The RefPlus Light-Industrial Walk-In Evaporators, EK-EM-EJ-LM-LJ-DJ Series, are designed for refrigeration duty in light-industrial walk-in coolers and freezers. These units are part of the EcoEfficient+ program, which aims to reduce refrigerant leakage, noise, and power consumption while maintaining high performance. The series includes AWEF registered models, ensuring energy efficiency.
Function Description:
These evaporators are ceiling-mounted units that facilitate heat transfer from the refrigerated space. They are available in both single-coil and dual-coil constructions, catering to different air distribution requirements. The fans draw air through the evaporator coil and discharge it to cool the room. Various defrost types are available, including air defrost, electric defrost, reverse cycle defrost with electric drain pan, three-pipe defrost with electric drain pan, reverse cycle defrost with hot gas drain pan, and three-pipe defrost with hot gas drain pan. The units are designed for use with HFC, HFO, and CO2 refrigerants and are provided with sweat-type connections.
Important Technical Specifications:
- Unit Series:
- EK: Kompact light-industrial walk-in
- EM: Light-industrial walk-in
- EJ: Light-industrial walk-in with high efficiency motor(s)
- LM: Low velocity light-industrial walk-in
- LJ: Low velocity light-industrial walk-in with high efficiency motor(s)
- DJ: Down flow light-industrial walk-in with high efficiency motor(s)
- Model Generation: 0-6 for conventional refrigerant generation, 7-9 for CO2 generation.
- Nominal Capacity: Ranges from 4,300 BTU/H to 235,000 BTU/H at 10°FTD.
- Voltage Options: 120/1/60, 240/1/60, 208-240/3/60, 575/3/60, 480/3/60.
- Coil Construction: Seamless deoxidized heavy wall smooth copper tubes and aluminum plate fins, mechanically expanded into self-spaced plate fins with full collar for a permanent bond. Factory leak tested at 300 psig and purged with -40°F dew point dry air.
- Casing: Heavy-gauge stucco aluminum with stainless steel or plated hardware for lightweight and rustproof assembly.
- Drain Fittings: EM and EJ series have removable 1 1/4" female pipe thread drain fittings. EK, LM, LJ, and DJ series have removable 7/8" female pipe thread drain fittings.
- Fan Motors: EK, EM, and LM models use AC standard-efficiency fan motors. EJ, LJ, and DJ models are equipped with 500mm (20") high-efficiency cast-aluminum industrial fans with seven sickle-shaped blades for optimal airflow dynamics and sound power reduction.
- Defrost Heaters: All standard EKE, EME, EJE, LME, LJE, and DJE models include incoloy low watt density tubular heaters embedded within the coil for positive defrost and high-energy efficiency. These are available for various voltages (208-240/3/60, 480/3/60, 575/3/60, 240/3/60, and 480/3/60).
- Controls: Defrost termination switch, heater safety thermostat, and fan delay thermostat are standard on EKE, EME, EJE, LME, LJE, and DJE models. EMG, EJG, LMG, LJG, DJG, EMH, EJH, LMH, LJH, and DJH models also feature fan motor contactors, heater contactors, drain pan heater safety, fan delay, and defrost termination thermostats. EKT, EMT, EJT, LMT, LJT, and DJT models include fan delay, defrost termination thermostat, and hot gas defrost pan grid.
- External Equalizer: All units require an externally equalized expansion valve and are provided with a 1/4" OD equalizer line.
- Refrigerant Line Velocities (for good oil return with POE and HFC):
- Condensate: ≤ 100 FPM (0.5 m/s) design, 150 FPM (0.8 m/s) maximum.
- Liquid: ≤ 300 FPM (1.5 m/s) design, 300 FPM (1.5 m/s) maximum.
- Suction: 1000-3000 FPM (5.1-15.2 m/s) design, 4000 FPM (20.3 m/s) maximum.
- Discharge: 2000-3000 FPM (10.2-15.2 m/s) design, 3500 FPM (17.8 m/s) maximum.
- HG Defrost: 1000-2000 FPM (5.1-10.2 m/s) design, 3000 FPM (15.2 m/s) maximum.
Usage Features:
- Modular Design: Facilitates easy part replacement and availability.
- Factory Wired: All controls, motors, and heaters are factory wired for fully automatic operation.
- Installation Flexibility: EK models use support brackets for ceiling mounting, while EM, EJ, LM, LJ, and DJ models use steel rod hangers. LM, LJ, and DJ units must be tilted for proper draining.
- Drain Line Connection: Drain line unions are recommended for ease of installation and servicing. Drain lines must be trapped and run to an open drain, never connected to the sewer system. Traps should be in a warm ambiance to prevent freeze-up.
- Refrigerant Line Connection: Use top-quality refrigeration tubing. Dry nitrogen must be swept through lines during brazing. External piping must be well supported. Suction lines should slope away from the evaporator toward the compressor and be insulated.
- Expansion Valve Control: The expansion valve bulb must be securely fastened to a clean, straight, and horizontal section of the suction line at the evaporator outlet for optimal thermal contact and control.
- Multiple Evaporator Installations: Piping should be arranged to prevent flow from one valve affecting another, ensuring individual control and preventing refrigerant/oil draining into the compressor during off-cycle.
- AWEF Registered: Many models are AWEF registered, indicating high energy efficiency.
- EcoEfficient+ Program: Incorporates features like CityQuiet for reduced noise, ZeroLeak for minimizing refrigerant leakage, and SmartPower for optimized energy consumption.
Maintenance Features:
- Initial Inspection: After system charging and operation, check for vibration, liquid line sight glass operation, superheat settings, defrost control settings, and proper drain pan drainage.
- Periodic Inspections (Monthly): Check for proper defrosting and adjust defrost cycles or duration as needed.
- Periodic Maintenance (Every Six Months):
- Check all wiring and insulators.
- Tighten all electrical connections.
- Inspect contactors for proper operation and worn contact points.
- Check all fan motors, tighten motor mount bolts/nuts and fan set screws.
- Clean condenser coil surface.
- Check refrigerant and oil level.
- Check operation of the control system and safety controls.
- Check defrost controls.
- Clean the unit coil surface.
- Clean the drain pan and check the drain pan drain line for proper drainage.
- Check drain line heater for proper operation, cuts, and abrasions.
- Check and tighten all flare connections.
- Cleaning: Periodically remove dirt, grease, and dust from the fan, fan guards, and drain pan. Finned surfaces can be dusted and cleaned with a mild detergent and warm water spray. Always pressure clean in reverse of the air flow. Avoid alkaline or acidic solutions as they can damage the coils. Remove fan guards for inner coil face cleaning.
- Troubleshooting Chart: A comprehensive chart is provided to diagnose common problems such as fan malfunction, high room temperature, ice accumulation, and defrost issues, along with possible causes and corrective steps.
- Replacement Parts: Parts manuals are available for download at refplus.com.
- Startup Report Form: A detailed startup report form must be filled out, signed, and submitted to RefPlus for warranty validation. This form covers general information, pre-startup checks, startup parameters (refrigerant, electrical, temperature, pressures), and controls settings. An online form is also accessible via QR code on the control panel.
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