaching full level, the prods thould be fully immersed or for ‘ow level, probe is exposedPACKAGED REFRIGERANT RECIRCULATION UNITS 160500 10m INSTALLATION ~ OPERATION — MAINTENANCE Page 7 Notes: 1H there i a power fallure or fault in the power pack on the con troller, th feleys wil go to the high level position (tl safe) but the Indiator wil read 0% and the LED Tamas wil not fight up. 1 ere 6 break io the wiring to the probe, the ely wil go to the low level postion, the indicator wil read OM and the LED lamps will, tie. there is @ short or partial short in the wiring to the probe, the PUMP CAVITATION Pump cavitation isthe result of sudden chenges in vapor aressure in the PAR accumulator. SUDDEN DROPS IN PRESSURE OF ONLY. 18 FEW POUNDS CAN CAUSE THE LIQUID REFRIGERANT TO" SUDDENLY BOIL AND THE RECIRCULATOR FUMP TO CAV! TATE, The Frick PAR poeksee bes boon designed to minimize 1. PROBLEM. Loss of Liquid level and failure of the tow evel cutout fo shut down the pump. 2. PROBLEM, System Fluctuations, 3 PROBLEM. Pump cavitates when liquid solenoid de. ‘energizes 4 PROBLEM. Extended low load conditions PUMP LUBRICATION — See Manufacturers Recommendation. relays will go t0 the high level position, the indicator will re30 OOK, and the LED lamps wil no: fight uo. Radio frequencies near the relay unit may cause distortions in level readings. Never sighten prate on hex head locates directly below eable/probe Connection, Tis wil cus damage to the lads from the electrode fensor and lve ication willbe incorrect pump cavitation. Cavitation, however, ean result from the folloning ‘operational probleme (Note: Some periodie or wansient cavitation iS not unusial and is generally a function of system design and ‘operation} SOLUTION, a. Chack low level cutout location. The setting ‘nay have tobe adjusted oF moved up ‘The sandipe may be ail fogged. Drain oll guid strainer may be clogged, Clean. {uid solenoid may nave Tale, Replace Hand expansion valve may require adjust SOLUTION. a Gonsult tocal Frick Factor or Service Department, Frick Company. SOLUTION. a. Adjust hand expansion valve to minimize solenoid cycling, SOLUTION. 2 Operation at low load conditions can ‘make relabvely small systom fluctuations hhave @ profound impact on the vapor pressure inside the PAR vessel. For {ended periods of low load operation in- stall @ balance load line trom tho systom intermediate to the PRR package with a ‘solenoid and back pressure regulator to maintain downstream pressure at design conditions. Desuperheated intermed: ‘925 Is required. In high temperature ap- Plications consult the factory5160-500 1084 PACKAGED REFRIGERANT RECIRCULATION UNITS Page INSTALLATION ~ OPERATION MAINTENANCE ELEMENTARY DIAGRAM — PACKAGED REFRIGERANT RECIACULATOR suey ay ous) "ensues Fee rowas0%4601975-30900 HE or # 8 2 | 26 7 + wane mY omeas 23 * @ cur Pal Fos RUB AAT. ol PACKAGED REFRIGERANT RECIRCULATION UNITS. INSTALLATION — OPERATION ~ MAINTENANCE Leseno CONTROL LIGUD RELAY CONTROL RELAY “FUSED DYSCONNECT SWITCH HIGH LIQUID RELAY “Low LiguIO RELAY LNT SWITCH LIGHT (A:AMBER, F-RED) = MOTOR STARTER ‘MOTOR. OVERLOAD PUSH BUTTON Sage e PACKAGED REFRIGERANT RECIRCULATOR Cant) 8 swarror Sot" SOLENOID POO) « CLGSED LEFT. OPEN MIGOLE, OPEN RIGHT (GOK) OPEN LEFT, OPEN MOLE, CLOSED RIGHT po) “CLOSED LEFT OPEN fIGHT (OX) OPEN LEFT, CLOSED ‘gir ‘s160-509 108 Page sug. us a ag. rep160-500 10m PACKAGED REFRIGERANT RECIRCULATION UNITS Page 10 INSTALLATION — OPERATION ~ MAINTENANCE ‘CONTROL CENTER — PACKAGED REFRIGERANT RECIRCULATOR : = = a) | mawromon || on owe | fos) : | i | LEGEND t = SEE ELEMENTARY. s DIAGRAM | r l WIRING DIAGRAM — OPTIONAL CONTROL CENTER (NEMA 1}ea YORK Retrgeration FP ick: 100Cv Avenue+P.0. 80x 997 » Waynesboro, Pennsylvania USA 17268-0997 Phone: 717-762-2121 «FAX: 717-762-8624 * www.trickcold.com ‘Subject To Change Without Notice (© 2008, YORK Netigeravon