PREPARATION AND START-UP PROCEDURE

RECEIPT OF EQUIPMENT
All ColdZone systems are pressurized to 25 PSIG with nitrogen charge before shipment. If watercooled, the condenser water piping is pressurized to 10 PSIG. Check these pressures upon ARRIVAL. If systems are received with no pressure, contact the ColdZone Service Department IMMEDIATELY PRESSURE TESTING

After all refrigerant lines are connected, the entire system must be leak tested. Careful attention should be given to those parts which will be inaccessible at a later date and to all flare fittings.

The complete system should be pressurized to 175 PSIG with refrigerant and dry nitrogen. Wait at least 30 minutes for the refrigerant to reach all parts of the system. The use of an electronic leak detector is highly recommended because of its greater sensitivity to small leaks. After all leaks have been found and repaired, the system must be pressurized again and retested. As a further check, prior to charging, the system must be evacuated to a pressure of 1 PSIA or less and sealed for 24 hours. Any leakage of air into the system will cause the pressure reading to increase.

If an air leak is indicated, the system should again be charged with the nitrogen-refrigerant mixture, leak tested and leak repaired. To meet our factory installation standards the system must be leaktight before start-up.

After the final leak test, liquid lines exposed to high ambient temperatures should be insulated to reduce heat pick-up and the formation of flash gas in the lines. All suction lines are to be insulated. EVACUATION Connect a rotary vacuum pump to the gauge port on the suction and discharge service valves. Connection between the pump and evacuation valves should be made with copper tubing or high vacuum hose having a diameter of at least 3/8" I.D. Compressor suction and discharge valves must be open. The motor-compressor must not be operated during evacuation. Micron gauge installed at furthest point away from compressor.

Operate the pump until vacuum of 1000 microns is obtained. At this point, the vacuum should be broken by the introduction of refrigerant into the system. Repeat this procedure two more times. During the third and final evacuation a vacuum of 500 microns should be obtained. After this vacuum is reached, the system can be fully charged with refrigerant and put into operation.
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START-UP Check electrical connections. Be sure they are all tight. Observe the motor-compressor oil level before start-up. The oil level should be at or slightly above the center of the sight glass. Use 3GS or equivalent for mineral oil applications and Mobil EAL Artic 22 CC for polyolester oil applications. Insure that the rubber grommets are installed under the motor-compressor mounting nuts and that the motor-compressor rides freely on its mounting vibration isolators. Check the high and low pressure controls and all other safety controls. Adjust if necessary. Check the fixture thermostat for correct operating temperature. Refer to R-1 sheet and markings on compressors which indicate the refrigerant used in the system. Make proper refrigerant connections and weigh the refrigerant drum before charging, an accurate record must be kept of the weight of refrigerant put into the system. THE ColdZone CHARGING REPORT MUST BE COMPLETED. Charge the system with the refrigerant to be used. All HFC, R-404A (HP-62), AZ-50 and all refrigerant blends have to be charged into the system in a liquid state. After final evacuation weight in as much liquid refrigerant into system receiver without going over recommended charge or 90%. Pump down capacity of the receiver. If more refrigerant is needed after starting compressor meter the liquid refrigerant into the low side of system. Use extreme caution not to slug liquid into compressor crankcase. When charging a system with a head pressure control fill to a full sight glass and add the extra refrigerant needed for low ambient conditions. Observe system pressures during charging and initial operation. Do not add oil while the system is short of refrigerant unless the oil level is dangerously low.

The instruction manual, bulletins, tags, etc., attached to the unit should be placed inside the electrical control panel for future reference. Return signed Procedure and completed Charging Report to ColdZone within 10-days after start-up to activate warranty. IF NOT RETURNED WARRANTY WILL BE REVOKED.

SIGNED ________________________________
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DATE _______________________

ColdZone CHARGING REPORT

JOB NAME: ______________________________________________ MODEL NUMBER :______________________________ LOCATION: ______________________________________________

DATE: ___________ SERIAL NUMBER :__________ AMBIENT TEMP: ___________

SIGNATURE & COMPANY: _______________________________________________________ SYS. FIXTURE DESCRIPTION DISCHARGE PRESSURE SUCTION PRESSURE TYPE OF REFRIG. SUPERHEAT

LBS.

THIS REPORT MUST BE RETURNED TO ColdZone WITHIN 10 DAYS OF START-UP DATE TO ACTIVATE WARRANTY. WARRANTY WILL BE REVOKED IF REPORT NOT RETURNED.

MAIL TO : COLDZONE P.O. BOX 1030 BREA, CA 92822-1030 ATTN: WARRANTY

PREP. START-UP REV. 7/06/04

UNIT CHARGING PROCEDURE

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Once the system has been energized for 24 hours and a proper vacuum has been accomplished, be sure
the compressor discharge valve is open and the suction valve is

open 2 or 3 turns with a valve stem wrench attached for quick throttle adjustments if needed. With gauges attached charge the unit with 50 to 60% of the system charge into the receiver (mandatory R-404A and R507 must be charged with liquid) before the start up of the compressor. Once started it may be necessary to throttle the compressor suction valve to keep suction pressure reasonable to prevent trip outs during charging and pull down. If necessary to add liquid refrigerant to the suction side, a full control ball valve must be used in the charging line to slowly meter refrigerant into the system.

Note: The fixture must be down to temperature before completing final charge.

When charging the unit it will be necessary to bring the head pressure to a minimum of 200 PSIG
before just clearing the sight glass, in low ambient conditions it may be necessary to block off part of the condenser to achieve the 200 PSIG. When this has been accomplished you will then need to add the extra charge needed for winter conditions as follows, on Medium Temperature units you will need to add 3 lbs. of refrigerant per compressor horse power and 4 lbs of refrigerant per horse power for Low Temperature.

SUPERHEAT SETTING
Superheat setting should be 25 TO 40 degrees and measured on the suction line within 6 to 9 inches of the compressor.