Mueller 8824390, Installation And Operation Manual

Page 1: ...Part No 8828748 Effective June 16 2020 E Star OESE Condensing Unit 7 5 and 9 HP HFC INSTALLATION AND OPERATION MANUAL ...

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Page 3: ...ing Unit Connection Sizes 4 2 5 Electrical Connections 5 2 6 Compressor Rotalock Torque Specifications 5 2 7 Oil Sight Glass Torque Specifications 5 Section 3 0 Refrigerant Charging 3 1 EPA Refrigerant Regulations 6 3 2 Initial Refrigerant Charge 6 Table 6 Recommended Startup Refrigerant Charge 6 3 3 Weigh In Refrigerant Charging 6 3 4 Final Operating Charge 7 3 5 Refrigerant Testing 7 3 6 Safety ...

Page 4: ...ifications 14 7 8 Copeland Scroll Compressor Functional Check 15 Section 8 0 Electrical Schematics 8 1 OESE 7 5 and 9 HP 200 220 50 3 208 230 60 3 16 8 2 OESE 7 5 and 9 HP 380 50 3 460 60 3 575 60 3 17 Section 9 0 Pressure Switches and Fan Control 9 1 Low Pressure Switch with Auto Reset 18 9 2 High Pressure Switch with Auto Reset 18 9 3 RGE Electronic Fan Pressure Control 18 9 4 RGE Electronic Fan...

Page 5: ...68 Warning Place Screen Guard Before Unit Operation 27 13 13 Label No 8820769 Warning Fan Will Start Automatically 28 13 14 Label No 8824383 Mueller Logo 28 13 15 Label No 8822705 CSA 28 Section 14 0 Safety 14 1 Safety Alert 29 14 2 Refrigerant Health Hazards 29 14 3 First Aid 29 14 4 Personal Protective Equipment 29 Section 15 0 Technical Data 15 1 E Star OESE Electrical Data 30 15 2 E Star OESE ...

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Page 7: ...ssor from liquid refrigerant A custom tube and fin condenser with rifled tubing and integral subcooling loop provides an enhanced heat exchange surface The subcooling loop maintains subcooled liquid refrigerant to the thermal expansion valve ensuring maximum evaporator efficiency A single variable speed high efficiency fan motor provides maximum condensing efficiency over a wide range of ambient t...

Page 8: ...ler com 1 3 INSTALLATION INFORMATION Electrical and refrigeration installation and service must be performed by an authorized service technician who has the proper training to install and service refrigeration and electrical equipment Local state and or country electrical and refrigeration regulations must be followed during installation service and or operation of this equipment United States Env...

Page 9: ...denser Serviceability The condensing unit should be located with the compressor and electrical enclosure accessible for service Do not pipe refrigerant lines in front of the electrical enclosure Efficiency Locate the condensing unit as close to the evaporator as possible This will improve efficiency by reducing pressure drop in the refrigerant piping Lubrication For proper oil return do not instal...

Page 10: ...commends the shortest pipe run possible TABLE 5 CONDENSING UNIT CONNECTION SIZES 4 Compressor Horsepower Equivalent Length of Pipe Feet 30ˇ 30ˇ 50ˇ 50ˇ 100ˇ 3 5 1 2 1 2 1 2 5 1 2 1 2 5 8 7 5 5 8 5 8 5 8 9 5 8 5 8 7 8 Compressor Horsepower Equivalent Length of Pipe Feet 30ˇ 30ˇ 50ˇ 50ˇ 100ˇ 3 5 7 8 11 8 11 8 5 11 8 11 8 13 8 7 5 11 8 13 8 15 8 9 13 8 15 8 21 8 Compressor Horsepower Equivalent Lengt...

Page 11: ...the Rotalock fittings on compressors The Rotalock fittings need to be checked after installation and the compressor has been in operation due to the changes in temperature that could reduce the torque from the original setting The compressor Rotalock torque specifications are as follows 2 7 OIL SIGHT GLASS TORQUE SPECIFICATIONS The scroll compressor s sight glass may be susceptible to leakage due ...

Page 12: ...able 6 The refrigerant charge should be adjusted for the final operating charge as described in Section 3 4 TABLE 6 RECOMMENDED STARTUP REFRIGERANT CHARGE NOTE R 507 is recommended for use with Mueller E Star OESE condensing units however other refrigerants may be compatible Contact the Mueller Dairy Farm Equipment Service Department for more information IMPORTANT The compressor is equipped with R...

Page 13: ...rheat adjustment 3 Check the sight glass installed at the TEV inlet If the sight glass shows vapor refrigerant bubbles go to step 4 If the sight glass is clear with liquid refrigerant slowly recover refrigerant from the system at P6 high side service valve until an occasional bubble of vapor is seen in the sight glass 4 Slowly add refrigerant at P2 suction charging access port until the sight glas...

Page 14: ...changer coil before entering the evaporator there will be less flash gas at the inlet of the expansion valve Any liquid refrigerant returned from the evaporator is evaporated into vapor when it contacts the warmer heat exchanger coil in the bottom of the suction accumulator Vapor leaving the accumulator heat exchanger will be superheated an additional 2 5 F 1 1 2 75 C prior to entering the compres...

Page 15: ...ion a genuine Mueller accumulator heat exchanger must be used Accumulator Heat Exchanger Fan Control FP Off Cycle HP LP FIGURE 2 REFRIGERANT PIPING SCHEMATICS IMPORTANT When charging the system with liquid refrigerant always charge upstream of the accumulator heat exchanger charging access port P2 to ensure the compressor is protected against damage caused by liquid refrigerant slugging 9 Example ...

Page 16: ... 7 THERMAL EXPANSION VALVE SELECTION FIGURE 3 THERMAL EXPANSION VALVE INSTALLATION 10 Section 5 0 Expansion Valve No Description Specifications Part No for Milk Cooler Applications Part No for Chiller Applications 1 R 507 TEV 7 5 HP 1 2 ODF inlet x 7 8 ODF outlet 8825838 N A 2 Sight Glass 7 5 HP 1 2 ODF inlet x 1 2 ODF outlet solder 8824494 N A 3 R 507 TEV 9 HP 5 8 ODF inlet x 7 8 ODF outlet 88258...

Page 17: ... temperature chart 4 The superheat is calculated by subtracting the saturation temperature dew point determined in step 3 from the actual suction line temperature taken in step 2 5 If the superheat is not in the proper range of e g 4 6 F for milk coolers 10 12 F for chillers at conditions as described above adjust the TEV 6 If superheat is below the proper range turn the TEV s adjustment stem cloc...

Page 18: ...r evaporates accumulated liquid returning from the evaporator providing cool vapor refrigerant to the suction inlet of the compressor Oil Return to the Compressor Oil settles to the bottom of the accumulator and is returned to the compressor through an orifice in the accumulator s suction outlet IMPORTANT The custom Mueller accumulator heat exchanger utilizes a special pancake heat exchange coil T...

Page 19: ...n all other switches remain off 7 3 CORESENSE LED STATUS 7 4 CORESENSE DIAGNOSTIC FAULT CODE DETAILS The LEDs will flash a number of times consecutively pause and then repeat the process To identify an alert code number count the number of consecutive flashes Detailed descriptions of specific alert codes are shown below 1 Code 8 displays for 24 hours after last detection With Terminal D energized ...

Page 20: ...olt and the compressor is not running then the problem is external to the motor protector module IMPORTANT Do not run a Copeland Scroll compressor in a deep vacuum Failure to heed this advice can result in arcing of the Fusite pins and permanent damage to the compressor IMPORTANT Scroll compressors as with any refrigerant compressor should never be used to evacuate a refrigeration system The compr...

Page 21: ...l compressor is functioning properly 1 Verify proper unit voltage 2 Normal motor winding continuity and short to ground checks can be used to determine proper motor resistance or if an internal short to ground has developed 3 With service gauges connected to the suction and discharge pressure fittings turn on the compressor If suction pressure falls below normal levels the system is either low on ...

Page 22: ...d copper wire on field wiring 3 Fan motor is internally thermal protected 4 Connect 24 volt control wiring to leads with supplied wire nuts 5 All enforced electrical codes must be followed during installation service and or operation of this equipment 6 Fan may start automatically even if the compressor is not running 7 All grounds terminate in the control box CONDENSING UNIT WIRING SCHEMATIC FOR ...

Page 23: ...field wiring 3 Fan motor is internally thermal protected 4 Connect 24 volt control wiring to leads with supplied wire nuts 5 All enforced electrical codes must be followed during installation service and or operation of this equipment 6 Fan may start automatically even if the compressor is not running 7 All grounds terminate in the control box CONDENSING UNIT WIRING SCHEMATIC FOR CONTROL CABINETS ...

Page 24: ...not operate as indicated above 9 2 HIGH PRESSURE SWITCH WITH AUTO RESET The high pressure switch should be tested during installation to ensure proper operation This can be accomplished by completing these steps 1 Attach an accurate high pressure gauge to P6 high side service valve 2 Disconnect the fan motor wires from the high voltage terminal strip and monitor the high side pressure on the gauge...

Page 25: ...fy RGE operation connect the high side of a manifold gauge to the liquid line service valve P6 Energize the condensing unit and monitor the fan operation in accordance with the high side pressure In low ambient conditions the condenser may have to be partially blocked to increase high side pressure To adjust the pressure range remove the RGE cover and locate the adjustment screw see Figure 5 To in...

Page 26: ...e switches will be marked with a red tie band to indicate if a Schrader core is present If a pressure switch connection does not have a red tie band the refrigerant will require recovery before the pressure switch can be removed NOTE All high side pressure safety connections will not have a Schrader core This is due to a safety regulation on the high side of a system 20 ...

Page 27: ...r normal operating conditions with the compressor and condenser fan motor operating Measurements were taken with a sound meter Model 33 2055 on the A weighted scale 10 2 SOUND MEASUREMENT All sound measurements were recorded at a distance of 1 meter 3 28 feet from the operating equipment The highest recorded measurement was 84 dB FIGURE 7 SOUND MEASUREMENT 21 Section 10 0 Equipment Sound Level 84 ...

Page 28: ...Evaporator Inlet P5 Pressure After Liquid Line Filter Drier P6 Pressure at Liquid Line Service Valve P7 Pressure at Receiver Outlet TEMPERATURE READINGS T1 Milk Temperature T2 Suction Line Temperature at Evaporator Outlet T3 Line Temperature at Accumulator Inlet T4 Line Temperature at Accumulator Outlet T5 Ambient Temperature Entering Condenser T6 Suction Line Temperature Entering Compressor T7 Co...

Page 29: ...ly voltage 5 Measure the amperage draw of the compressor and verify that it is within 10 of the compressor s technical data chart 6 Check all electrical connections ensuring that they are clean and tight 7 Check the compressor s wrap around crankcase heater for proper operation 8 Check for proper operation of the low high and fan pressure switches as described in Section 9 9 Complete a performance...

Page 30: ...ls refrigerant and oils are handled and or disposed of according to applicable codes and regulations 12 2 COMPRESSOR REFRIGERANT OIL The compressor contains a lubricant consisting of polyolester POE oil Dispose of in accordance with local regulations 12 3 METAL COMPONENTS The condensing unit s basic structure consists of steel tin aluminum plastic and copper all of which may be separated and recyc...

Page 31: ...SURE THROUGH SERVICE PORTS OR SCHRADER VALVES BEFORE REMOVING FITTINGS EVACUATE THE SYSTEM TO 500 MICRONS BEFORE CHARGING WITH REFRIGERANT DISCARD THIS TAG UPON CHARGING SYSTEM WITH REFRIGERANT AND APPLY A SYSTEM REFRIGERANT SPECIFICATION DECAL NOTE IT IS THE TECHNICIAN S RESPONSIBILITY TO COMPLY WITH ALL CURRENT REFRIGERANT USAGE REGULATIONS 11 94 8820454 Final Inspection Date INSPECTION CARD Uni...

Page 32: ...he supplied power This requires care during installation to ensure the compressor is operating in the proper direction Verification of proper rotation is done by observing suction and discharge pressures when the compressor is energized Reverse rotation is indicated by a decrease in discharge pressure and an increase in suction pressure Reverse rotation has no negative impact on the scroll compres...

Page 33: ...UPPLIES BEFORE SERVICING ADVERTISSEMENT RISQUE DE DÉCHARGE ÉLECTRIQUE PEUT CAUSER DES BLESSURES OU PROVOQUER LA MORT DÉBRANCHER TOUTES LES SOURCES D ALIMENTATION À DISTANCE AVANT L ENTRETIEN PELIGRO RIESGO DE CHOQUE ELÉCTRICO PUEDE CAUSAR HERIDA O MUERTE DESCONECTAR TODOS LOS SUMINISTROS DE REMOTO ELÉCTRICO DE PODER ANTES DE SERVICIO DESCONECTE LA ELECTRICIDAD ANTES DE REMOVER LA TELA DE PROTECCIO...

Page 34: ...48 Effective June 16 2020 13 13 LABEL NO 8820769 WARNING FAN WILL START AUTOMATICALLY 13 14 LABEL NO 8824383 MUELLER LOGO 13 15 LABEL NO 8822705 CSA 28 8906 8820769 WARNING FAN WILL START AUTOMATICALLY ADVERTISSEMENT LE VENTILATEUR DÉMARRERA AUTOMATIQUEMENT PELIGRO EL ABANICO COMIENZA AUTOMATICAMENTE ...

Page 35: ...enated compounds will decompose at high temperatures such as those associated with gas flames or electric heaters The chemicals that result under these circumstances always include hydrofluoric acid These dangerous vapors have a sharp stinging effect on the nose and can be detected by odor at concentrations below its toxic level These odors serve as a warning that decomposition has occurred If det...

Page 36: ...e Unit R 507 200 230 50 60 3 46 8 80 8827021 Compressor Scroll ZB58K5E TFC 200 230 50 60 3 195 35 4 8824390 Fan Motor 1 2 HP 200 208 230 50 60 1 2 5 OESE A754 HFC 8827002 7 5 HP Three Phase Unit R 507 380 460 50 60 3 20 7 35 8827022 Compressor Scroll ZB58K5E TFD 380 460 50 60 3 95 15 4 8824825 Fan Motor 1 2 HP 380 460 50 60 1 1 4 OESE A93 HFC 8827003 9 HP Three Phase Unit R 507 200 240 50 60 3 53 ...

Page 37: ...ts A Current Amps M Mass Flow lb hr E EER Btu Wh Isentropic Efficiency Nominal Performance Values 5 based on 72 hours run in Subject to change without notice Current 230 V 2018 Emerson Climate Technologies Inc Autogenerated Compressor Performance Printed 5 7 2018 11 88 2051 Evaporating Temperature F Sat Dew Pt Pressure psig Condensing Temperature F Sat Dew Pt Pressure psig 115 0 298 10 0 25 5 0 30...

Page 38: ...ss Flow lb hr E EER Btu Wh Isentropic Efficiency Nominal Performance Values 5 based on 72 hours run in Subject to change without notice Current 460 V 2018 Emerson Climate Technologies Inc Autogenerated Compressor Performance Printed 5 7 2018 11 88 2051 Evaporating Temperature F Sat Dew Pt Pressure psig Condensing Temperature F Sat Dew Pt Pressure psig 115 0 298 10 0 25 5 0 30 5 0 40 10 0 46 20 0 5...

Page 39: ... Mass Flow lb hr E EER Btu Wh Isentropic Efficiency Nominal Performance Values 5 based on 72 hours run in Subject to change without notice Current 230 V 2018 Emerson Climate Technologies Inc Autogenerated Compressor Performance Printed 5 7 2018 11 90 2051 Evaporating Temperature F Sat Dew Pt Pressure psig Condensing Temperature F Sat Dew Pt Pressure psig 115 0 298 10 0 25 5 0 30 5 0 40 10 0 46 20 ...

Page 40: ...s Flow lb hr E EER Btu Wh Isentropic Efficiency Nominal Performance Values 5 based on 72 hours run in Subject to change without notice Current 460 V 2018 Emerson Climate Technologies Inc Autogenerated Compressor Performance Printed 5 7 2018 11 90 2051 Evaporating Temperature F Sat Dew Pt Pressure psig Condensing Temperature F Sat Dew Pt Pressure psig 115 0 298 10 0 25 5 0 30 5 0 40 10 0 46 20 0 58...

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Page 43: ...r Inlet P5 Pressure After Liquid Line Filter Drier P6 Pressure at Liquid Line Service Valve P7 Pressure at Receiver Outlet TEMPERATURE READINGS T1 Milk Temperature T2 Suction Line Temperature at Evaporator Outlet T3 Line Temperature at Accumulator Inlet T4 Line Temperature at Accumulator Outlet T5 Ambient Temperature Entering Condenser T6 Suction Line Temperature Entering Compressor T7 Compressor ...

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Page 46: ...1600 West Phelps Street Springfield Missouri 65802 U S A DFE Service 1 800 756 5991 DFETechService paulmueller com 1 800 MUELLER WWW PAULMUELLER COM 2020 Paul Mueller Company 20 DFESGF 0142 8828748 ...