Hussmann Super Plus Service Manual Download Page 1

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Summary of Contents for Super Plus

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Page 2: ...s of pressure for leak testing low side Use only a striker to light torch Know whether a circuit is open at the power supply or not Remove all power before opening control panels Always supply proper ventilation Refrigerants and nitrogen can displace oxygen causing suffocation Refrigerants exposed to flame can produce phosgene a poisonous gas Be sure refrigeration lines are free of pressure before...

Page 3: ...nd proper adjustment are the keys to customer satisfaction The information presented in this manual includes many details resulting from our experience over many years Its use will guide the contractor to a successful installation Time taken to read and to understand this information will pay off in reducing lost time and duplication work Should there be questions concerning this information do no...

Page 4: ...Installation and Service Manual 12999 St Charles Rock Road Bridgeton MO 63044 2483 314 291 2000 August 1996 Printed in USA Super Plus Fibertronic ...

Page 5: ... Capacities 1 2 Machine Room Requirements 1 3 Unit Placement 1 4 Lifting and Leveling 1 5 Setting without a Crane 1 6 Figures Super Plus System 1 1 Electrical Clearance Requirements 1 3 Allowable Distances 1 4 Lifting and Leveling the Super Plus 1 5 Isolation Pad Location 1 5 Dolly Placement 1 6 Revised August 1 1996 P N 340272A CONTENTS ...

Page 6: ...em 2 2 Refrigeration Cycle 2 4 Turba Shed 2 4 Heat Reclaim Valve 2 4 Flooding Valve 2 4 Main Liquid Line Pressure Differential Valve 2 5 Liquid Branch Solenoid Valve 2 5 TEV 2 5 EPR Valve 2 5 Heat Reclaim Cycle 2 6 Receiver Pressure Regulation 2 6 A9 and A9B Valves 2 6 Koolgas Defrost Cycle 2 7 Koolgas Defrost with Valve 2 7 Satellite Oil System 2 8 Autosurge for Ambient Subcooling 2 9 Mechanical ...

Page 7: ... Line Piping 3 9 Tables L Values 3 7 Equivalent Feet 3 8 Figures Supporting Refrigeration Lines 3 1 Insulating a Riser 3 2 Vibration Allowance 3 2 P Trap Construction 3 2 Reduced Riser 3 2 Rack to Condenser Piping 3 3 Rack to Condenser Piping 3 Way Valve 3 4 Rack to Condenser Piping 2 Way Valves 3 5 Offset Tee Construction 3 6 Remote Satellite Piping 3 6 Offset Construction 3 7 Expansion Loop Cons...

Page 8: ...al Low Pressure Control 4 8 Compressor Board EPC Control 4 10 K2 and Motor Contactor Circuits 4 12 K1andCompressorAlarmCircuits 4 13 Parallel Switchback Controls 4 14 Series Switchback Controls 4 15 Switchback Controls 4 16 Koolgas and Interlock Relays 4 17 Compressor Protection 4 18 Carlyle Internally Compounded Compressor Protection 4 19 Head Cooling Fan and Demand Cooling 4 20 Circuits Parallel...

Page 9: ...mote Condensers 5 1 Remote Satellite 5 6 Figures Lifting the Condenser 5 2 Schematic Ambient Temperature Control 5 4 Schematic Pressure Control 5 5 Satellite Rigging and Lifting 5 6 Revised August 1 1996 P N 340272A CONTENTS ...

Page 10: ... 6 1 Proper Installation 6 1 Setting Precision Timer 6 2 Resetting Alarm Switch 6 3 Precision Defrost Timer 6 4 Paragon Program Module 6 5 Paragon Program Module Removal and Installation 6 6 Motor Module Removal and Installation 6 7 Paragon Defrost Timer 6 8 Revised August 1 1996 P N 340272A CONTENTS ...

Page 11: ...oolgas Valve Piping 7 2 2 Way Solenoid Valve 7 3 3 Way Solenoid Valve 7 3 Main Liquid Line Solenoid 7 4 Alco Main Liquid Line Solenoid 7 5 Branch Liquid Line Solenoid 7 6 Probe Locations For Setting TEV 7 7 TEV 7 7 3 Way Heat Reclaim Valve 7 9 Condenser and Receiver Pressure Regulation 7 10 A8 Flooding Valve 7 10 A9 Receiver Pressure Regulator 7 11 A9B Receiver Pressure Regulator 7 11 Autosurge an...

Page 12: ...l and Tube Subcooling Controls 8 1 Compound Rack Additional Settings 8 1 EPR Settings 8 2 Winter Condensing Pressure Controls 8 2 Mechanical Low Pressure Controls 8 2 Alco 8 2 Others 8 4 Condenser Settings 8 8 Merchandiser Settings 8 9 Revised August 1 1996 P N 340272A CONTENTS ...

Page 13: ...g 9 1 Test Charge 9 1 Oil Levels 9 2 Evacuation 9 2 Charging 9 3 Final Checks 9 4 Maintenance 9 5 Compressor Replacement 9 5 Cleaning the Turba shed 9 6 Replacing Drier and Filter Cores 9 6 Revised August 1 1996 P N 340272A CONTENTS ...

Page 14: ...lows Addendum Condenser Installation provides information on installing condensers with SuperPlus systems place behind index and in front of warranty page Section 3 Piping changed Equalizing Line size to 7 8 inch when required discard page 3 3 and replace with page 3 3 dated April 15 1997 Section 8 Settings updated Impact medium temperature settings and added low temperature settings and new case ...

Page 15: ...lication or 3 4 to 3 HP rating on Copeland air cooled compressors 2 Factory piping with a Suction Discharge and LiquidHeaders b Turba shed Oil Separator and return system c Dual Receiver Tanks d Suction Filters on each compressor e Liquid Filter Drier and Sight glass f Liquid Level Indicator 3 Factory wired control panel with a Pre wired Distribution Power Block b Individual component Circuit Brea...

Page 16: ...chanical Subcooler or Vertical receiver adds 32 inches to length Piping stubs and shipping crate may extend 6 inches beyond the frame Optional suction accumulators or water cooled condensers will add 15 inches to depth Note For 08VY and other Extended Racks consult with Hussmann Engineering Bridgeton Mo SYSTEM WEIGHTS Base Rack Weight Rack Assembly Nomenclature Base Weight lbs 01VK 02VK 04VY 1600 ...

Page 17: ...ader defrost assembly Equipment must be located in the machine room to provide enough working space for service personnel and to meet electrical codes Consult NEC National Fire Handbook particularly Installation of Switch Boards and Working Space Requirements The figure below demonstrates some suggested distances Refer to local codes for each installation Super Plus Load Points Center to Center Ra...

Page 18: ... The maximum allowable elevation is 6 feet from the bottom of the Satellite to the bottom of the Rack When piping from the Rack to a Remote Satellite the maximum allowable piping equivalent is 50 feet When piping from the Rack to a Remote Header the maximum allowable piping equivalent is 50 feet When piping from the Rack to a Condenser the maximum allowable piping equivalent is 100 feet When pipin...

Page 19: ...s when lifting Vibration Isolation Pads are supplied with each rack The entire weight of the rack must rest on these pads with the rack cross leveled To adjust for slightly uneven floors place 16 gauge 3x3 inch galvanized steel shims between the vibration pads and the floor Shims must be field supplied Revised August 1 1996 P N 340272A 1 5 Figure 1 4 Lifting and Leveling the Super Plus HUSSMANN CO...

Page 20: ...ny bars Do not push or pull on any of the pipes valves accessories or Control Panel when moving the Super Plus Rack For mezzanine installations a fork lift operated within its height and weight limits may be used to raise the Rack into place NOTE This unit is slightly front heavy due to the Control Panel Take necessary precautions when moving and lifting INSTALLATION INSTRUCTIONS Revised August 1 ...

Page 21: ...s of prime interest it should be noted that the low center of gravity inherent with the twin receiver design minimizes vibration extending system life and reducing service needs In this instruction the following constants are maintained to assist the reader In the diagrams refrigerant flow direction is generally clockwise Electrical solenoid valves carry the same initial abbreviations as in the el...

Page 22: ...REFRIGERATION PROCESS Revised August 1 1996 2 2 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ...

Page 23: ...lve TEV Pressure Regulating Valve A8 for Condenser A9 for Receiver EPR for Evaporator Main Liquid Line Pressure Differential Valve Autosurge Valve Optional Heat Exchanger Optional High Pressure Hot Vapor High Pressure Warm Vapor High Pressure Warm Liquid Reduced Pressure Warm Liquid Low Pressure Cool Vapor Cut away not shown Empty HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ...

Page 24: ...e condenser or a Heat Reclaim Coil When the HS solenoid is de energized the valve directs the refrigerant to the condenser The Condenser discharges the unwanted heat from the system The Flooding Valve maintains head pressure in low ambient conditions by reducing the available condensing area Restricting liquid refrigerant flow from the Condenser the Flooding Valve prevents the liquid refrigerant f...

Page 25: ...or Koolgas Defrost The Liquid Manifold distributes liquid refrigerant to all Branch Liquid Lines The Branch Liquid Line Solenoid Valve S_ closes off refrigerant supply to the evaporator yet allows back flow of refrigerant into the Liquid Manifold The TEV located in the merchandiser meters liquid refrigerant through its orifice to the low pressure side of the system where it evaporates absorbing he...

Page 26: ...R PRESSURE AND VAPOR TEMPERATURE REGULATION Receiver Pressure The Pressure Regulator Valve A9 or A9B Valve responds to Receiver pressure If the Receiver pressure drops below its set point the A9 Valve opens directing Hot High Pressure Vapor to the Receiver Receiver Temperature During Koolgas Defrost if the Koolgas Manifold temperature drops below 85 F the A9B Solenoid opens its valve directing Hot...

Page 27: ...ectly into the Koolgas Manifold This Koolgas Vapor maintains the same high pressure as the Receiver A 3 WayValve closes the suction line to the Suction Manifold and opens the Koolgas line to the Evaporator Koolgas Vapor flows backward through the Evaporator giving up heat to the Evaporator for defrost The Koolgas Vapor condenses and flows into the reduced pressure liquid line through a Bypass Chec...

Page 28: ...balance oil level among the compressors An Equalizing Line returns any excess oil in one Oil Level Regulator to the rest of the system A Check Valve is placed in the Equalizing Line between the Low End Satellite and the rest of the system The check valve is necessary to keep the Low End Satellite from filling up with oil With a High End Satellite note that the Satellite has no Equalizing Line Note...

Page 29: ...e Valve reacts to the condensing pressure through its equalizer line and to the temperature of the liquid refrigerant returning from the Condenser through a bulb mounted on the Liquid Return Line up stream of the Flooding Valve When the refrigerant temperature returning from the condenser drops below its condensing temperature the system has ambient subcooling The valve is factory set at 10 F of s...

Page 30: ... expansion device it is not limited by ambient temperature A Liquid Line Solenoid Valve and a TEV control refrigerant to the subcooler An EPR prevents the subcooler temperature from dropping below desired liquid temperature Electrically a thermostat responding to main liquid line temperature controls a solenoid valve on the liquid supply line REFRIGERATION PROCESS Revised August 1 1996 2 10 HUSSMA...

Page 31: ...tive Temperature Coefficient NTC Thermistor to provide signals to the Control Module The NTC resistance drops on temperature rise The Control Module responds to the Temperature Sensor input by energizing the Injection Valve Solenoid when 292 F is exceeded Too high or too low a resistance from the thermistor circuit will cause the Module to shutdown the compressor after one minute The Injection Val...

Page 32: ...set Plan proper pitching expansion allowance and P traps at the base of all suction risers Use long radius elbows to reduce line resis tance and breakage Avoid completely the use of 45 elbows Install service valves at several locations for ease of maintenance and reduced service costs These valves must be UL approved for 450 psig minimum working pressure HUSSMANN CORPORATION BRIDGETON MO 63044 248...

Page 33: ...stalled at the bottom of all suction risers to return oil to the compressors Reduced Riser When a reduced riser is necessary place the reduction coupling downstream of the P Trap Factory Supplied Stubs Stub sizes provided from the Manifolds do not automatically correspond to the line sizes nec essary It is the installer s responsibility to supply reduction couplings Protecting Valves and Clamps Wh...

Page 34: ...r line is piped between the Receiver and the Condenser A Check Valve allowing flow only to the Condenser and a shut off valve upstream of the Check Valve will be field supplied and installed Purge Valve Location The purge valve will be installed at the high est point of an inverted P trap with at least a 6 inch rise Use with approved recovery vessel HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Pri...

Page 35: ...ovide Purge valve at the highest point Liquid Return Lines will be teed into the Main Liquid Return Line after 6 feet of verti cal drop from the outlet stubs Liquid Return Line will be pitched downstream and provide trapless drainage to the Super Plus COMPONENT PIPING Revised August 1 1996 3 4 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ...

Page 36: ...Revised August 1 1996 P N 340272A 3 5 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ...

Page 37: ...pending on whether a Low end or High end Satellite is used A Low end Satellite Suction Line is piped to its check valve on the Suction Manifold and from there to the evaporator If Koolgas Defrost is used pipe through the proper Koolgas valve A High end Satellite is piped directly to the evaporator Discharge Lines for Two Satellites Installations having two Satellites are tee d together upstream of...

Page 38: ...wn until it intersects the OD line size of the run The number listed at the intersection is the L value for figuring offset and expansion loop sizes Example The smallest Inches Expansion equal to or greater than 1 4196 is 1 5 The 1 5 column intersects with the 1 3 8 line at 21 Use L value 21 STEP 3 For an offset multiply the L value by 3 to determine the length of the offset Example An L value of ...

Page 39: ...he CPR is field installed in the suction line s from the evaporator s The installer is responsible for proper adjustment of the Valve see Control Valve Section for adjustment procedures CONNECTING PARALLEL 3 WAY VALVES Due to the size limitations of 3 Way Valves some of the larger Koolgas systems will require parallel connection to two suction stubs at the header using an offset tee con struction ...

Page 40: ...ST May be reduced by one size after one half the case load run Do not reduce below evaporator connection size Take offs to evaporators exit the bottom of the liquid line Provide an expansion loop for each evaporator take off Minimum 3 inch diameter KOOLGAS DEFROST Maximum of 6 evaporators per Branch System Increase the liquid line size inside the case by two sizes over the branch size Branch Size ...

Page 41: ...equired by governing electric codes will be the responsibility of the installer The lugs on the circuit breaker package in the compressor control panel are sized for copper wire only with 75O C THW insulation All wiring must be in compliance with governing electrical codes For Remote Header Defrost Assembly To the remote defrost control panel provide one 120V 1PH 15A branch circuit Between the rem...

Page 42: ...heck the store legend for door switch kits M115 or M116 The switch must be mount ed to the cooler door frame and must be wired to control the field installed liquid line solenoid and the fan circuit For Koolgas applications kit M116 includes a check valve to bypass the liquid line solenoid valve Sizing Wire and Overcurrent Protectors Check the serial plate for Minimum Circuit Ampacity MCA and Maxi...

Page 43: ...nd T9A circuits remain open during normal operation If either circuit closes a 120V input to the Alarm Board activates A9 or T9A LED andAlarm Condition AR Coil DE energizes AR Contacts open between Terminals 34 and 35 AR Contacts close between Terminals 34 and 36 after Fuse F1 Energizing Alarm Light Bell Stop Switch Terminals 31 and 32 With A9 or T9A the Board will remain in Alarm until the Reset ...

Page 44: ...COMPRESSOR CONTROLS Alarm Board HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 4 ...

Page 45: ...per Circuit from X1 to COMP Go to 6 0V Alarm Board Failure 6 Alarm Light Not Lit Close Jumper Circuit from X1 to A9 Go to 7 Lit Alarm Board Failure 7 A9 Light Lit Go to 8 Not Lit Alarm Board Failure 8 3 Min Delay Lit Open Jumper Circuit from X1 to A9 Go to 9 Alarm Light Not Lit Alarm Board Failure 9 Alarm Light Lit Go to 10 Not Lit Alarm Board Failure 10 32 X2 120V Press Bell Stop Switch Go to 11 ...

Page 46: ...ssor On Yellow LED indicates that there is 120VAC to the contactor coil Alarm Red LED indicates that this com pressor has had an alarm failure and the alarm relay is energized This light will go off when the alarm condition is corrected and the control switch is reset Fuse Failure Red LED lights if the fuse has blown Fuse is on board High Pressure Failure Red LED lights under high pressure failure...

Page 47: ...es overload protection T10 and T9 provide input to the board from Koolgas or Interlock contacts T3 provides power to the K2 Relay Circuit T1 and T2 provide input to the board from EPC compressor contacts for the K2 Relay T5 and T6 provide output to the Alarm Board Compressor Relay T8 provides common for all board circuits T4 is the power input from a switchback con trol contact T7 is the power inp...

Page 48: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 8 Compressor Board using Mechanical Low Pressure Control or Series Switchback ...

Page 49: ...r 5 P1 1 T8 120 Go to 7 0 Test ON OFF Switch and connections to Board If OK Board Failure 6 P1 2 T8 120 Low Pressure Control closed Go to 7 0 Low Pressure Control opened Should be closed to continue Board check 7 P1 3 T8 120 Go to 8 0 Board Failure 8 P1 8 T8 120 Go to 9 0 Compressor Protector open 9 P2 2 T8 120 Go to 10 0 Board Failure 10 P1 5 T8 120 Go to 11 0 Check Fuse and connections If OK Boa...

Page 50: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 10 ...

Page 51: ...back correct cause and reset 5 T3 T8 120 Go to 6 0 Check Power Supply to T3 from X1 6 T1 T8 120 Go to 7 0 Board Failure 7 T2 T8 120 Go to 8 0 EPC not calling for compressor run 8 P1 3 T8 120 Go to 9 0 Board Failure 9 P1 8 T8 120 Go to 10 0 Compressor Protector open 10 P1 5 T8 120 Go to 11 0 Check Fuse and connections If OK Board Failure 11 P1 6 T8 120 Go to 14 0 Alarm tripped Go to 12 12 P1 4 T8 0...

Page 52: ... Contacts close the Compressor Motor Contactor Coil is ener gized If an electronic control other than EPC is applied with Series Switchback the K2 Circuit is not used Normally Closed Contacts from the controller are wired in series with the low pressure control through terminal T4 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 12 ...

Page 53: ... its own circuit through the Normally Open K1 Contacts The Compressor Board Switch must be opened to de energize the K1 Relay The three Normally Closed K1 Contacts are held open during alarm conditions The K1 Contacts between T5 and T6 open the circuit to the Compressor Alarm on the rack s Alarm Board HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 4 1...

Page 54: ...circuits to T3 on all the rack s compressor boards and closes the circuits to T4 on half the boards plus Time Delay Split Relay After another 24 second delay the Split Relay closes the circuits to T4 on the remaining half of the boards With a compound rack the medium tempera ture side is brought on first and the low tem perature side by the Split Relay HUSSMANN CORPORATION BRIDGETON MO 63044 2483 ...

Page 55: ...closed and compressor cycling falls to the control wired between P1 1 and P1 2 A Time Delay Split TDSP prevents all the compressors from coming on at once on start up after the control panel has been off HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 4 15 ...

Page 56: ...nd for switchback operation These controls take over compres sor run functions of the EPC in case of EPC failure The rack will continue to operate less efficiently until the EPC is brought back on line HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 16 ...

Page 57: ...120V Control Panel and the low Voltage EPC circuit boards DO NOT CROSS VOLTAGES Interlock Relay On Compound Systems at least one high side compressor must be running when a booster compressor comes on The first high side compressor is designated for this function If compounding is between racks this will be the 1 Compressor On a com pound rack the first high side compressor will be forced on if no...

Page 58: ... 4 18 Compressor Protection EXCEPT CARLYLE INTERNALLY COMPOUNDED COMPRESSORS Compressor protection is determined by the type of compressor used These controls are wired between P1 3 and P1 8 Since the con trols reset automatically an open compressor protector will not cause an alarm situation ...

Page 59: ... both Oil Failure and compressor protection To determine which caused the failure take the following steps in order 1 Turn off the compressor board switch to reset it then turn it on If the compressor starts the failure was from a compressor protector 2 If the compressor does not start press the reset for the oil safety If the compressor starts the failure was from Oil Failure HUSSMANN CORPORATION...

Page 60: ...itions Demand Cooling Demand Cooling is powered between P1 6 and P2 5 L1 and L2 are spliced into the P1 6 and P2 5 circuits in the Compressor Terminal Box The modules time delayed safety is placed in front of the High Pressure control If opened by sustained high temperature it will cause a compressor alarm condition HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised Aug...

Page 61: ...ed contacts of the Crankcase Heater Relay open when the Compressor Motor Contactor Coil is ener gized so the heater is off while the compres sor is running Unloader The Unloader circuit is powered only during compressor run The Unloader is controlled by the normally open contacts of the EPC Unloader Board HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A...

Page 62: ...defrost This light will turn off if the defrost has been terminated due to time or temperature and if the branch is in drip cycle EPR Solenoid Green LED indicates the suction stop solenoid is energized which means the valve is open Liquid Branch Solenoid Green LED indicates the liquid branch solenoid is ener gized It will turn off when the thermostat no longer calls for refrigeration HUSSMANN CORP...

Page 63: ...mechanical defrost clock when contacts close branch relay R1 will switch into defrost TEMP TERM is input from defrost termina tion thermostat closes to end defrost X1 and X2 are 120VAC input to the board and defrost branch X1 is Line and X2 is Neutral KR is output to Koolgas Relay KG 3W SOL is output to the Koolgas or 3 Way Valve Solenoid depending on which is applied EPR CNTR is input from case t...

Page 64: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 24 ...

Page 65: ...p If OK Board Failure 3 P2 2 T11 X2 0 End Test 120 Defrost timer contacts closed Correct and reset system Defrost Mode Voltmeter Voltmeter Action Lead Placement Reading Lead 1 Lead 2 1 T1 X1 T11 X2 120 Go to 2 0 Check Power Supply to Board 2 P2 1 T11 X2 120 Go to 3 0 Check Fuse F1 5 Amp If OK Board Failure 3 P2 2 T11 X2 120 Go to 4 0 Defrost timer circuit open Check and correct 4 T4 T11 X2 120 Go ...

Page 66: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 26 ...

Page 67: ...Q2 Input on the does NOT light Branch Board if OK Go to 2 Branch Board Verify Clock Terminal and DefrostYellow LED Branch Board for match lights for a different Consult Defrost Clock 1000 Manual Branch Board for correction procedures Voltmeter Voltmeter Action Lead Placement Reading 2 T1 X1 T11 X2 120 Go to 3 0 Check Power Supply to Board 3 P2 1 T11 X2 120 Go to 4 0 Check Fuse F1 5Amp If OK Board ...

Page 68: ... used to accomplish defrost The basic circuit is controlled by a defrost clock which closes the circuit energizing relay coil R1 R1 controls one contact 1R1 normally closed and two contacts 2R1 nor mally open NC 1R1 controls refrigeration components NO 2R1 s control defrost com ponents As the system requirements vary so will the components controlled by the con tacts Once begun defrost continues u...

Page 69: ...Stop Koolgas Defrost When the defrost clock energizes Defrost Relay Coil R1 Contact 1R1 will turn OFF the EPR Solenoid ES Contacts 2R1 will turn ON the Koolgas Solenoid KS and Koolgas Relay KR power to T4 thru Yellow wire to KR terminal thru Red wire to Koolgas Relay KR and thru Brown wire to Bypass Circuit ...

Page 70: ...frost When the defrost clock energizes Defrost Relay Coil R1 Contact 1R1 will turn OFF the Liquid Line Solenoid Contact 2R1 will turn ON Branch Defrost Contactor in the Electric Defrost Panel power to T4 thru Orange wire to D__ terminal thru field wiring to corresponding D__ terminal in Electric Defrost Panel ...

Page 71: ...ORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 4 31 Off Cycle Defrost When defrost clock energizes Defrost Relay Coil R1 Contact 1R1 will turn OFF Liquid Line Solenoid Valve S ...

Page 72: ...on level pressure 30 minutes for EPC 2000 not needed or recommended Faulty defrost timer motor 30 minutes not available with Paragon timer Copeland Solid state Delay Copeland compressors equipped with an inter nal solid state protector cycle 120 seconds after power break Thermostats EVAPORATOR MOUNTED LIQUID LINE SOLENOID Wire the thermostat in series with the liquid line solenoid Any 120V uninter...

Page 73: ... monitor has an indicator that lights as long as it is not tripped The low voltage cutout is adjustable from 180 to 230 volts for 208 230 volt units and from 380 to 460 volts for 440 volt units This should be adjusted to 15 below the nominal line voltage at power source A voltmeter should be used to establish actual supply voltage The monitor controls a two pole bypass relay BP making and breaking...

Page 74: ...Lifting and Leg Assembly Under no circumstances should the condenser manifolds piping return bends or control panel be used for lifting or moving the unit Lifting channels are provided at each corner of the condenser Condensers with three or more fans will have additional intermediate lifting channels Use these locations only for attaching cables during leg assembly Unmounted legs and and lifting ...

Page 75: ...e top of the condenser To reverse change L1 and L3 at the motor If equipped Gravity dampers moving freely Preliminary Control Setting Set controls according to the charts in Control Settings for start up These settings will need to be checked and adjusted once the system is running The settings listed are general guidelines and may require some variation because of local conditions or store design...

Page 76: ...60V R22 R507 R22 R507 1x1 2 8 2 6 1 3 205 221 19 35 1 1 8 HLCVB 1x2 5 6 5 2 2 6 410 445 40 75 1 3 8 1x3 8 4 7 8 3 9 615 666 59 110 1 3 8 1x4 11 2 10 4 5 2 925 1002 88 165 1 5 8 1x5 14 0 13 0 6 5 1039 1125 99 185 2 1 8 1x6 16 8 15 6 7 8 1239 1343 119 223 2 1 8 1x7 19 6 18 2 9 1 1551 1679 147 275 2 5 8 1x2 8 8 8 0 4 0 1081 1137 64 120 1 5 8 HLCVF 1x3 13 2 12 0 6 0 1574 1658 96 180 2 1 8 1x4 17 6 16 ...

Page 77: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA REMOTE CONDENSER REMOTE SATELLITE Revised August 1 1996 5 4 ...

Page 78: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 5 5 ...

Page 79: ...rier may refuse claim The carrier will supply the necessary claim forms Concealed Loss or Damage When loss or damage is not apparent until after equipment is uncrated a claim for concealed damage is made Upon discovering damage make request in writing to carrier for inspection within 15 days and retain all packing The carrier will supply inspection report and required claim forms NOTE The compress...

Page 80: ...st cycle from 2 to 120 minutes 3 The Time Setting Dial rotates once every 24 hours and appears to be 7 hours ahead of the Program Timers This time difference compensates for the location of the defrost switches and the pointer marked TIME The field technician will set the Time Setting Dial at the approxi mate time of day Setting Precision Defrost Timer Setting Defrost Start Times Rotate the Progra...

Page 81: ...Tool pull the dials apart and reset teeth when required minutes of defrost is opposite the indicator mark Setting Time of Day Turn the setting knob until the correct time of day on the Time Setting Dial is opposite the Arrow Time Marker Note that the time indicated on the Time Setting Dial does not match the position of the numbers on the Program Timer Dials HUSSMANN CORPORATION BRIDGETON MO 63044...

Page 82: ...ntinue to drive the timer the alarm switch will close warning that the timer requires service To reset the alarm switch 1 Push gear A toward the motor or lever B will be broken 2 Using a non metallic object depress the plastic cam until it snaps into position holding the switch open HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 6 3 ...

Page 83: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA MECHANICAL DEFROST TIMERS Revised August 1 1996 6 4 ...

Page 84: ...odules cannot be substituted for each other or converted to the other type Setting Paragon Defrost Timer Setting Defrost Start Times Insert a black tripper in white Program Module Dial notch for each defrost start time on a system Remove any extra trippers P M hours are represented by numbers 13 through 24 Setting Length of Defrost Rotate the copper termination lever of the Minute Dial to the requ...

Page 85: ...out on the bottom of the Module Installation Be sure power is off Set all the Modules including the one to be installed for the same hour on the 24 hour dials Set all red tabs on the Minute Dials including the one to be installed in a front most position Slip the Module onto the slotted rod of the frame top and mate the Minute Dial axle into the axles on both sides of it Insure that all the red ta...

Page 86: ...osen the hex head bolt next to the motor And slide the module up until the three locator studs clear the key slots Installation Be sure power is off Check new motor voltage application Rotate the main drive gear until the axle tongues and grooves are vertical red tabs will be directly above the axle Place locator studs in key slots and slide down Tighten hex head bolt Reconnect wires HUSSMANN CORP...

Page 87: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA MECHANICAL DEFROST TIMERS Revised August 1 1996 6 8 ...

Page 88: ...ply must maintain a positive differential of at least 50 psig above the down stream side of the valve Lower pressure differentials may cause valve malfunction Basically all evaporator pressure regulator valves open on upstream suction pressure rise Achieve the desired suction pressure by bal ancing Adjustment Spring against Upstream Suction Pressure and Fixed Pressure Counter Spring As upstream pr...

Page 89: ... open find and repair open stuck in defrost mode correct defrost clock problem Fails to close High pressure inlet strainer plugged Clean or replace High pressure line pinched shut off Clean or replace If oil filled repipe or plugged so high pressure line is not an oil trap Sleeve or piston scored allowing Replace high pressure leak from piston chamber Dirt in piston chamber causing drag Clean or r...

Page 90: ...rt in the piston provides for de compression of the piston chamber when the pilot port closes Troubleshooting Koolgas Valves HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 7 3 Malfunction Cause Action Fails to Open Dirt plugging pilot port Disassemble and clean Solenoid not energized bad solenoid Replace solenoid circuit open Find and repair open NOT ...

Page 91: ...t closed The Main Valve Chamber starts to empty and upstream pressure forces the main valve towards open Differential Mode Quick Test 1 Connect pressure gauges up and down stream of the valve 2 All branches on the rack must be in refrigeration mode 3 Disconnect power to Solenoid 4 Check gauges for differential NOTE Low refrigerant demand may prevent the differential from building up to the valve s...

Page 92: ...lowing flow around the modulating valve Differential Mode Quick Test 1 Connect pressure gauges up and down stream of the valve 2 All branches on the rack must be in refrig eration mode 3 Disconnect power to Solenoid 4 Check gauges for differential NOTE Low refrigerant demand may prevent the differential from building up to the valve s real setting HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Print...

Page 93: ...the valve Higher Pressure downstream back flows closing the Check Valve and forcing the Valve up Equalizing Port allows Valve Chamber pressure to escape upstream Note The Solenoid of the branch valve is energized during refrigeration and for back flow during defrost Troubleshooting Branch Liquid Line Solenoid Valves HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL VALVES Revised...

Page 94: ...both the TEV bulb location under the clamps and between the TEV and the evaporator Inlet While the valve is hunting the temperature difference between the two probes should not exceed 3 5 F The differential may fall to zero To reduce differential turn the adjusting stem counter clockwise and wait at least 15 minutes before checking results Valve Recommended Body Adjustment G 1 2 turn BF 1 4 turn H...

Page 95: ...ing branch line from bottom repipe Liquid supply line too small repipe Insufficient pressure Raise head pressure drop across valve Install valve with adequate capacity at reduced pressure Dead Bulb Replace Undersized TEV Install correct size Evaporator Superheat adjusted Adjust to proper superheat Flooded too low Bulb not getting Check bulb and correct for good contact location good thermal pickup...

Page 96: ... inlet is stopped and the passage between suction and valve chamber is open When the solenoid is energized the suction outlet is stopped and the passage between high pressure and the valve chamber is open B version of the valve has a bleed port through the drive piston to the suction mani fold The bleed port provides a vent for fluids trapped in the Heat Reclaim circuits during normal operation HU...

Page 97: ...lve prevents the liquid refrigerant from leaving the Condenser as fast as it is forming so the Condenser floods with its own condensate A8 Valve Operation Upstream Pressure from the condenser must be sufficient to hold Diaphragm off Valve Port so main Valve Chamber stays filled and holds Main Valve open When upstream pressure falls below Adjustment Spring set point the valve port closes the main V...

Page 98: ... Solenoid is de energized the valve operates like the standard A9 When the solenoid is energized the Solenoid Port opens filling the Valve Chamber and open ing the Main Valve one full turn 25 psig change Troubleshooting Receiver Pressure Regulator HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 7 11 Malfunction Cause Action Fails to Open Set too high R...

Page 99: ...stream of the Flooding Valve The Autosurge Valve reacts to the condensing pressure through its equalizer line and to the temperature of the liquid refrigerant returning from the Condenser through a bulb mounted on the Liquid Return Line up stream of the Flooding Valve When the refrigerant temper ature returning from the condenser drops below its condensing temperature the system has ambient subcoo...

Page 100: ... to substitute a TEV element Emergency Bypass If the pilot valve fails for any reason the sys tem will be forced into Surge flow around the Receiver To achieve Flow through the Receiver follow the steps below 1 Valve off the high pressure pilot line at Discharge Manifold 2 Disconnect flex hose at Surge Valve A and plug hose with a 1 4 inch flare plug finger tighten 3 Valve off the suction pressure...

Page 101: ...re Reading 1 is 98O F the refriger ant has 10O F of subcooling Because of the 5O F accuracy of the pilot valve the system may be in Surge as soon as 103O F is reached or not until 93O F is reached Determining Flow Direction When the Autosurge Valve Chamber Pressure Reading 3 is five pounds or more below the High Side Pressure Reading 2 the valve is in Flow through the Receiver For example a pressu...

Page 102: ... unit supplying subcooling A standard liquid line solenoid valve and a TEV control refrigerant on the rack An EPR on the unit supplying the subcooling prevents the subcooler temperature from dropping below desired liquid temperature Shell and Tube Subcooler Controls Thermostat setting is 50 F with minimum differential or customer specifications The TEV should be set with the highest possible super...

Page 103: ...ve and a TEV con trol refrigerant flow to the Plate Heat Exchanger An EPR on the return suction line prevents the subcooler temperature from drop ping below desired liquid temperature Plate Subcooler Controls Thermostat setting is 50 F with minimum differential or customer specifications The TEV should be set with the highest possible superheat that will still maintain the desired liquid temperatu...

Page 104: ... manual reset is required The System Parts Temperature Sensor Control Module Injection Valve The Temperature Sensor employees a Negative Temperature Coefficient NTC Thermistor to provide signals to the Control Module The NTC resistance drops on temperature rise Temperature Approximate Ω F Reading 77 90 000 282 2 420 292 2 110 310 1 660 Probe test readings between 100 000Ω and 1 600Ω usually indica...

Page 105: ...essor Valve sizes correspond to the four compressor bod ies 2D 3D 4D 6D Component Testing Remove power to the system Unplug the Temperature Sensor from the Module The Sensor should ohm out between 1 600Ω and 100 000Ω Leave the Sensor unplugged and restart the system There should be no voltage between terminals S and L2 on the Module The inlet and outlet sides of the Injection Valve should feel the...

Page 106: ...re wired into the compressor control circuit so an alarm condition removes the compressor from the line and power to the Module A manual reset is required to call attention the alarm condition Alarm Relay The Alarm Relay is activated after a one minute delay under the following three condi tions 1 Compressor discharge temperature exceeds 310 F 2 A shorted circuit or very low Thermistor Resistance ...

Page 107: ...t suc tion pressure on one oil system Turning the adjustment stem clockwise 1 4 turn will increase the pressure to the oil level regu lators about 1 psig 1 4 turn clockwise 1 psig increase Oil Level Regulators For any brand of oil level regulator to work accurately the unit and each compressor must be level Both Sporlan and AC R regulators may be damaged by over adjusting Do not exceed 175 psig wh...

Page 108: ...e desired height by turning the stem clockwise Each full turn will represent about 0 05 inches change in oil level Do not exceed 9 turns from the top stop going down or the control by be damaged AC R Oil Level Regulator The AC R Oil Level Regulator comes preset to maintain oil level 1 8 inch below the center line if the sight glass Turn the adjustment stem counterclockwise to increase the oil leve...

Page 109: ...Low Temperature Cut out 1 psig High end Satellite Refrigerant Cut out Cut in psig psig R502 36 59 R22 29 49 PLATE SUBCOOLING CONTROLS Thermostat setting is 50 F with minimum dif ferential or customer specifications The TEV should be set with the highest possi ble superheat that will still maintain the desired liquid temperature EPR setting is listed on the store legend SHELL AND TUBE SUBCOOLING CO...

Page 110: ...imum distance above the Flooding Valve add 1 psig to the Flooding Valve Setting for every additional 2 feet of elevation Refrigerant Flooding Receiver Valve Pressure Liquid Vapor psig psig R22 175 165 R404A R507 205 195 MECHANICAL LOW PRESSURE CONTROLS Alco The Alco Low Pressure Control comes with a factory set cut in pressure of 15 psig Since the differential is fixed at 10 psig the cut out is 5 ...

Page 111: ...16 17 18 16 15 16 17 18 19 20 15 16 17 18 19 20 21 10 20 21 22 23 24 25 7 35 36 37 38 39 40 10 38 39 40 41 42 43 12 40 41 42 43 44 45 14 43 44 45 46 47 48 15 44 45 46 47 48 49 16 45 46 47 48 49 50 20 50 51 52 53 54 55 23 53 54 55 56 57 58 25 56 57 58 59 60 61 R22 Design Compressor Capacity Suction Largest to Smallest Temp 1 2 3 4 5 6 F psig 33 5 6 7 8 9 10 30 5 6 7 8 9 10 28 5 6 7 8 9 10 25 5 6 7 ...

Page 112: ...ig 12 14 15 17 18 20 21 24 25 29 CO psig 8 10 11 13 14 16 17 20 21 25 Compressor Number 2 CI psig 10 12 13 15 16 18 19 22 23 27 CO psig 6 8 9 11 12 14 15 18 19 23 Compressor Number 1 CI psig 9 11 12 14 15 17 18 21 22 26 CO psig 5 7 8 10 11 13 14 17 18 22 Design Suction Temp F 33 30 28 25 23 21 20 16 15 10 R404A R507 Low Temperature Compressor Number 6 CI psig 14 16 17 19 20 22 23 26 27 31 CO psig ...

Page 113: ...5 60 64 CO psig 34 37 39 41 42 44 49 54 58 Compressor Number 2 CI psig 38 41 43 45 46 48 53 58 62 CO psig 32 35 37 39 40 42 47 52 56 Compressor Number 1 CI psig 36 39 41 43 44 46 51 56 60 CO psig 30 33 35 37 38 40 45 50 54 Design Suction Temp F 7 10 12 14 15 16 20 23 25 R404A R507 Medium Temperature Compressor Number 6 CI psig 44 47 49 52 53 54 60 64 66 CO psig 40 43 45 48 49 50 56 60 63 Compresso...

Page 114: ... 33 34 35 39 42 45 51 57 64 72 Compressor Number 2 CI psig 30 33 35 37 38 39 43 46 49 55 61 68 76 CO psig 24 27 29 31 32 33 37 40 43 49 55 62 70 Compressor Number 1 CI psig 28 31 33 35 36 37 41 44 47 53 59 66 74 CO psig 22 25 27 29 30 31 35 38 41 47 53 60 68 Design Suction Temp F 7 10 12 14 15 16 20 23 25 30 35 40 45 R22 Medium Temperature Compressor Number 6 CI psig 34 37 39 41 42 43 47 49 51 59 ...

Page 115: ... 9 10 11 12 13 15 16 20 CO psig 3 4 5 6 7 8 9 11 12 16 Compressor Number 2 CI psig 5 6 7 8 9 10 11 13 14 18 CO psig 1 2 3 4 5 6 7 9 10 14 Compressor Number 1 CI psig 4 5 6 7 8 9 10 12 13 17 CO psig 0 1 2 3 4 5 6 7 9 13 Design Suction Temp F 33 30 28 25 23 21 20 16 15 10 R22 Low Temperature Compressor Number 6 CI psig 9 10 11 12 13 14 15 17 18 22 CO psig 5 6 7 8 9 10 11 13 14 18 Compressor Number 5...

Page 116: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL SETTINGS Revised August 1 1996 8 8 ...

Page 117: ...6 F 21 F 6 Hrs 43 F 40 Min M3 M4G M5 28 F 18 F 6 Hrs 48 F 30 Min M3E M5GE 28 F 21 F 6 Hrs 48 F 35 Min M3G 27 F 18 F 6 Hrs 48 F 30 Min M3GE 28 F 21 F 8 Hrs 48 F 35 Min Application MEAT Models Refrigeration DischargeAir Temperature F Evaporator Temperature F Fan Cycling CI CO F Defrost Frequency Hrs Electric Temp Term F Failsafe Min Reverse Air Temp Term F Failsafe Min Koolgas Duration Min Offtime T...

Page 118: ...porator Temperature F Fan Cycling CI CO F Defrost Frequency Hrs Electric Temp Term F Failsafe Min Reverse Air Temp Term F Failsafe Min Koolgas Duration Min Offtime Temp Term F Duration Min P4E 31 F 24 F 6 Hrs 48 F 30 Min PW End 32 F 21 F 8 Hrs 45 Min P4 29 F 21 F 6 Hrs 48 F 30 Min PW 34 F 21 F 8 Hrs 45 Min PWE 34 F 24 F 8 Hrs 45 Min PWE End 32 F 24 F 8 Hrs 45 Min Application PRODUCE ...

Page 119: ...ailsafe Min Reverse Air Temp Term F Failsafe Min Koolgas Duration Min Offtime Temp Term F Duration Min C2LE C2E C2LGE 27 F 21 F 6 Hrs 48 F 30 Min C2XLE C2XE C2XLGE 29 F 21 F 6 Hrs 48 F 30 Min D5L D5 D6L D6 D5LR D5R D5HR 31 F 21 F 6 Hrs 48 F 30 Min D5LE D5E D5HE D6LE D6E D5LRE D5RE D5HRE D5NLE D5NE 32 F 24 F 6 Hrs 48 F 35 Min D5G D5H 31 F 21 F 6 Hrs 48 F 35 Min D5GE D5NHE D5NGE 32 F 24 F 6 Hrs 48 F...

Page 120: ...ctric Temp Term F Failsafe Min Reverse Air Temp Term F Failsafe Min Koolgas Duration Min Offtime Temp Term F Duration Min RM 34 F 27 F 24 Hrs TBD TBD TBD RM 30 F 23 F 24 Hrs TBD TBD TBD RL 5 F 11 F 24 Hrs 48 F 40 Min 20 Min RL 12 F 19 F 24 Hrs 48 F 40 Min 20 Min Application DAIRY DELICATESSEN FROZEN FOOD ICE CREAM Preliminary Data Preliminary Data Preliminary Data Preliminary Data Preliminary Data...

Page 121: ... Term F Failsafe Min Reverse Air Temp Term F Failsafe Min Koolgas Duration Min Offtime Temp Term F Duration Min LNG 10 F 20 F 24 Hrs 48 F 60 Min 15 Min L LG LN LNG LI LIG LW LWG LWU LWUG LWE LWEG 12 F 20 F 24 Hrs 48 F 60 Min 15 Min LIG 12 F 20 F 24 Hrs 48 F 60 Min 18 Min L LG LN LI LW LWG LWU LWUG LWE LWEG 22 F 30 F 24 Hrs 48 F 60 Min 18 Min LNG 20 F 30 F 24 Hrs 48 F 60 Min 18 Min LIG 20 F 30 F 24...

Page 122: ...Duration Min G5C G5CH G6C G6CH NC6 NC6H 20 F 30 F 6 Hrs 54 F 36 Min 48 F 60 Min 22 Min GF GFI GG GTF GWI GWIT GWI6 NF1 NF1N NFN NFW NFCW NFFS NFWE NFCWE 10 F 20 F 24 Hrs 52 F 60 Min 48 F 90 Min 20 Min GC GCI GGC GTC GWIC GWIT GWI6 NC1 NC1N NCN NCW NFCW NCFS NCWE NFCWE 20 F 30 F 24 Hrs 52 F 60 Min 48 F 90 Min 24 Min RCA RCH NRC NRCV 12 F 19 F 24 Hrs 54 F 40 Min 20 Min FML FMLG 10 F 25 F 12 Hrs 50 F...

Page 123: ... NM4G NDD3 NDD3G NDD4 NDD4G 22 F 11 F 28 38 F 6 Hrs 48 F 46 Min 14 Min 46 Min CGDMG CGDMGT CSDMG NEGDF NEGSF NEGDT NEGDH 24 F 21 F 24 Hrs 48 F 90 Min 14 Min 90 Min CGDM CSDM NEBDH NEBSH 24 F 20 F 24 Hrs 54 F 40 Min 24 Min 90 Min FM FMG FMV FMGV FMGC VFMGC FMGCD NM1 NM1G 22 F 17 F 28 38 F 12 Hrs 48 F 46 Min 48 F 70 Min 14 Min 70 Min FMR FMRV FMRG FMRGV FMRGC 22 F 9 F 28 38 F 12 Hrs 48 F 46 Min 48 F...

Page 124: ...Duration Min DMD DMDH DMDA NDD5 NDD5H NDD5A 32 F 18 F 6 Hrs 48 F 40 Min 14 Min 40 Min RDM RDMH 30 F 20 F 24 Hrs 12 Min 60 Min CWI CWI6 MWI MWI6 30 F 20 F 6 Hrs 14 Min 56 Min FHM FHMG FHMH FHMGH FHMS FHMSG MHF MHFG MHFGH NM3 NM3G NM4 NM4G NDD3 NDD3G NDD4 NDD4G 32 F 20 F 28 38 F 6 Hrs 48 F 40 Min 14 Min 40 Min FM FMG FMV FMGV FMGC VFMGC FMGCD NM1 NM1G 30 F 25 F 28 38 F 12 Hrs 48 F 70 Min 14 Min 70 M...

Page 125: ...ilsafe Min Koolgas Duration Min Offtime Temp Term F Duration Min JVMR JVMRS 29 F 15 F 6 Hrs 60 Min RMFA NRFL NRFLV 30 F 23 F 24 Hrs 12 Min 60 Min DMZ DMZA DMZH DMX DMXA DMXH ND5LZ ND5Z ND5HZ ND5LX ND5X ND5HX 32 F 21 F 8 Hrs 48 F 40 Min 14 Min 40 Min RDM 32 F 25 F 24 Hrs 12 Min 60 Min RMA RMFA NRD NRDV NRFL NRFLV 34 F 27 F 24 Hrs 12 Min 60 Min Bulk PRO PHSM PH PHRO P NP1 NP2 37 F 21 F 6 Hrs 12 Min ...

Page 126: ...perature F Fan Cycling CI CO F Defrost Frequency Electric Temp Term F Failsafe Min Reverse Air Temp Term F Failsafe Min Koolgas Duration Min Offtime Temp Term F Duration Min CGFMG CSFMG 36 F 20 F 24 Hrs 90 Min Cheese DSRP 30 F 18 F 8 Hrs 12 Min 50 Min CGFM CSFM NESDH NESSH 24 F 20 F 24 Hrs 100 Min VFL VFS VFK VFT NVSA NVSB NVSC 34 F 27 F 24 Hrs 110 Min Meat DSRP 26 F 12 F 8 Hrs 48 F 50 Min 14 16 M...

Page 127: ...n Cycling CI CO F Defrost Frequency Electric Temp Term F Failsafe Min Reverse Air Temp Term F Failsafe Min Koolgas Duration Min Offtime Temp Term F Duration Min Frozen Food Return 5 F 12 Hrs 54 F 24 Min 16 Min Produce Return 41 F 12 Hrs 16 Min 60 Min Ice Cream Return 15 F 12 Hrs 54 F 24 Min 16 Min Meat Deli 28 F 12 Hrs 54 F 24 Min 16 24 Min 90 Min Dairy Beverage Return 36 F 12 Hrs 16 Min 60 Min Pr...

Page 128: ...trical supply and component require ments Test Charge Use properly regulated dry nitrogen and R22 to pressurize the system with vapor only Charge about 25 pounds of R22 through a dehydrator Through another line add dry nitrogen to bring the system pressure up to 150 psig Use an electronic leak detector to inspect all connections If a leak is found isolate repair and retest Be sure system is at 150...

Page 129: ...st three access ports on the rack Connect one micron vacuum gauge at the pump and one at the furthest point in the system from the rack Plan procedures so breaking the vac uum with refrigerant will not introduce conta minates into the system The vacuum pump must be in good condition filled with fresh oil to achieve desired results Procedure Pull a vacuum to 1500 microns If the vacuum fails to hold...

Page 130: ... required control settings for the sys tem A copy of the equipment legend will be needed to determine the system s design oper ating points High and low pressure heat reclaim lockout winter control settings and other controls on the system should be noted Charging Open Compressors Backseat Service Valves on Suction and Discharge Open oil supply line immediately downstream of the Turba shed Pressur...

Page 131: ...off all compressors and recheck oil levels in each compressor and the Turba shed Leak testing evacuation and initial charging are now completed Final Checks Once the system is up and running it is the responsibility of the installer to see that all the fine adjustments are made so the Super Plus Fibertronic delivers maximum tem perature performance and efficiency for the customer These include Def...

Page 132: ...ations Remove bolts from suction and discharge service valves Remove mounting bolts When moving the compressor use a come along hoist or hydraulic lift to carry the weight Do not use the rack piping or panel to support a hoist or come along Do not use ceiling trusses to support a hoist or come along The rear support channel on the rack or a properly constructed ceiling rail may be used to support ...

Page 133: ...ker Number 2 23 Compound557 Precision Rubber Number 023 Compound 2337 Leak test evacuate and charge with fresh oil only Suniso 3G or Texaco Capella WF32 Open valves closed to isolate the oil system and bring the rack back on line Replacing Drier and Filter Cores Shut down the system Isolate the core to be replaced and bleed off pressure into an approved recovery vessel Open housing replace core an...

Page 134: ...Piping 3 3 5 Control Panel Compressor Board 4 6 Defrost Board 4 23 24 SUBJECT CHAPTER PAGE Defrost Clock Mechanical Paragon 6 5 Precision 6 1 Demand Cooling 2 11 7 17 19 Dimensions Load Points 1 3 Machine Room 1 3 Receiver 1 2 Super Plus Rack 1 2 Satellite 5 6 Electrical Schematics Remote Condenser 5 4 5 Super Plus In Unit Equalizing Line 3 3 5 Evacuation 9 2 Expansion Loop 3 7 Heat Reclaim 2 6 7 ...

Page 135: ...5 6 Remote Satellite 5 9 Super Plus 1 2 Single Phase Protector 4 33 Solder 3 1 Subcooling Ambient 2 9 7 12 Mechanical 2 10 7 15 SUBJECT CHAPTER PAGE Valves Autosurge 7 12 2 9 Branch Liquid Line 7 6 2 5 EPR 7 1 2 5 Koolgas 7 2 2 7 Flooding 7 10 2 4 Heat Reclaim 7 9 2 4 Main Liquid Line Solenoid 7 4 5 2 5 Oil Pressure and Level 7 20 21 2 8 Receiver Pressure Regulator 7 10 2 6 TEV 7 7 2 5 2 Way 7 3 2...

Page 136: ...nser to mini mize the refrigerant charge The valving may be field or factory installed If any of the following conditions exist split condenser valving is recommended 1 The difference between summer and winter dry bulb temperatures is greater than 90O F 2 The local climate conditions are anticipated to be more severe than those stated in the ASHRAE charts 3 The heat reclaim coil is sized for more ...

Page 137: ... condenser with at least three feet of clearance space on all sides to provide ade quate air circulation and room for servicing Mount the condenser on beams supported by building columns or load bearing walls The mounting surface for the condenser should be at least 6 feet higher than the flooding valve when the compressor unit is equipped with condensing pressure control valves This height requir...

Page 138: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Addendum April 15 1997 P N 340272A A 3 Figure A 2 Rigging for Leg Assembly and Lifting ...

Page 139: ... supplied check valve installed to prevent flow from the condenser to the receiver A shutoff valve should be installed on the condenser side of the check valve Normally equalizer lines are not required unless the condensate lines are trapped and or undersized 1 Discharge line Connect the two inlet stubs to the discharge line by forming an expansion loop extending at least 12 inches away from the m...

Page 140: ...5 Split Condenser Wiring Diagram Factory and Field Installed Kits High Pressure Control Settings Refrigerant Cut Out Cut In R 404a 250 195 R22 210 160 R507 260 200 Note Units with Heat Reclaim should have the lockout control set to prevent the heat reclaim from being activated below the following discharge pressure values R 22 135 psig R 507 170 psig R404a 165 psig ...

Page 141: ...pressure control has been applied as fol lows a When more than one compressor unit is connected to the same condenser all fan banks except the one nearest the discharge and liquid manifolds must be cycled by thermostats each com pressor unit must also be equipped with condenser flooding valves b When only one compressor unit is connected to a condenser either of two types of controls can be used 1...

Page 142: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Addendum April 15 1997 P N 340272A A 7 ...

Page 143: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONDENSER INSTALLATION Addendum April 15 1996 A 8 ...

Page 144: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Addendum April 15 1997 P N 340272A A 9 ...

Page 145: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONDENSER INSTALLATION Addendum April 15 1996 A 10 ...

Page 146: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Addendum April 15 1997 P N 340272A A 11 ...

Page 147: ...HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONDENSER INSTALLATION Addendum April 15 1996 A 12 ...

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