Hillphoenix Adaptapak ADP-M0000-L0032 Installation And Operation Manual Download Page 54

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AdaptaPAK® Maintenance and Troubleshooting

Air-Cooled Condensers

At every six month interval, or sooner if local conditions cause clogging of air passages through the finned surface, the
following items should be checked.

1. Visually inspect unit.

a. Look for signs of corrosion on fins, cabinet, copper tubing and solder joints.

b. Look

for excessive or unusual vibration for fan blades or sheet metal panels when in operation. Identify fan cell(s)

causing vibration and

check motor and blade carefully.

c. Look for oil stains on headers, return bends, and coil fins. Check any suspect areas with an electronic leak

detector.

2. Clean condenser coil and blades.

a. Periodic cleaning can be accomplished by using brush, pressurized water or a commercially available coil

cleaning foam. If a foam cleaner is used, it should not be an acid based cleaner. Follow label directions for
appropriate use.

b. Clear unnecessary trash and debris away from condenser.

3. Check the operation of all fans.

a. Check that each fan rotates freely and quietly. Replace any fan motor that does not rotate smoothly or makes an

unusual noise.

b. Check

all fan set screws and tighten, if needed.

c. Check

all fan blades for signs of stress or wear. Replace any blades that

are worn, cracked or bent.

d. Verify that all fan motors are securely fastened to the motor rail.

e. Lubricate motors, if applicable (most Heatcraft condenser motors are permanently sealed, ball bearing type and

do not require lubrication).

4. Inspect electrical wiring and components.

a. Visually inspect all wiring for wear, kinks, bare areas and discoloration. Replace any wiring found to be

damaged.

b. Verify that all electrical and ground connections are secure, tighten, if necessary.

c. Check operation/calibration of all fan cycle controls, when used.

Fixture Cleaning

The evaporator coils in most refrigeration cases are, by design, located at the bottom of the case. This arrangement

keeps the piping, valves and fans needed to operate the cases out of sight and places the product closer to

Summary of Contents for Adaptapak ADP-M0000-L0032

Page 1: ... all specifications shown in this manual are subject to change without notice Important Notices 2 General Information 3 AdaptaPAK Product Information 5 Two Fan AdaptaPAK Unit 4 Three Fan AdaptaPAK Unit 5 Two Fan AdaptaPAK Unit 8 Three Fan AdaptaPAK Unit 10 Four Fan AdaptaPAK Unit 12 AdaptaPAK Models Overview 14 Key to Codes in AdaptaPAK Model Numbers 16 DX Refrigeration Systems 17 Refrigeration Sy...

Page 2: ...ommon schedule similar to traditional refrigeration circuits of traditional remote systems Important Notices Hillphoenix designates important information in all Hillphoenix installation and operations handbooks with alert symbols These notices provide information about potential dangers to personal health and safety as well as case damage if these instructions are not carefully followed Service No...

Page 3: ...written request along with photos of the damage to the carrier for inspection within 14 days of receipt of the unit Missing Items Hillphoenix refrigeration systems are inspected before shipping to ensure the highest level of quality Any claim for missing items must be made to Hillphoenix within 48 hours of receipt of cases Technical Support For technical support issues regarding this unit contact ...

Page 4: ...4 AdaptaPAK Parallel Refrigeration System ...

Page 5: ...ares suction discharge and an integrated condenser across several compressors As a result compressor capacity may be varied to match the required loads a much more efficient design Multiple single units with compressors running constantly at maximum output waste energy and reduce component life Parallel installations on the other hand do just the opposite Because compressor capacities are allowed ...

Page 6: ...1 4 inches high Clearances for AdaptaPAK Units 2 fan and 3 fan Air Intake 36 inches recommended Air Exhaust 36 inches recommended Piping Clearance 36 inches minimum recommended Hinged Front Door 36 inches outward from door by 50 inches width NEC Electrical 36 inches outward from door by 50 inches width Weights of AdaptaPAK Units 2 fan and 3 fan Fans Compressors Estimated Weight 2 4 3 000 lbs 3 6 3...

Page 7: ...ish for durability Each unit has its own designated lifting points to facilitate easy lifting and site placement Removable panels and hinged access doors provide for both equipment protection and serviceability In addition to the standard equipment detailed in the list above customer selectable options may have been include on the unit being installed Please check the customer order or the Hillpho...

Page 8: ...uld be the determining the number capacity of the compressors the receiver size and the details of the parallel system A rear isometric view of the two fan AdaptaPAK unit is shown below Note that on this drawing the access panels and doors have been removed Note that the condenser coil s are located at the rear of the unit The two fans on the top of the unit would draw ambient outdoor air in throu...

Page 9: ...as previously noted a drawing is supplied which depicts the lifting points on the two fan AdaptaPAK unit and details an appropriate lifting jig and the necessary rigging for the cable rope to perform a level lift and successful placement of this unit Two Fan AdaptaPAK Unit LEFT END VIEW FRONT VIEW RIGHT END VIEW Lifiting Detail Two Fan AdaptaPAK Unit ...

Page 10: ...determining the number capacity of the compressors the receiver size and the details of the parallel system A rear isometric view of the three fan AdaptaPAK unit is shown below Note that on this drawing the access panels and doors have been removed Note that the condenser coil s are located at the rear of the unit The three fans on the top of the unit would draw ambient outdoor air in through the ...

Page 11: ...s previously noted a drawing is supplied which depicts the lifting points on the three fan AdaptaPAK unit and details an appropriate lifting jig and the necessary rigging for the cable rope to perform a level lift and successful placement of this unit LEFT END VIEW FRONT VIEW RIGHT END VIEW Three Fan AdaptaPAK Unit Lifiting Detail Three Fan AdaptaPAK Unit ...

Page 12: ...determining the number capacity of the compressors the receiver size and the details of the parallel system A rear isometric view of the four fan AdaptaPAK unit is shown below Note that on this drawing the access panels and doors have been removed Note that the condenser coil s are located at the rear of the unit The four fans on the top of the unit would draw ambient outdoor air in through the co...

Page 13: ...as previously noted a drawing is supplied which depicts the lifting points on the four fan AdaptaPAK unit and details an appropriate lifting jig and the necessary rigging for the cable rope to perform a level lift and successful placement of this unit LEFT END VIEW FRONT VIEW RIGHT END VIEW Four Fan AdaptaPAK Unit Four Fan AdaptaPAK Unit Lifiting Detail ...

Page 14: ...1 8 208 0 185 5 200 0 ADP M0299 L0000 3 2 6 3500 2 1 8 1 1 8 208 0 208 0 225 0 ADP M0349 L0000 3 2 6 3200 3 1 8 1 1 8 208 0 194 0 225 0 ADP M0403 L0000 4 2 6 4000 3 1 8 1 1 8 208 0 232 0 250 0 ADP M0442 L0000 4 2 6 4000 3 1 8 1 1 8 208 0 240 0 250 0 Low Temp Units ADP M0000 L0032 2 1 2 2600 1 5 8 7 8 208 0 62 2 80 0 ADP M0000 L0052 2 1 2 2600 1 5 8 7 8 208 0 81 8 110 0 ADP M0000 L0076 2 1 3 2700 2...

Page 15: ... L0052 2 2 4 2800 1 5 8 1 5 8 7 8 1 1 8 208 0 120 0 150 0 ADP M0106 L0052 2 2 4 2800 1 5 8 1 5 8 7 8 1 1 8 208 0 139 8 175 0 ADP M0048 L0076 2 2 5 2950 2 1 8 1 5 8 7 8 1 1 8 208 0 130 3 150 0 ADP M0079 L0076 2 2 5 2950 2 1 8 1 5 8 7 8 1 1 8 208 0 143 9 175 0 ADP M0106 L0076 2 2 5 2950 2 1 8 1 5 8 7 8 1 1 8 208 0 163 7 175 0 TM Model Overview Not available with split condenser due to single coil de...

Page 16: ...0 ADP 2 M0048 L0012 ADP 3 M0178 L0032 ADP 2 M0000 L0052 ADP 2 M0079 L0000 ADP 2 M0079 L0012 ADP 3 M0152 L0052 ADP 2 M0000 L0076 ADP 2 M0106 L0000 ADP 2 M0106 L0012 ADP 3 M0178 L0052 ADP 2 M0000 L0099 ADP 2 M0152 L0000 ADP 2 M0152 L0012 ADP 3 M0152 L0076 ADP 2 M0000 L0122 ADP 2 M0178 L0000 ADP 2 M0178 L0012 ADP 3 M0178 L0076 ADP 2 M0000 L0145 ADP 2 M0198 L0000 ADP 2 M0048 L0032 ADP 4 M0221 L0052 AD...

Page 17: ...orator the superheated refrigerant vapor enters the compressor and the refrigerant is compressed and changed from a low pressure superheated vapor to a high pressure superheated vapor more on this later It then flows to the condenser In a simple refrigeration system the ambient air outside of the condenser flows through the coils of the condenser where it absorbs heat from the vapor refrigerant ca...

Page 18: ... compressor and reject it to the cooler outside ambient air This process causes the high pressure refrigerant vapor to condense and become a high pressure liquid The condenser operates as follows The high pressure temperature refrigerant vapor enters the condenser via the compressor discharge line As the hot vapor enters the condenser and begins to flow through tubes of the condenser coil lower te...

Page 19: ...ce that is being refrigerated Several things happen in the evaporator The liquid refrigerant entering the evaporator from the metering device expansion valve undergoes an instantaneous large pressure decrease per the P T chart this is also a large temperature decrease As it enters the evaporator the liquid refrigerant immediately begins to absorb heat from the warm air flowing over the tubes and f...

Page 20: ...20 AdaptaPAK Parallel Refrigeration System ...

Page 21: ...tions flawlessly It is a terrific choice for automatic control of all AdaptaPAK parallel system control functions It does a great job of controlling compressors and condensers as well as other functions such as oil management and heat reclaim It includes standard alarming functions with and audible buzzer and a flashing red light It also records system conditions and provides for alarm logging for...

Page 22: ...oportional band and neutral zone control Maximum control of 3 or 2 fans Four different condenser fan rotation types time LIFO FIFO and custom Fans can be configured for modulation pwm or 0 10 volts Standard condenser fan alarms high and low condensing psi and fan overload alarms Other Functions Oil management subcooling liquid injection and heat reclaim are available features for optimum compresso...

Page 23: ...ne in order to maintain the proper saturated suction pressure for the rack J14 Split Condenser Control Normally Open Relay J14 Split Condenser Valve If split condenser operation is called for the relay will close and only one portion of the condenser will receive refrigerant flow J16 Condenser Fan Control Normally Open Relay J16 Condenser Fans 1 2 3 As required to meet system operational demands c...

Page 24: ...roller will close the relay activating rack alarms INPUTS J1 INPUT PWR 24V AC DC J1 24VAC Power to Controller J2 NTC PRESS INPUTS J2 Suction Pressure 1 Discharge Pressure Drop Leg Pressure J3 TEMP INPUTS J3 Suction Temperature 1 Ambient Temperature J4 0 10VDC OUTPUTS J4 24 VAC Power EC Fan Speed Digital Compressor 1 Speed Digital Compressor 2 Speed J5 24V AC DC DIGITAL INPUTS J5 Rack Oil Alarm Pha...

Page 25: ...25 multiMAX Controller for AdaptaPAK HILLPHOENIX multiMAX CONTROLLER INSTALLED IN AN ADAPTAPAC CONTROL PANEL SEE NEXT PAGE FOR A FULL TWO PAGE SPREAD OF HILLPHOENIX multiMAX CONTROLLER WIRING ...

Page 26: ...26 multiMAX Controller for AdaptaPAK Hillphoenix AdaptaPAK multiMAX Controller Input Output Schedule left side ...

Page 27: ...27 multiMAX Controller for AdaptaPAK Hillphoenix AdaptaPAK multiMAX Controller Input Output Schedule right side ...

Page 28: ...28 multiMAX Controller for AdaptaPAK ...

Page 29: ...ures be used Installation Materials The process of installing AdaptaPAK systems generally involves a variety of materials In addition to the equipment itself the items that are required to install a system often include Valves stop pressure relief solenoid etc Refrigeration piping Insulation Filter dryers Assorted hardware and miscellaneous items Wiring Drain lines and traps Hangers piping support...

Page 30: ...2 28 3 51 1 81 3 13 4 85 2 49 4 35 6 69 3 1 8 3 5 8 4 1 8 2 09 2 83 3 68 3 06 4 12 5 38 5 02 6 76 8 82 6 93 9 36 12 20 9 54 12 92 16 81 Both types of tubing K and L are manufactured by either of two means Drawn Annealed Drawn tubing is typically referred to as hard drawn and annealed as soft drawn Most of the piping used for refrigeration is of the latter type hard drawn Because soft drawn as it n...

Page 31: ... fittings include T s flairs and flair nuts Although good piping practice calls for avoiding the use of the latter flair nuts are sometimes found in certain applications and if installed properly can work well However sweat fittings should be used instead whenever possible Besides the three general uses of piping mentioned earlier other specific applications for refrigeration systems include Circu...

Page 32: ...ns maximum severity of 90 F dry bulb temperature 80 relative humidity and 0 ft min air velocity The mild design condition is typical of most indoor climate conditioned environments in the U S A typical supermarket indoor design point of 75 F dry bulb temperature and 55 relative humidity can be considered equivalent to this mild condition for the purpose of sizing insulation Although insulation thi...

Page 33: ...unted on receivers to protect the system from reaching dangerously high pressure level pressure relief valves vent excess pressure and consequently release refrigerant Solenoid either of a combination of two sets of functions temperature control or isolation and either normally open or normally closed Another functional variation is that solenoids can be either one way or two way flow permitting T...

Page 34: ...ation the proper refrigerant and oil must be added to the system The refrigerants primarily used in commercial refrigeration are classified into three main groups CFC chlorofluorocarbons R 11 and R 12 HCFC hydrochlorofluorocarbons HCFCs R 22 and R 124 HFC hydrofluorocarbons HFCs R 134a R 404a and R 507 R 407a R 448 449 Because of their harmful effects on the environment CFC refrigerants have been ...

Page 35: ...to as mechanical fasteners The material used for these purposes of course must be of sufficient strength to support the weight of the pipe Unistrut a particular type of pipe support is widely used for refrigeration piping Angled steel pipe clamps with plastic or rubber compound liner material that is held in place by an outer steel layer along with wires and bands are also commonly used These latt...

Page 36: ...t freezing of drains in cold applications Heating tape comes in a number of variations Varieties of heating tape include self regulating adjustable and continuously on Pipe and Conduit Penetration Covers Exterior penetrations are used whenever any part of a system is located outside of the building For instance the piping that connects exterior set mechanical houses Weather Pac units typically roo...

Page 37: ...tion 4 Provide proper support and clamping to refrigeration lines 5 Properly brazed joints 6 Insulate suction lines 7 Pressure test line sets 8 Properly evacuate system Careful consideration of each step includes 1 Verify components positively confirm as with all other aspects of the installation process that all components match each other i e all TEVs have the same refrigerant as the rack legend...

Page 38: ...n never the female After brazing excess flux should be removed 6 Insulate suction lines use only material listed in the customer specification Insulation must be thick enough to keep heat from getting in and moisture sweating getting out Maintaining proper return gas temperatures cools compressor windings and prevents water damage and mold growth by keeping suction lines from sweating When using s...

Page 39: ...lation to prevent condensation on all refrigeration suction piping in the sales area from the pits to the cases at the point of piping entrance to the case and insulate all refrigeration suction piping that is located in non air conditioned areas If ambient or mechanical sub cooling is used all liquid refrigerant lines should also be insulated The more insulation that is used the less heat gain th...

Page 40: ... the vacuum pump before shutting it off Always read the micrometer at the furthermost point of the system from the vacuum pump Make sure to change the oil in the systems as necessary during evacuation Fittings and Connections All fittings and connections for components should be sweat type unless otherwise specified For instance a safety relief valve of the proper pressure rating should be piped w...

Page 41: ...cess may vary from manufacturer to manufacturer so always make certain to follow the specific steps provided by the manufacturer Choose and Install Lines for Circuit Piping Considerations for circuit piping include checking for Pipe size Insulation Riser sizing Hangers and clamps Line slope and traps Heat reclaim Vibration elimination Building penetrations Condenser types i e evaporative air plate...

Page 42: ...d by the customer or should be part of the standard installation practice is to install a plan holder Usually these are placed near the refrigeration system typically attached to the wall inside the unit and contain a set of as built plans for the system as well as an updated refrigeration schedule and floor plan These documents should be stored in such a way as to protect them from loss or damage...

Page 43: ... oil Adding refrigerant Installing liquid line driers and suction filters Whether customers provide one or not a startup checklist like the one included here beginning on next page should always be used The checklist provides space for two types of entries information to be filled in and items to be checked off Unless an item is not applicable to the installation all items should be filled in or c...

Page 44: ...5 If the rack has heat reclaim verify that it is operating correctly _____ 16 Check and record the suction temperature suction pressure and rack superheat _____ 17 Check and record the drop leg temperature and pressure _____ 18 Check and record the discharge pressure _____ 19 Check and record the ambient temperature 20 Check low pressure and high pressure switch operation _____ 21 Verify all contr...

Page 45: ... s operating costs through the application of proper maintenance procedures Foremost among the maintenance procedures for DX systems is checking the system s safety and operating controls The checks to be performed also include verification that the original settings are maintained Operating Strategies Maintaining Compressor Efficiency One means of reducing a compressor s electrical consumption an...

Page 46: ... systems is of the utmost importance to the company Therefore it is essential that the safety and operation controls installed on each system are functioning correctly As part of regular maintenance these should be checked at specific intervals Refrigeration systems include operating controls that cycle on and off in order to maintain certain temperatures They also require safety controls to stop ...

Page 47: ...ut and Cut in points are properly set In addition to temperature controls refrigeration systems also commonly rely on pressure control schemes These work in basically the same manner as the temperature differential controls except that the set points are determined in psig instead of degrees F To imagine how such a system would work in the example described above substitute pressure in psig for te...

Page 48: ... flooding back to compressor and washing the oil out of the crankcase When a loss of pressure is detected an alarm indicator light turns on to indicate that an oil failure has occurred The oil failure switch should never be reset without determining and fixing the cause of the problem Otherwise the compressor will undoubtedly fail The safe and efficient operation of the system depends on the regul...

Page 49: ...the condenser inlet air e Watch high pressure gauge for cutout point 6 Check head pressure controls for pressure settings 7 Check crankcase heater operation if used 8 Re check all safety operating controls for proper operation and adjust if necessary Monthly Inspections Approximately once a month the following inspections should be performed 1 Clean drain pan interior Dirt and other impurities whi...

Page 50: ... Contaminants such as moisture air etc trapped in the system If the discoloration is not severe a new liquid line filter drier and 1 or 2 oil filters are usually enough to remove contamination and clean the oil If the discoloration is severe and caused by contamination alone the oil should be replaced and a new liquid line filter drier and oil filter installed as many times as necessary to elimina...

Page 51: ...s and tighten if needed c Check all fan blades for signs of stress or wear Replace any blades that are worn cracked or bent d Verify that all fan motors are securely fastened to the motor rail e Lubricate motors if applicable 4 Inspect electrical wiring and components a Visually inspect all wiring for wear kinks bare areas and discoloration Replace any wiring found to be damaged b Verify that all ...

Page 52: ...per oil level 5 Check condition of condenser Look for accumulation of dirt and debris clean as required 6 Check for unusual noise or vibration Take corrective action as required 7 Inspect wiring for signs of wear or discoloration and repair if needed 8 Check and tighten flare connections if necessary Semi Annually On a semi annual basis the following checks should be performed 1 Repeat all quarter...

Page 53: ... b Check pressure drop across all filters and driers Replace as required c Verify that superheat at the compressor conforms to specification i e 30 F to 45 F d Check pressure and safety control settings and verify proper operation Annually Finally once a year perform the following checks 1 In addition to quarterly and semi annual maintenance checks submit an oil sample for analysis a Look for high...

Page 54: ...trash and debris away from condenser 3 Check the operation of all fans a Check that each fan rotates freely and quietly Replace any fan motor that does not rotate smoothly or makes an unusual noise b Check all fan set screws and tighten if needed c Check all fan blades for signs of stress or wear Replace any blades that are worn cracked or bent d Verify that all fan motors are securely fastened to...

Page 55: ...ration unit is turned off before cleaning In some installations more than one disconnect switch may have to be turned off to completely de energize the case 2 Check the waste outlet to insure that it is not clogged before starting to clean and avoid introducing water faster than the case drip pipe can carry it away 3 Avoid spraying cleaning solutions directly on fans or electrical connections 4 Pl...

Page 56: ...ems occur they can be determined rather quickly to involve a certain part of the system At other times it may be necessary to check the entire system in order to isolate the cause of a problem The following charts provide guidelines for both general and specific indications of trouble in the system General System Troubleshooting Specific aspects of system troubleshooting focus on the following are...

Page 57: ... open 8 Motor electrical trouble 1 Close switch 2 Check electrical circuits and motor winding for shorts or grounds Investigate for possible overloading Replace fuses after fault has been corrected 3 Overloads are automatically reset Check unit closely when it comes back online 4 Repair or replace defective component 5 Determine type and cause of shutdown and correct it before resetting safety swi...

Page 58: ...itch Swap any two of the threee power input wires Turn power on indicator light should glow and compressor should start Observe motor for correct rotation 2 TROUBLESHOOTING COMPRESSOR NOISY VIBRATING SYMPTOMS SYMPTOMS POSSIBLE ACTIONS Compressor is noisy or vibrating 1 Flooding of refrigerant into crankcase 2 Improper piping support on suction or liquid line 3 Worn compressor 4 Scroll compressor r...

Page 59: ...OMPRESSOR LOW DISCHARGE PRESSURE SYMPTOMS SYMPTOMS POSSIBLE ACTIONS Low compressor discharge pressure 1 Faulty condenser temperature regulation 2 Suction shutoff valve partially closed 3 Insufficient refrigerant in system 4 Low suction pressure 5 Variable head pressure valve 1 Check condenser control operation 2 Open valve 3 Check for leaks repair and add charge 4 See corrective steps for low suct...

Page 60: ...rnal compressor part 1 Check for leaks repair and add charge 2 Clean Check Remote 3 Replace cartridge s 4 Clean strainers 5 Check and reset for proper superheat 6 Check means for regulating condensing temperature 7 Fix component repair or replace compressor 7 TROUBLESHOOTING COMPRESSOR LOSES OIL SYMPTOMS SYMPTOMS POSSIBLE ACTIONS Compressor loses oil 1 Lack of refrigerant 2 Excessive compression r...

Page 61: ...n valve plate and or gasket 4 Dirty condenser coil 5 Overcharged system 1 Add components to bring conditions within acceptable limits i e CPR EPR valves additional condenser surface liquid injection etc 2 Open valve 3 Replace valve plate or and or gasket 4 Clean coil 5 Reduce charge If after performing the steps above problems persist and you are not able to determine their cause you may need to c...

Page 62: ...it for completion of cycle 6 Adjust fan delay setting of thermostat check defrost thermostat Case or Walk In temperature is too high 1 Thermostat set too high 2 Superheat too high 3 System low on refrigerant 4 Coil iced up 5 Unit cooler located too close to doors 6 Heavy air infiltration 1 Adjust thermostat 2 Adjust thermal expansion valve 3 Add refrigerant 4 Manually defrost coil check defrost co...

Page 63: ...eplace defective component Ice accumulating in drain pan 1 Defective heater 2 Unit or pan not pitched properly 3 Drain line plugged 4 Defective drain line heater 5 Defective timer or thermostat 1 Replace heater 2 Check and adjust if necessary 3 Clean drain line 4 Replace heater 5 Replace defective component Uneven coil frosting 1 Defective heater 2 Location is too close to door or opening 3 Defros...

Page 64: ...erally use a single pole double throw switch Usually the red lead wire is wired to common The black wire is then wired in series with the fan motors A brown wire is often wired in series with the defrost termination When controls are wired this way the brown and red contacts close and the black and red contacts open when the temperature is above the ON set point e g 55ºF The black and red contacts...

Page 65: ...le Sometimes the location of the drain and the ambient air temperature at the drain outside of the case may cause the drain pan to freeze up A drain line heater may be required to correct the freeze up condition To avoid this condition any traps in the drain line must be located in a warm ambient temperature location often the case for case drains Finally after correcting any faulty condition it i...

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