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1. Inspect or Place Probes Result Action 1 Alarm Light Lit Go to 3 Not Lit Go to 2 2 Probe across Alarm 120V Repair Alarm Light Circuit Go to 3 Light Terminals OV Alarm Board Failure 3 31 2 120V Go to 4 OV Alarm Board Failure 4 36 2 120V Go to 5 OV Alarm Board Failure 5 32 2 120V Close Jumper Circuit from X1 to COMP Go to 6 OV Alarm Board Failure 6 Alarm Light Not Lit Close Jumper Circuit from X1 to A9 Go to 7 Lit Alarm Board Failure 7 9 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 2 120V Press Bell Stop Switch Go to 11 OV Alarm Board Failure 32 2 OV Press Reset Go to 12 120V Check Bell Stop circuit If O K Alarm Board Failure 12 35 2 120V Go to 13 OV Alarm Board Failure 13 Alarm Light Not Lit Close Jumper Circuit from X1 to T9A Go to 14 Lit Alarm Board Failure 14 T9A Light Lit Go to 15 Not Lit Alarm Board Failure 15 30 Min Delay Lit Open Jumper Circuit from X1 to T9A Press Reset Go to 16 Alarm Light Not Lit Alarm Board Failure 16 Alarm Light Not Lit Test Completed Power OFF Re instate Control Lit Alarm Board Failure HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL 4 6 Compressor Circuit Board Compressor Control Circuit
2. no wedge 4 renin inui To Heat iie Main suppled Liquid Return 7 Liquid ond Bes ded Bed Line wi 2 5 Line Bod off Loops E Return Y 2 PEE d zo E ete AS ee ue ues fen eee Rm 2 de See noue cr EUG so Bee St a ee cael E these 21 E AU x3 S m 2537 I al n m fU mee Buction Manifold o ey een nanan 7 gon eee 7 7 Fboding 4 bre UE Super Plus Fack Discharge Lines Ball alve Condenser Manifold r Return Lines GA Check Valve ae Vale Solenoid Equalizing Line IA Berrice Valve PD Pump Down iid Tubing Purge Valve Figure 3 7 Rack to Condenser 3 Way V alve Mote Liquid Retum Lines must be free draining with na Tra ps WARNING 34nstall Solenoid Valves inside Equipm ent A aam Vert the Receiver Pump D em Line shoud nat enter Ehe Suction Marifald Safaty Relief Val over a Com pressor Inlet ely elie va PEOPERLY dnstall Ball Valves to isolate C ondere er HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 3 5 J 2 HeslerEnd 0 2 of Conde mer Vei 2 EA 6 Foot Minimum Drop A before All re z Testo and Valves U 2 From Main above this line NUR Heat Liquid are Field 2 2 Py Rec him xd o Line suppli 5 E T Heat 5
3. 7 2 Koolpas Valve asian 7 2 2 Way Solenoid Valve 7 3 Main Liquid Line Solenoid 3 Way Solenoid 7 3 DOULA Mm ea cae eter cis 7 4 Liquid Line Solenoid 7 4 PCD e cuit iu ntu 7 5 Alco Main Liquid Line Solenoid 7 5 Branch Liquid Line Solenoid Valves 7 6 Branch Liquid Line Solenoid 7 6 7 7 Probe Locations For Setting TEV 7 7 Heat Reclaim Valve dieere 19 7 7 Flooding Valve and Receiver Pressure 3 Way Heat Reclaim Valve 7 9 Regulating 7 10 Condenser and Receiver Pressure et abad tin 7 12 Repulation 7 10 Mechanical Subcooling 7 15 8 Flooding 7 10 Demand Cooling 7 17 A9 Receiver Pressure Regulator 7 11 OIl System 7 20 Receiver Pressure Regulator 7 11 Autosurge and By Pass Valves 7 12 Autosurge Valve Connections 7 13 Establishing Valve Operating Range 7 14 Shell and Tube Type Mechanical SUDCOQOG GE oou cd ies hg dt edt n aon evi ves 7 15 Plate Type Mechanical Subcooling 7 16 Demand Cooling Components 7 17 Demand Cooling Piping
4. allt cates 2 5 Demand esses 2 11 EPR ValVe 2 5 Heat Reclaim 2 6 Receiver Pressure Regulation 2 6 A9 AQB Valves cases 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 Subcooling 2 10 2 11 Revised August 1 1996 P N 340272A CONTENTS Topics Figures 3 1 Supporting Refrigeration Lines 3 1 Refrigeration Line Runs 3 1 Insulating a Riser 5 eer 3 2 Rack to Condenser Piping 3 3 Vibration 3 2 Rack to Remote Header 3 6 Construction 02 3 2 Rack to Remote Satellite 3 6 Reduced Riser utei eese 3 2 Rack to Heat Reclartnmn soos oe 3 7 Rack to Condenser Piping 3 3 Offset and Expansion Loop Construction 3 7 Rack to Condenser Piping Special Piping for Open Rooms 3 8 3 Way alveus 3 4 Connecting Parallel 3 Way Valves 3 8 Rack to Condenser Piping Run Lengths and Equivalen
5. 7 18 OIL Syste Ree Chek tacit 7 20 Oil Pressure Differential Valve 7 20 Sporlan Oil Level Regulator 7 21 AC amp Oil Level Regulator 7 21 Tables Troubleshooting EPR Valves 7 2 Troubleshooting Koolgas Valves 7 3 Troubleshooting Branch liquid Line Solenoid Valves zu ecl eee 7 6 Troubleshooting 7 8 Troubleshooting Flooding Valve 7 10 Troubleshooting Receiver Pressure Regulator 7 11 Revised August 1 1996 P N 340272A CONTENTS Topics n 8 1 Pressure 8 1 Plate Subcooling Controls 8 1 Shell and Tube Subcooling Controls 8 1 Compound Rack Additional Settings 8 1 EPR sce oes 8 2 Winter Condensing Pressure Controls 8 2 Mechanical Low Pressure Controls 8 2 8 2 ioi 8 4 Condenser Sette coetus 8 8 Merchandiser Settings 8 9 Revised August 1 1996 P N 340272A CONTENTS Topics STAMP Ee 9 1 Leak TESINE 9 1 cata 9 1 Ib VIS eroe aa E 9 2 Evacuation est res ress tiit e sd 9 2 9 3 DinalC heeKksoss 9 4 e 9 5 Compressor Replacement 9 5 Cleaning the Turba shedTM 9 6 Replacing Drier an
6. 48 F 35 Min 60 F 43 Min 43 F 35 Min 43 F 35 Min 48 F 30 Min 48 F 30 Min HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL SETTINGS Revised March 1 1997 8 10 MERCHANDISER SETTINGS Cont d Application Models Refrigeration Discharge Air Temperature F PRODUCE PWE 34 F Evaporator Temperature F 24 F Fan Cycling F Defrost Frequency Hrs Electric Temp Failsafe Min Reverse Air Temp Failsafe Min Koolgas Duration Min Offtime Temp Duration Min 45 Min HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed USA Revised March 1 1997 P N 340272A 8 11 MERCHANDISER SETTINGS Cont d Application MEAT DELI DAIRY PRE CUT amp PKG DAIRY DELICATESSEN Models Refrigeration Discharge Air Temperature F Evaporator Temperature F Fan Cycling CI CO F Defrost Frequency Hrs Electric Temp Failsafe Min Reverse Air Temp Failsafe Min Koolgas Duration Min Offtime Temp Duration Min HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL SETTINGS Revised March 1 1997 8 12 MERCHANDISER SETTINGS Cont d Preliminary Data Preliminary Data Preliminary Data Preliminary Data Application DAIRY D
7. m 4 99 n Weg 203 uu Th eo HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Addendum April 15 1996 CONDENSER INSTALLATION A 12 amesarg parado VOTI q jonas SE Pd BU im Lug pei 4243 r3 1 pete kag HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA
8. Satellite control All thermostat and temperature sensor wires should be sized for pilot duty at 120VA 120VAC Run a 2 wire circuit for each system using any of the five controls listed above Unit Cooler Fan Wiring Provide a 120 1 60 fused power supply for each cooler Check the store legend to see if 208 230 1 60 is required at this location Evaporator Mounted Liquid Line Solenoid Power for a liquid line solenoid in the case can be picked up from the fan circuit Check fan motor and solenoid voltages first Revised August 1 1996 Select Wire Size Based on the serial plate ampacity of the sys tem select the largest connectable wire size from Table 1 Cooler Door Switch Wiring Check 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 Maximum Overcurrent Protective Devices MOPD Follow NEC guidelines Defrost Controls These circuits may be repeated and or inter mixed in one store Other Controls When other controls are used refer to the manual included with that control Table 1 Required Field Wire Size TOTAL CONNECTED MCA LARGEST CONNECTA
9. This section deals with standard guidelines for installation of Remote Satellites and Remote Air Cooled Condensers Piping is covered in Piping Refer to specific manufacturer s instructions for installation Proper installation is the installer s responsibility REMOTE CONDENSERS Air Cooled Application Split condenser valving is recommended if any of the following conditions exist 1 The difference between summer and winter dry bulb temperatures is greater than 90 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 than 50 of the heat of rejection for the unit 4 The condenser liquid return line is longer than 100 feet 5 The system is equipped for low head pressure operation that seeks to obtain a maximum of subcooling Other Applications If Water Cooled Condensers are used they will be shell and tube construction and must be field installed Evaporative Condensers are shipped directly to the job site by the selected supplier Proper installation is the installer s responsibility Shutoff Valves These valves are field supplied and should be installed in such a manner as to isolate the entire condenser 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
10. Addendum April 15 1996 CONDENSER INSTALLATION A 8 TOMO we pq Jap p m 74627543 n n ag 1241 E X ki iN ped Fund 1 EL ELE MUS 59492 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA P N 340272A Addendum April 15 1997 9 SFO 33 rae 91340344 Bo m Jpop eH im 4021453 n ie 43 ea EJU O Pig A T 5 Mg PUG da HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Addendum April 15 1996 CONDENSER INSTALLATION 10 Ieo 1004 6 7 Smp 140 0 ndg re 3g 712903 FE URLUS bur 1007 TE 1B ul 5 Od bag He Lg Ep TED zBumez Oyu PAILS He LUA 4 200 Joi al HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA P N 340272A Addendum April 15 1997 A 11 g WH 1009 39 Jue ppt nod 303 20 5 uH cpu thet at eH a BRS a 135p op HH
11. 4 7 TAE a Bled Line 2 2 m4 a Fhoding Ta Manifold _ Valve Heat pae Rehim nmm m 2 Valve inm T Buper Plus Rack anna Discharge Lines Ti Ball Valve Purge Valve seeren Liguid Return Lines ED Check Valve Condenser Mani old ing Line Equalizing Line WHEN REQUIRED A inch equalizer 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 Service Valve 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 Printed in USA COMPONENT PIPING 3 4 Connecting to Two Manifolds Discharge Line will be tee d upstream of the manifolds into expansion offsets with at least a 1 foot drop to the manifolds Provide Purge valve at the highest point Revised August 1 1996 eLiquid 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 Mini wm Ere a A Z 2 5 Minmum All Piping ie nre Drop and Valres 2
12. Models 1 Refrigeration Discharge Air Temperature F DAE 28 F MIG 26 F MQ2E M2GE M4E MSE 26 F 29 F M3 M4G M5 28 F M3E M5GE 28 F M3G M3GE 27 F 28 F Evaporator Temperature F 18 F 21 F 18 F 21 F 21 F 18 F 18 Fan Cycling F Defrost Frequency Hrs 6 Hrs 6 Hrs 6 Hrs 6 Hrs 6 Hrs 6 Hrs 6 Hrs 6 Hrs 8 Hrs Electric Temp Failsafe Min gt Reverse Air Temp Failsafe Min Koolgas Duration Min Offtime Temp Term F Duration Min 43 F 35 Min 43 F 35 Min 43 F 35 Min 43 F 40 Min 48 F 30 Min 48 F 30 Min 48 F 35 Min 48 F 30 Min 48 F 35 Min Application MEAT PRODUCE Models M4 M4GE Refrigeration Discharge Air Temperature F 28 F 29 F M5G MWG MWGE 26 F 31 F 31 F P2 P2E 37 F 33 F Evaporator Temperature F 18 F 21 F 18 F 18 F 21 F 24 F 21 F 24 F Fan Cycling CI CO F Defrost Frequency Hrs 6 Hrs 6 Hrs 6 Hrs 8 Hrs 8 Hrs 8 Hrs 6 Hrs 8 Hrs Electric Temp Failsafe Min Reverse Air Temp Failsafe Min Koolgas Duration Min Offtime Temp Duration Min 48 F 25 Min 48 F 35 Min
13. Sizing STEP 1 For low temperature application multiply the length of the run in feet by 0 0169 For medium temperature application multiply the length of the run in feet by 0 0112 The product will be inches of linear expansion for the length of run Example A low temperature application with a run of 84 feet of 1 inch OD 84 x 0 0169 1 4196 inches expansion STEP 2 Select the smallest Inches Expansion figure equal to or greater than the product in step one from Table 3 1 Follow that column down 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 line at 21 Use value 21 P N 340272A 3 7 Table 3 1 L Values for Figuring Offsets and Expansion Loops Line Size Inches Expansion 0 5 1 0 1 5 OD 10 15 19 11 16 20 11 17 21 12 18 23 14 20 25 16 22 27 18 24 30 20 28 34 STEP 3 For an offset multiply the value by 3 to determine the length of the offset Example An L value of 21 would mean 3L23x21 63 The offset distance required for low temperature application for an 84 foot run of 1 line is 63 inches HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA COMPONENT PIPI
14. WINTER CONDENSING PRESSURE CONTROLS The customer may specify lower pressure set tings than those recommended however refrigeration performance may be affected Minimum receiver pressure is 140 psig If the condenser is mounted more than the 6 foot minimum 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 Revised August 1 1996 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 psig which is the lowest possible cut out for this control A small right angle Phillips screwdriver is required to access the adjust ment screw located next to the pressure con nection Turn the screw clockwise when fac ing screw head to increase cut in pressure Note 3 7 rotations of the screw represent the entire 70 pound adjustment range Very roughly 7 turn equals 10 psig HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 8 3 Alco Cartridge style Low Pressure Control Cut Out Pressures Apply data from compressors 1 and 2 for a 2 compressor rack data from compressors 1 through 3 for a 3 compressor rack and so on R22 Design Compressor Capacity Suction Largest to Smal
15. branch solenoid valve Q2 is fiber optic input from Fibertronic Defrost Clock 1000 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL 4 24 ASSY 0340132 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 Revised August 1 1996 P N 340272A 4 25 Troubleshooting Defrost Board with Mechanical Time Clock Be sure Board Switch is closed Refrigeration 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 P22 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 to 5 0 Board Failure 5 T5 T11 X2 120 End Test 0 Board Failure For each remote component determine its board terminals from the wiring diagram then use standard test procedures HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 26 l
16. environment and decrease the hazard of refrigerant burn HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 MECHANICAL SUBCOOLING By lowering the temperature of the liquid supplied to the TEV the efficiency of the evaporator is increased The lower tempera ture liquid refrigerant produces less flash gas exiting the TEV Shell and Tube Subcooler Electrically a thermostat responding to main liquid line temperature of the rack receiving subcooling controls a solenoid valve on the liquid supply line from the 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 P N 340272A 7 15 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 superheat that will still maintain the desired liquid temperature EPR setting is listed on the store legend Valve 3 1 Thermostat i Liquid Line 0 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL VALVES 7 16 Plate Subcooler Electrically a thermostat responding to main liquid line temperature immediately down stream of the Plate Subcooler controls a sole noid valve on the liquid supply line from the L
17. 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 channels are furnished with necessary bolts washers and nuts Mount legs and channels with the hard ware provided Location Locate the condenser with at least six feet of clearance on all sides to provide adequate air circulation If roof mounted place on column supported beams or load bearing walls The mounting surface for the condenser should be at least six feet higher than the flooding valve Leveling and Mounting Cross level the coil section carefully then bolt the condenser legs to the support beams For multi circuit condensers consult the store legend and refer to the identification tags on the manifold end of the condenser to determine compressor unit and manifold connections Route and support all piping in a manner that relieves stress caused by vibration thermal expansion and gradual base or building movement Where piping is routed through a roof construct a pitch box HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA REMOTE CONDENSER REMOTE SATELLITE 5 2 Revised August 1 1996 Figure 5 1 Lifting the Condenser Preliminary Electrical Check Before working on any electric equipment disconnect all power supplies to it and verify that power is off After the condenser is c
18. E A 9 LECH C amp R b I tf r2 A TEF TET ll 2 HUSSMANN CORPORATION BRIDGETON 63044 2483 Printed USA Revised August 1 1996 P N 340272A 4 27 Troubleshooting Defrost Board with Fibertronic Time Clock Be sure Branch Board Switch is Closed Refrigeration Mode Test Result Action 1 From the Time Clock Branch Board System OK to Branch Board force the Branch into Defrost Yellow LED Go to 5 Defrost Mode Refer lights to Defrost Clock 1000 Manual Branch Board Consult Defrost Clock 1000 Manual Defrost Yellow LED to test up to Q2 Input on the does NOT light Branch Board if OK Go to 2 Branch Board Verify Clock Terminal and Defrost Yellow 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 2 120 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 Failure 4 P2 2 X2 120 Go to 5 0 If Jumper J4 open closed if closed Board Failure 5 T4 T11 X2 120 Go to 6 0 Board Failure 6 T5 T11 X2 120 End Test 0 Board Failure For each remote component determine its board terminals from the wiring diagram then use standard test procedures HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRIC
19. Fiter DA Angle Vabe DE 3 Way Valve Pressure Regulator oh Dil Le vel Re gubtor Dj Check Valve 9 Pressure ene Reluced Pressure Equaliz Broken Field supphed in t4lbd Revised August 1 1996 RACK TO REMOTE SATELLITE eThe compressor Discharge Line will be piped through a vibration absorber to its stub on the Super Plus Discharge Manifold compressor Suction Line will be piped one of two ways depending 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 the discharge manifold Use an offset tee construction Do not use a bullhead tee Oil Lines for Remote Satellites All oil lines are run in inch copper Lines will be installed securely and run under tapered cover plates when crossing walkways 110 HH tle M HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 RACK TO HEAT RECLAIM Because of the variety of Heat Reclaim sys tems refer to the instructions accompanying the system to be installed at the site OFFSET AND EXPANSION LOOP CONSTRUCTION
20. GWI6 NC6H GWI6 Temperature NF6 NCI NF1 NF6H NCIN NF6L NCN NEN NCW NEW NFCW NFCW NCFS NFFS NCWE NFWE NFCWE NFCWE Refrigeration Discharge Air Temperature F 200F 20F 12F 10F 10F 8 F 5 F 24 F 24 F Evaporator Temperature F 30F 30F I9F 25F 20F ISF IIF 18 F 20 F Fan Cycling CI CO F m Defrost Frequency 24Hrs 6Hrs 24Hrs 12Hrs 24Hrs 12Hrs 24Hrs 6 Hrs 24 Hrs Electric Temp 52 F 54 F 54 F 50 F 52 F 54 F 54 F 48 F Failsafe Min 60Min 36Min 40Min 46Min 60Min 36Min 40Min 40 Min Reverse Air Temp 48 F 48 F 48 F 48 F m Failsafe Min 90 Min 60 Min 90 Min 60 Min Koolgas Duration Min 24Min 22Min 20Min 14Min 20Min 22 Min 20 Min Offtime Temp 48 F Duration Min 40Min 90 Min HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed USA Revised March 1 1997 P N 340272A 8 15 MERCHANDISER SETTINGS Cont d Application MEAT DELI Models CGDM FHM FM FMR CGDMG MWI VGL CGDM CSDM FHMG FMG FMRV CGDMGT GF MWI6 CSDM For all Merchandisers FHMH FMRG CSDMG GG VGS with Gravity Coils the FHMGH FMGV FMRGV GWIT VGLR Temperature listed in FHMS FMRGC GWI VGSR the Discharge Air FHMSG GTF tow ds Product MHF FMGCD GWI6 Temperature MHFG GFFS
21. Switch ON OFF shuts off all power to the com pressor contactor and all components in that compressor s control circuit and resets the alarm circuit After a failure condition is cor rected and reset the switch must be turned OFF until the alarm light turns off then the switch may be turned ON again WARNING ON OFF switch does not remove power from the circuit board The Control Panel Circuit Breaker must be shut off Board Power Green LED indicates that 120VAC is applied to the board It can only be turned off at the panel circuit breaker Revised August 1 1996 BOARD POWER Oh PRESS OF ON ALARM OFFTO ET FA LURES FUSE HIGH FRESSURE OIL FALURE Compressor 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 condition Oil Failure Red LED lights under oil fail ure condition HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 B24 54821 E E E EJEJEJEJE FIZE E Esby F
22. Valve should feel the same temperature After one minute the alarm relay should trip Remove power to the system Press the manual reset on the Module ES Conlenser k k k oy EE RR RR ER ER RR ORO RR TR RR OO OR RR TR RR RR RR on Figure 7 21 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 Using a small piece of wire jump the Sensor circuit at the female plug in the Module Restart the system There should be voltage between terminals S and L2 on the Module The outlet side of the Injection Valve should feel colder than the inlet side After one minute the alarm relay should trip Remove power to the system Press the manu al reset on the Module Remove the jumper wire and plug in the Temperature Sensor Restart the System Alarm Circuit The Alarm Circuit has three terminals in the Control Module L Common M Normally Closed Normally Open L and are 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 P N 340272A 7 19 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 3
23. and TEV s in merchandisers and coolers Electrical supply and component require ments Warning Always recapture test charge using approved recovery methods 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 psig and all valves closed to isolate the leak are opened After the last leak 1s repaired and tested the system must stand unaltered for 12 hours with no pressure drop from 150 psig HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA START UP and MAINTENANCE 9 2 Oil Levels Check oil levels for each compressor and the Turba shed Compressor sight glass to full Turba shed between two lower sight glasses If oil level is low add recommended oil only Copeland Carlyle R22 Suniso 3GS Suniso 3GS R404A Mobile EAL ICI Emkarate R507 ARCTIC 22 CC RL68H Evacuation Nitrogen and moisture will remain in the system unless proper evacuation procedures are followed Nitrogen left in the system may cause head pressure problems Moisture causes TEV ice blockage wax build up acid oil and sludge formation Do not simply purge the system this proce dure is expe
24. below gives equivalent lengths for these components Table 3 2 Equivalent Feet for Angle Valve and Elbow 90 Tubing Angle Long Radius Size Valve Elbow 90 A 6 0 9 7 1 0 9 1 4 1 12 1 7 1 15 29 1 18 2 6 2 24 2 9 2 29 4 1 3 35 5 0 3 41 5 9 4 47 6 7 ASHRAE Fundamentals Handbook HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 LINE SIZING Sizing of all refrigerant lines is the responsi bility of the installing contractor Refer to Hussmann Refrigerant Line Sizing and SuperPlus Fibertronic System Planning Data documents BRANCH LINE PIPING Suction Line Pitch in direction of flow May be reduced by one size at one third of case run load and again after the second third Do not reduce below evaporator connection size eSuction returns from evaporators enter at the top of the branch line P N 340272A 3 9 Liquid Line OFF TIME AND ELECTRIC DEFROST 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 In Case Size A 1 1 1 1 1 2 Take offs to evapora
25. control shuts down the compressor The Temperature Sensor employees a Negative Temperature Coefficient NTC Thermistor to provide signals to the Control Module The NTC resistance drops on temperature rise L Injection Valve LLL E 5g P N 340272A 2 11 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 Valve meters saturated refrigerant into the suction cavity of the compressor nt 4 4 4 4 4 4 4 4 4 4 A 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 F ff AH nir HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 3 1 COMPONENT PIPING OVERVIEW This section deals with the information neces sary for installing the refrigeration lines for a Super Plus refrigeration system The Super Plus components are piped as completely as practical at the factory Field piping requires only interconnection of the major components and to the refrigerators WARNING Always use a Pressure Regulator on nitrogen tanks Us
26. expected some condenser flooding will already be occurring and required additional charge will be lower If the coldest expected temperature is above 20 F the flooding charge required will be less than 50 of each condenser circuit HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 REMOTE CONDENSER REMOTE SATELLITE 5 4 4 HUSSMANN CORPORATION BRIDGETON 63044 2483 Printed in USA 5 5 P N 340272A Revised August 1 1996 1 d M 1 a 1 cA L d 0M x 1 1 ip pa I ri 1 5 1 1 1 1 ME 1 E amp 5 z i ae gt ar aaa EE 1 1 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA REMOTE CONDENSER REMOTE SATELLITE 5 6 Remote Satellite Components Each Remote Satellite contains the following 1 One Copeland or Carlyle semi hermetic compressor with a High and Low Pressure Controls b Oil Pressure Safety Control when required c Primary Overload Protection and d Compressor Cooling Fans on low temperature application 2 Factory piping with a Suction and Discharge Stubs and b Oil Float c Suction Filter 3 Factory wired control panel with a Compressor Circuit Breaker and Contactors and b Compressor Time Delay Shipping Damage All equipment should be thorou
27. may be lifted into position The spreader bar is required to prevent damage to the unit NOTE This unit is slightly front heavy due to the Control Panel Take necessary precautions when lifting P N 340272A 1 5 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 fat M ol fem Figure 1 4 Lifting and Leveling the Super Plus HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA INSTALLATION INSTRUCTIONS 1 6 Extended racks may have an additional cross foot These racks are supplied with 12 isolation pads and require cross leveling for all six load points te BB ledation Pads WN Additional Foot an extended Back Revised August 1 1996 SETTING WITHOUT A CRANE In many locations crane lifting may not be practical Where possible use equipment dollies centered under each foot or Johnny 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
28. of the liquid supplied to the TEV the efficiency of the evaporator is increased The lower temperature liquid refrigerant produces less flash gas exiting the TEV Since mechanical subcooling uses a direct expansion device it is not limited by ambient temperature Shell amp Tube hanical Bubcooler Thermostat Eu broo irg Liquid Line Valu Figure 2 17 Mechanical Subcooling Revised August 1 1996 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 EPR Valve Supp hing Eubeonlinz Li wid Line Bok noid Vahe 1 Thermostat E Liquid Bok noid Mam Liquid Line Pressure Differertml Valve dine BM Liquid 2774 Thermostat Conta Liquid Line mil One per Compressor HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 DEMAND COOLING Copeland The Demand Cooling System is designed to inject saturated refrigerant into the suction cavity when the compressor internal head temperature exceeds 292 Injection continues until the temperature is reduced to 282 F If the temperature remains above 310 F for one minute the
29. of the system where it evaporates absorbing heat from the coil An evaporator pressure regulating valve may be used to control the evaporator temperature by preventing the evaporator pressure from dropping below a set point At critical locations along the refrigerant path service valves or ball valves allow isolation of components HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA REFRIGERATION PROCESS Revised August 1 1996 2 6 HEAT RECLAIM CYCLE The Heat Reclaim 3 Way Valve HS routes the discharge heat laden vapor to an remote mounted coil or water heating coil The heat energy removed from the merchandisers can be returned for a desired function A Check Valve assures no back ug flow and flooding when Heat gal Turta Zhed Reclaim Cycle is off The Heat 2 Reclaim Cycle removes superheat from the refrigerant vapor then dumps the vapor into the Condenser to discharge latent heat and produce quality liquid for the refrigeration process RECEIVER 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 High Pressure Vapor to the
30. remain closed and compressors from coming on at once on start compressor cycling falls to the control wired up after the control panel has been off between P1 1 and P1 2 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 16 Y ZEE Switchback Compressor Controls Tidi Hri Tine Y Between P1 1 and P1 2 one of three compres E sor controls may be found for switchback Y T operation These controls take over compres as sor run functions of the EPC in case of EPC IT EL x2 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 Revised August 1 1996 P N 340272A 4 17 Koolgas Relay To assure proper operation of the rack it is required that a compressor be running when a branch goes into Koolgas Defrost The Koolgas Relay contacts are wired between T9 and T10 of the 1 Compressor Board only When any Koolgas Branch Board calls for defrost the Koolgas contacts close forcing 1 Compressor run Koolgas Relay with EPC With an EPC Control the Koolgas acts as an interface between the 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 comp
31. 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 P N 340272A 7 9 De ere rized To Suction Manifold Bleed Part To Heat Feclaim To Conde ner Valve in Normal Operation To Heat To Conde nzer Valve in Heat Reclaim Mode HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL VALVES Revised August 1 1996 7 10 FLOODING VALVE AND RECEIVER Condenser PRESSURE REGULATING VALVE The Flooding Valve and the Receiver Pressure Regulating Valve work together the opera ag O tion of one affects the operation of the other The Flooding Valve responds to upstream pressure from the Condenser The Receiver Pressure Regulating Valve responds to down stream pressure in the Receiver High Pressure Hot Vapor High Pressure Warm Liquid The Pressure Regulator Valve A9 Valve responds to Receiver pressure If the Receiver NE EEE pressure drops below its set point 9 Valve opens directing Hot High Pressure Figure 7 11 Vapor to the Receiver The Flooding Valve A8 maintains head pressure in low ambient conditions by reduc Above 90 psig ing the available condensing area Restricting one ful
32. the high pressure pilot line at Discharge Manifold 2 Disconnect flex hose at Surge Valve A and plug hose with inch flare plug finger tighten 3 Valve off the suction pressure pilot line at Suction Manifold 4 Disconnect flex hose at Pilot Valve B and reconnect to Surge Valve Inlet A 5 Cap Pilot Valve Suction Outlet with a flare cap 6 Open suction pressure pilot line valve at Suction Manifold Figure 7 16 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL VALVES 7 14 Testing Valve Operation General When taking readings account for liquid line drop gauge error and thermometer accuracy Three measurements are required to determine if the Valve is working properly Reading 1 Liquid Return Line Temperature at the pilot valve bulb Reading 2 High Side Pressure up stream of the Flooding Valve Reading 3 Autosurge Valve Chamber Pressure through its Schrader Valve Pilot Valve When the Liquid Temperature Reading 1 is 10 F or more below its saturation temperature for the High Side Pressure Reading 2 the sys tem should be in Surge around the Receiver The pilot valve operates 5 F accuracy For example a thermometer is attached to the liquid return line at the pilot valve bulb and a pressure gauge is hooked up to the Liquid Return Line up stream of the Flooding Valve The gauge face at the right shows a pressure of 220 psig Reading 2 Accord
33. with the high pressure and oil failure controls In this position an open circuit will cause an alarm condition The Oil LED lights for 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 BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL 4 20 Head Cooling Fan Low Temperature compres sors require a head cooling fan The fan is powered between P1 5 and P2 5 Its actual connections are in the Compressor Terminal Box The fan continues to run during Alarm Conditions 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 Revised August 1 1996 Revised August 1 1996 P N 340272A 4 21 Internally Compounded Carlyle Compressors Both the Injection Solenoid and the Oil Solenoid are wired parallel to the Compressor Motor Conta
34. 1125 99 185 2 1 8 F 1x6 16 8 15 6 7 8 1239 1343 119 223 2 1 8 A 1x7 19 6 182 9 1 1551 1679 147 275 2 5 8 N 1x2 8 8 80 4 0 1081 1137 64 120 1 5 8 W HLCVF 1x3 13 2 12 0 6 0 1574 1658 96 180 2 1 8 I 1x4 17 6 16 0 8 0 2240 2352 128 240 5 8 D E HLCVG 1x5 22 0 20 0 10 0 3020 3231 242 453 2 5 8 1x6 26 4 24 0 12 0 3555 3809 291 545 2 5 8 2 2 11 2 10 4 5 2 820 897 88 165 1 3 8 W HLCVI 2x3 16 8 15 6 7 8 1230 1334 119 229 3 8 O 2x4 22 4 20 8 10 4 1850 2003 176 329 1 5 8 2 5 28 0 26 0 13 0 2078 2263 212 397 2 1 8 F 2x6 33 6 31 2 15 6 2420 2627 237 444 2 1 8 X 2x7 39 2 36 4 18 2 3075 3332 295 552 2 5 8 S 2x2 17 6 16 0 8 0 2001 2113 128 240 1 5 8 HLCVV 2x3 26 4 24 0 12 0 2889 3055 191 357 2 1 8 HM 2x4 35 2 32 0 16 0 3733 3955 255 477 2 1 8 D HLCVW 2x5 44 0 40 0 20 0 5020 5433 474 887 2 5 8 E 2x6 52 8 48 0 24 0 6030 6527 570 1067 2 5 8 Inlet 1 3 8 Outlet 1 1 8 The Flooding Charges listed in the table above reflect additional refrigerant required for split condenser method of winter control above normal summer operating charge and heat reclaim coil requirements Note when determining the flooding charge Condenser ambient should be noted If above 65 F add the specified amounts of refrigerant when the system stabi lizes after start up If below 65 F but above the coldest
35. 4 2483 Printed in USA Revised August 1 1996 P N 340272A 7 7 TEV The Thermal Expansion Valve regulates refrigerant flow into the evaporator by responding to the temperature of superheated vapor at the outlet of the evaporator Before attempting to set a TEV be sure the merchandiser is within 10 F of its normal operating range Attach temperature probes at 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 V tum BF tum HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL VALVES 7 8 Troubleshooting the TEV Revised August 1 1996 Malfunction Cause Action Evaporator Superheat adjusted Adjust to proper superheat Starved too high Moisture Dehydrate and install new liquid line filter dryer Dirt plugging strainer Remove and clean or replace or valve mechanism Wax Clean valve and install wax trapping dryer Equalizer Internal misapplied Install externally equalized TEV External plugged Clear Capped Install properly Restricted Correct or repipe Incorrect location Repipe Flash gas upstream Head pr
36. 5 06 500 Shipping Weight the Sum of Compressor Weights the Rack Base Weight RECEIVER REFRIGERANT CAPACITIES Receiver Capacities are based on 80 liquid fill at 110 F All receiver tanks have a 10 inch diameter Rack Assembly Receiver 404 Nomenclature Length R507 R 22 n lbs lbs OIVK 02VK 04VY 77 328 394 04 05VY 90 5 387 465 05 06VK 06VY 113 487 584 07 08 07 135 5 585 702 08 158 684 821 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 MACHINE ROOM REQUIREMENTS The equipment room floor must solidly support the compressor unit as a live load Ground level installation seldom presents problems but a mezzanine installation must be carefully engineered Ventilation should be 100 cfm compressor unit horsepower The air inlet should be sized for a maximum of 600 fpm velocity The ventilation fans should cycle by thermostatic control All machine room ventilation equipment must be field supplied Check local codes for variances Proper ventilation provides airflow across the compressors Duct work may be necessary Provide a floor drain for disposal of condensate that may form on the compressor unit or header defrost assembly Equipment must be located in the machine room to provide enough working space for service personnel and to meet electrical codes Super Plus Rack 3 it Min Live 150 to G
37. 6 Temperature EPWI6 0517 NRD NRFL 1 1 NEBBDT ND5Z NRDV NRFLV NP2 NP2 ND5HZ NRFL NDSLX NRFLV ND5X ND5HX Refrigeration Discharge Air Temperature F 32 F 29 F 32 F 34 F 30 F 37 F 33 F 33 F 30 F Evaporator Temperature F 21 F 15 F 25 F 2 23 F 21 F 18 F 20 F 18 F Fan Cycling CI CO F E EE 25 t Defrost Frequency 8 Hrs 6Hrs 24Hrs 24 24Hrs 6 Hrs 6 Hrs 8 Hrs 12 Hrs Electric Temp Failsafe Min am Reverse Air Temp 48 F a Failsafe Min 40 Min Koolgas Duration Min 14 Min 12 Min 12 Min 12Min 12Min 12 Min Offtime Temp Term F Duration Min 40 Min 60Min 60Min 60 Min 60 Min 40 Min 40Min 46Min 40 Min HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL SETTINGS 8 18 MERCHANDISER SETTINGS Cont d Revised March 1 1997 Application Fresh Fish Seafood Additional Merchandisers Models CGFM CGFMG VFL Meat Cheese Produce CSFMG VES DSRP DSRP DSRP For all Merchandisers VFK DSRP Y with Gravity Coils the Temperature listed in the Discharge Air row is Product Temperature NESDH NVSA NESSH NVSB NVSC Refrigeration Discharge Air Temperature F 24 F 36 F 34 F 26 F 30 F 36 F Evaporator Temperature F 20 F 20 F 2T F 12 F 18 F 18 F Fan Cyc
38. 9 and T9A circuits remain open during normal operation If either circuit closes a 120V input to the Alarm Board activates A9 or LED and Alarm 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 is pressed or power turn off turn on is used The Bell Stop Relay BSR circuit may operate only during Alarm Conditions When the Bell Stop Switch is closed BSR Electronic Circuit energizes BSR Coil BSR Contacts open the circuit to Terminal 32 BSR Contacts close the circuit for its own power supply HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 4 COMPRESSOR CONTROLS Alarm Board HUSSHMAHH PUSH TO RESET R ck ALARM 3 are shown D E mnergized HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 Alarm Board Troubleshooting Check power supply to the Alarm Board and its Fuse F1 Disconnect power Label discon nect and cap wires on terminals COMP A9 T9A 33 31 35 34 36 32 Install a fused jumper from X1 to 34 and with open switches to COMP A9 T9A P N 340272A 4 5 Turn Control panel ON Note Alarm Board will come up in Alarm Condition
39. AL 4 28 DEFROST TIMER MOTOR Timer motors are wired directly between X1B and neutral 2 so they are energized unless Power fails Control Panel Circuit Breaker is open Single Phasing Protector opens DEFROST CONTROL CIRCUITS The different defrost systems shown on the wiring diagrams all work from the same basic circuit The variations come from tailoring the systems to the customers needs by selection of components used to accomplish defrost Revised August 1 1996 The basic circuit is controlled by a defrost clock which closes the circuit energizing relay coil controls one contact normally closed and two contacts 2R1 nor mally open NC IRI 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 until the defrost termination thermostat or defrost clock opens the defrost circuit de energizing relay coil R1 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 4 29 Suction 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 B
40. Aliens with Tongue of Module Mext to it Copper Termination Lever HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA MECHANICAL DEFROST TIMERS 6 6 Paragon Program Module Replacement Removal Turn off power to control panel and meter check the Paragon to assure technician safety Disconnect and mark wires from the switch at the top rear of the Module The switch terminals are C NC and NO Adjust the timer so all the red tabs on the Minute Dials are facing directly front of the timer At the bottom rear of the Module pull down on the plastic latching lever and out on the bottom of the Module Revised August 1 1996 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 tabs are aligned and replace wires on switch terminals Reset time of day and turn on the control circuit Figure 6 7 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 Paragon Program Motor Replacement Removal Turn off power to control panel and meter check the Paragon to assure technician safety Disconnect and mark wires to motor Rotate the main drive gear until the ax
41. An open circuit or very high Thermistor Resistance Operational Notes Demand Cooling does NOT replace head cooling fans which are still required on low temperature applications Temperature Sensor cable must not touch any hot surfaces or the cable will be damaged HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL VALVES 7 20 OIL SYSTEM A Oi Fiter Angle Vale DE Way Valve m Pressure Regulator Hi Level Ee gubtor Cheek Yabe Eq ua bz Revised August 1 1996 a m HL B Ta R Broken Field supphed oq ma 20 gt nc na OO DE 20 gt nc D 20 i ec and in ta4lkd Differential Pressure Regulating Valve The oil pressure differential valve reduces oil pressure from high side pressure to a range of 3 to 20 psig above the suction pressure Typically the valve would be set between 10 and 15 psig above the suction pressure to pre vent over feeding of the oil level regulator A separate Oil Pressure Differential Regulating Valve must be applied for each different suc tion pressure on one oil system Turning the adjustment stem clockwise 7 turn will increase the pressure to the oil level regu lators about 1 psig turn clockwise 1 psig increase Oil Level Regulators For any brand of oil level regulator to work accurately the unit and each compresso
42. BLE WIRE Based on no more than 3 wires in the 75 C Wire Rating 50 C raceway and 30 C environment per NEC 140A max 00 per Phase 248A max 350 mcm per Phase 408A max 2 x 250 mcm per Phase 608A max 2 x 500 mcm per Phase Include control circuit amps if single point connection transformer option is used 12A for 208V systems 6A for 460V systems Refer to NEC for temperature derating factors HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 USING SCHEMATICS Lim Heu ral Alarmon Alarmon orou t close 5 Hm Pelari Alarm on eek close 30 Mink ehy P N 340272A 4 3 A s Open ond brm Alarm Cieut J Clee ondbem j shown DE energiz Figure 4 1 Alarm Board Circuits Schematics show Sequence of Operation Electronic circuit logic is omitted since print ed circuits are not field repairable Sequence of Operation Control Panel 120V circuit closes Power to X1 energizes Alarm Relay AR AR Electronic Circuit energizes AR Coil AR Contacts open between Terminals 34 and 36 after Fuse F1 AR Contacts close between Terminals 34 and 35 The closed Compressor Alarm Circuit inputs 120V at Terminal COMP If the circuit opens 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 The A
43. Carlyle semi hermetic compressors with a High and Low Pressure Controls b Oil Pressure Safety Control c Primary Overload Protection d Compressor Cooling Fans on low temperature application or 2 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 Dual Receiver Tanks Suction Filters on each compressor Liquid Filter Drier and Sight glass Liquid Level Indicator 3 Factory wired control panel with a Pre wired Distribution Power Block b Individual component Circuit Breakers and Contactors c Compressor Time Delays d Color coded wiring system e Customized wiring diagram 4 Items supplied separately for field installation a Liquid Drier Core b Vibration Isolation Pads 8 c Loose shipped items for accessories HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA INSTALLATION INSTRUCTIONS 1 2 SHIPPING DAMAGE All equipment should be thoroughly examined for shipping damage before and while unloading This equipment has been carefully inspected at our factory and the carrier has assumed responsibility for safe arrival If damaged either apparent or concealed claim must be made to the carrier Apparent Loss or Damage If there is an obvious loss or damage it must be noted on the freight bill or express receipt and signed by the carrier s agent otherwise carrier may refuse cl
44. Defrost Timer Setting Defrost Start Times Rotate the Program Timer Dials by turning the setting knob at the end of the Timer opposite the Motors As the Dial slots for start of defrost become accessible install a tripper for each desired time start The slot for each tripper time is located immediately above its number on the dial face To install a tripper push straight in until it snaps over its holding detent A properly installed tripper has its shoulders extended inch above the dial face and is square to it A misaligned tripper can jam the timer 1132 Properly Installed Hot Seated Cocked Figure 6 2 Proper Installation HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA MECHANICAL DEFROST TIMERS Revised August 1 1996 6 2 Setting Length of Defrost To set the length of each defrost cycle turn the setting knob until the indicator mark is facing forward and the Cycle Timer Dial stops CAUTION Failure to have the indicator mark visible before adjusting the Cycle Timer Dial may cause damage to the clock Insert the Time Setting Tool pull the dials apart and reset teeth when required minutes of defrost is opposite the indicator mark Time Setting Tool B hotte Figure 6 3 Setting Precision Timer Pull Dial Teeth Apart to Set Length of Defrost Time Setting Dial Time of Davi Timer Dia Defrost Start Time Setting Time of Day Turn the setting knob until th
45. ELICATESSEN FROZEN FOOD ICE CREAM Models Refrigeration Discharge Air Temperature F Evaporator Temperature F Fan Cycling F Defrost Frequency Hrs Electric Temp Failsafe Min Reverse Air Temp Failsafe Min Koolgas Duration Min Offtime Temp Duration Min Preliminary Data Preliminary Data Preliminary Data Preliminary Data HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed USA Revised March 1 1997 P N 340272A 8 13 MERCHANDISER SETTINGS Cont d Application FROZEN FOOD ICE CREAM Models Refrigeration Discharge Air Temperature F Evaporator Temperature F Fan Cycling F Defrost Frequency Hrs Electric Temp Failsafe Min Reverse Air Temp Term F Failsafe Min Koolgas Duration Min Offtime Temp Duration Min HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL SETTINGS 8 14 MERCHANDISER SETTINGS Cont d Revised March 1 1997 Application ICE CREAM FROZEN FOOD MEAT Models GC G5C RCA FML GF GSF RFA NM5 NEBSHM GCI G5CH RCH FMLG GFI GSFL RFH For all Merchandisers GGC G6C GG G5FH with Gravity Coils the GTC G6CH NRC GTF G6F NRF Temperature listed in GWIC NRCV GWI G6FL NREV the Discharge Air GWIT NC6 GWIT G6FH row is Product
46. HUSSMANnN Super Plus Fibertronic BRIDGETON REFRIGERATION Installation and Service Manual Revised August 1 1996 SAFETY TIPS Being Safe is Your Responsibility Wear proper eye protection whenever working Wear proper hearing protection whenever working in a machine room Stand to one side never work directly in front of Any valve you are opening or closing Manual refrigeration valves Regulator valves on brazing tanks and nitrogen tanks Electrical Circuit Breakers Refrigeration lines you are cutting or opening Always use a pressure regulator with a nitrogen tank not exceed 2 pounds of pressure and vent lines when brazing not exceed 350 pounds of pressure for leak testing high side Do not exceed 150 pounds 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 WARNING Some equipment has more than one power supply 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 cutting Check Both sides of a two way valve lines to a 3 way or 4 way valve Dangerous hydraulic explosions may result if you Isolate liquid lines or compressor when they can absor
47. L EL Cat on Com pressor Board 2 EL on Compressor Board 3 Compressor Board 1 Revised August 1 1996 Time hF 24 S Deh HF on Compressor Board 4 on Compressor Board 6 T4 aie EL EL on Compressor Board 5 EL T4 Parallel Switchback If the EPC fails to maintain control of the rack its Switchback Relay de energizes allowing the normally closed contacts to com plete the Time Delay Switchback Relay cir cuit After a 24 second delay the Switchback Relay opens the 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 Printed in USA Revised August 1 1996 P N 340272A 4 15 Compressor Board 1 on Compressor Board 2 nn Compressor Board 9 Tink Det Ethy T4 11 on Compressor Board 4 T4 fs nn Compressor Board 5 T4 41 J on Compressor Board Series Switchback If the electronic compressor controller fails Time Delay Split TDSP prevents all the its normally closed contacts
48. MHFGH NEBDH NMI NEGDF NFI NVGB NEBDH NEBSH NM3G NMIG NEGSF NVGC NEBSH NM4 NEGDT NVGA NM4G NEGDH NFW NDD3 NFCW NDD3G NFWE NDD4 NFCWE NDD4G NFFS Refrigeration Discharge Air Temperature F 24 F 22 F 22 F 22 F 24 F 24 F 22 F 24 F 26 F Evaporator Temperature F 20 F 11 F 17 F 9 F 21 F 18 F 10 F 22 F 22 F Fan Cycling CI CO F 28 38 F 28 38 F 28 38 F Defrost Frequency 24Hrs 6Hrs 12 12Hrs 24Hrs 24Hrs 8Hrs 24Hrs 24 Hrs Electric Temp 54 F 48 F 48 F 52 F Failsafe Min 40 Min 46Min 46 Min 60 Min mE Reverse Air Temp 48 F 48 F 48 F 48 F 48 F 48 F 48 F Failsafe Min 46Min 70Min 70Min 90Min 60Min 60Min 110 Min Koolgas Duration Min 24Min 14Min 14Min 14Min 14Min 20Min 14Min Offtime Temp Duration Min 90Min 46Min 70Min 70Min 90Min 60 Min 110 Min 100 Min HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL SETTINGS 8 16 MERCHANDISER SETTINGS Cont d Revised March 1 1997 Application DELI and CHEESE Models CWI DMD FHM FM RDM RMA VBL VGL CGDMG CWI6 FHMG RMFA VBS VGK CGDMGT For all Merchandisers MWI DMDA VBK VGS CSDMG with Gravity Coils the MWI6 FHMGH FMGV VBT VGLR Temperature listed in FHMS VGSR the Disch
49. NG 3 8 For an expansion loop multiply the L value by 2 if hard copper and long radius elbows are used If the the expansion loop is formed in soft copper the loop diameter equals L Example For the same 84 foot run a hard copper loop is 42 by 42 inches A soft copper loop is 21 inches Application Do not exceed a 100 foot straight run without constructing an offset or expansion loop Place the offset or loop in the middle of the run to minimize pipe shift and joint stress SPECIAL PIPING FOR OPEN ROOMS An open preparation room allows heat infiltra tion from the rest of the store at a rate which may jeopardize total refrigeration perfor mance Open preparation evaporators must be piped with a Crankcase Pressure Regulating Valve CPR to protect the rest of the refriger ation system The 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 Revised August 1 1996 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 Do not use a bull head tee Figure 3 13 RUN LENGTHS AND EQUIVALENT FEET When figuring run lengths angle valves and elbow 90 are figured as additional straight pipe The chart
50. RIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 4 11 Troubleshooting Compressor Board EPC Control Be sure Board Switch is closed Run Refrigeration Mode Voltmeter Voltmeter Action Lead Placement Readings Lead 1 Lead 2 1 T7 T8 120 Go to 2 0 Check Power Supply to Board 2 5 T8 120 Go to 3 0 Check Power Supply to 5 from X1A 3 T6 T8 120 Go to 4 0 Alarm Circuit open correct cause and reset 4 T4 T8 0 Go to 5 120 In Switchback correct cause and reset 5 T3 T8 120 Go to 6 0 Check Power Supply to T3 from X1 6 Tl 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 Go to 13 120 High Pressure Alarm Correct cause and reset 13 P1 7 T8 0 Go to 14 120 Oil Alarm Correct cause and reset 14 P2 3 T8 120 Go to 15 0 If K1 Contacts are open correct and reset If closed Board Failure 15 P2 5 T8 0 Circuit Complete End Test 120 Board Failure HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL 4 12 COMPRESSOR BOARD RELATED CIRCUITS Revised August 1 1996 EZ Relay Coil Cire
51. Receiver Electrically the circuit is supplied with power only during Koolgas Defrost The circuit is closed by a thermostat responding to Koolgas Manifold temperature HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 Defrost z RE dem I ER High Pressure Hot Vapor 2 Low Pressure Cool Vapor KOOLGAS DEFROST CYCLE Beginning with the Receiver the Koolgas Cycle splits in two directions Receiver Vapor and Receiver Liquid The high pressure liquid flowing from the Receiver is throttled by the Main Liquid Line Solenoid Valve causing a pressure reduction in the Liquid Manifold The Branch Liquid Line Solenoid Valve is designed to allow backflow into the reduced pressure Liquid Manifold When a branch of refrigeration cases enters the defrost cycle its Branch Valve allows refrigerant to flow into the Liquid Manifold The valve solenoid is energized both for refrigeration and for defrost The Receiver Vapor flows directly into the Koolgas Manifold This Koolgas Vapor maintains the same high pressure as the Receiver A 3 Way Valve 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 High Pressure Warm Vapor High Pressure Warm Liquid P N 340272A yy Refrigeration Mode 2 7 NE edu aad Pressure W arm Liqui
52. a Lig wid Return p Dp 2 22M and insta led eh bed Lie w 6 TES on A Boil off Loops pum potait gS 2 2M Ee A E G beu gor X m A Footing 2 J L 1 Super Plus Fack wenn Disoharge Lines Ball alve fr Condenser Mantol vovv Liquid Return Lines GD Check Valve Yabe Solenoid Equalizing Line Service Valve PD Pump Down E FA 88 Split Condenser 14 Tubing ay Purge Valve A Hot Powe red 5 Ud to equalize pressure drop Figure 3 8 Rack to Condenser 2 Wray V alves Hote Liquid Fetwn Lines must be free drainmg with no Traps Intl Bok noid inside Equipment Room Pump Down Line showld not enter the Ruction Manifold over a Compressor Inlet Tall Ball Valves to Folate Condenser Inter eonne ching Valving to be Field Supplied and Tost led WARNING Yent the Receiver safety Relief Valve PROPERLY HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA COMPONENT PIPING 3 6 RACK TO REMOTE HEADER Super Plus Suction Stub is connected as directly as possible to the Header Suction Manifold eSuper Plus Liquid Line Stub is connected as directly as possible to the Header Liquid Manifold equipped with Koolgas Defrost the Super Plus Koolgas Stub is connected as directly as possible to the Header Koolgas Manifold 9 il
53. ace core and close up Pressurize leak test and bring back into line HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 Revised August 1 1996 INDEX SUBJECT P N 340272A CHAPTER PAGE Defrost Clock Mechanical SUBJECT CHAPTER PAGE Alarm Delays 4 13 Remote 4 1 5 7 9 11 Allowable Distances 1 4 Branch Line Piping 3 9 Charging 1 2 5 3 9 3 Components Remote Satellite Super Plus 1 1 Weights Remote Condenser 5 3 Remote Satellite 6 Super Plus 1 2 Compressor Electrical 4 2 Replacing 9 5 Condenser Checkout 5 2 Control Settings 8 8 17 Electrical 5 45 Flooding Charge 5 3 Leveling 5 1 Piping 3 3 5 Control Panel Compressor Board 4 6 Defrost Board 4 23 24 Paragon 6 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 Super Plus Equalizing Line Evacuation Expansion Loop Heat Reclaim High Pressure Control Hoisting Remote Condenser Remote Satellite Super Plus Isolation Pads Koolgas Defrost 5 4 5 In Unit 3 3 5 9 2 3 7 2 6 7 9 8 1 5 1 2 6 1 5 1 5 2 7 7 2 SUPER PLUS FIBERTRONIC Revised August 1 1996 INDEX SUBJECT CHAPTER PAGE SUBJECT CHAPTER PAGE Valves Leak Testing 9 1 Autosurge 7 12 2 9 Leveling Remote Condenser 5 1 Branch Liquid Line 7 6 Super Plus 1 5 2 5 Line Sizing 3 9 EPR 1 2 Low Pr
54. ace of the air cooled Condenser to the mounting surface of the Super Plus Rack the minimum allowable distance is 4 5 feet With a Flooding Valve from the mounting surface of the air cooled Condenser to the center of the flooding valve the minimum allowable distance is 6 feet Condenser Flooding Yale Bb ft Min Field Installed Water ogled Condenser Colne Super Plus Rack Flo ding Valve Piping Equivalent 50 ft Piping Equivalent 30 ft Max Piping Equivalent 100 ft hac Remote Satellite E Remote Header Maximum Allowable Distances Remote Satellites should not be placed below the level of the Super Plus Rack The Satellite may be positioned above the Rack 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 piping from the Rack to a Heat Reclaim coil the maximum allowable piping equivalent is 50 feet Condenser Flooding Yale 4 5 ft Min B ft HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 LIFTING AND LEVELING Using rigging with a spreader bar the Super Plus
55. acts 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 subcooling The valve is factory set at 10 F of subcooling and is not field adjustable ra s 2 d E Oh AAA a HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 System Start up The pilot valve is pre set at the factory for 10 F subcooling Valve off pilot while leak testing the system excessive pressure can damage the Pilot Valve Element Do not attempt to field adjust On initial start up valve off the high pressure pilot line from the Discharge Manifold Once the system has stabilized open the valve Be sure all pilot lines are open Be sure pilot valve bulb has good contact to the Liquid Return Line and is well insulated n case of bulb charge loss or pilot failure do not attempt to substitute a TEV element Filot Valve Element Autosurge Valve P N 340272A 7 13 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
56. aim 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 SUPER PLUS FRAME DIMENSIONS Rack Assembly Length Height Depth Nomenclature in mn O1VK 02VK 04 77 78 35 04 05VY 90 5 78 35 05 06VK 06VY 113 78 35 07 08 07 135 5 78 35 O8VY 158 78 35 Shell and Tube Mechanical 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 Revised August 1 1996 SYSTEM WEIGHTS Base Rack Weight Rack Assembly Nomenclature Base Weight Ibs 02VK 04VY 1600 03VK 04VK 05VY 1700 05VK 06VK 06V Y 1800 07 08VK 07VY 1900 08VY 2200 Shell and Tube Mechanical Subcooler adds 500 Ibs to rack Plate Subcooler adds 100 lbs Compressor Weights Copeland Weight per Compressor Body compressor lbs M and N 300 2D and 3D 385 4D and 6D 575 3 AND 9 380 4 and 6 530 Carlyle Weight per Compressor Style compressor lbs 06D 29
57. are sized for copper wire only with 75 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 154A branch circuit Between the remote defrost control panel and the Super Plus System provide one 120V 15A 2 wire circuit For 208 230 3 60 Compressor Units To each Super Plus System rack provide one 208 230 3 60 branch circuit one 120V 1PH 30A circuit omit when single point connection kit is used To each remote air cooled condenser provide one 208 230 3 60 branch circuit For 460 3 60 Compressor Units To each Super Plus System rack provide one 460 3 60 branch circuit one 120V 1PH 30A circuit omit when single point connection kit is used To each remote air cooled condenser provide one 460 3 60 branch circuit For Alarm Wiring Between the Compressor Control Panel and the in store alarm bell provide one 120 1 60 10A circuit HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL 4 2 WIRING GUIDELINES BASED ON VARIOUS COMPONENTS Check the store legend for components requir ing electrical circuits to either the compressor unit or the defrost control panel These include Defrost termination thermostat Thermostat controlling a header mounted liquid line solenoid CDA temperature control ETR temperature control
58. arge Air FHMSG VFMGC row is Product MHF FMGCD Temperature MHFG MHFGH NDD5 NMI NRD NVBA NVGB NEGDF NDD5H NM3G NMIG NVGC NEGSF NDD5A NRDV NVBC NEGDT NM4G NRFLV NDD3 NDD3G NDD4 NDD4G Refrigeration Discharge Air Temperature F 30 F 32 F 32 F 30 F 30 F 30 F 34 F 38 F 25 F Evaporator Temperature F 20 F 18 F 20 F 25 F 20 F 23 F 20 F 20 F 21 F Fan Cycling CI CO F 28 38 F 28 38 F Defrost Frequency 6 Hrs 6 Hrs 6 Hrs 12Hrs 24Hrs 24Hrs 24Hrs 24 Hrs 24 Hrs Electric Temp 48 F E Failsafe Min 70 Min ae a Reverse Air Temp 48 F 48 F en at 0 Failsafe Min 40 Min 40 Min 2 5 Koolgas Duration Min 14 14Min 14Min 14Min 12Min 12Min Offtime Temp Duration Min 56Min 40Min 40Min 70Min 60Min 60Min 60Min 110 90Min HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed USA Revised March 1 1997 P N 340272A 8 17 MERCHANDISER SETTINGS Cont d Application DAIRY FLORAL PRODUCE BAKERY Models DMZ JVMR RDM RMA RMFA Pack PVWI CGBR DMZA JVMRS RMFA PRO PRO PWI For all Merchandisers DMZH PHSM PHSM PWIRO with Gravity Coils the DMX PH PH EPWI Temperature listed in DMXA PHRO PHRO PVWI6 the Discharge Air DMXH P P PWI6 row is Product PWIRO
59. b heat over an extended time period Overfill containers pumpdown refrigerant Never vent refrigerants into the atmosphere Hussmann Corporation 12999 St Charles Rock Road Bridgeton MO 63044 2483 314 291 2000 Congratulations With the purchase of Hussmann s Super Plus System you are receiving equipment designed to provide the finest refrigeration and temperature control for modern supermarket display equipment and coolers Since the introduction of Hussmann Central Refrigeration Systems thousands of installations have confirmed our belief that as with all fine equipment good installation and 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 not hesitate to write me Your inquiry will be welcomed George Ballinger Manager of Field Service 960801 Super Plus Fibertronic Installation and Service Manual 12999 St Charles Rock Road Bridgeton MO 63044 2483 314 291 2000 August 1996 Printed in USA Revised August 1 1996 P N 340272A CONTENTS Topics Figures 1 1 Super Plus System 1 1 Su
60. ber Pushed i777 to its opposite position the piston assembly stops the suction line and opens the Koolgas i line A bleed port in the piston provides for de compression of the piston chamber when the pilot port closes M5 Troubleshooting Koolgas Valves 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 in defrost mode Correct defrost clock problem Fails to close Piston port plugged Clean or replace Barrel or piston scored Replace Dirt in piston chamber causing drag Clean or replace Stuck in defrost mode Correct defrost clock problem HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL VALVES MAIN LIQUID LINE SOLENOID VALVES The Sporlan Main Liquid Line Solenoid Valve goes into differential mode when the coil is de energized or fails When the Pilot Port opens Upstream pressure fills the Main Valve Chamber and forces the Main Valve towards a closed position The downstream pressure falls to the point that the Pilot Valve Spring can not keep the downstream outlet closed The Main Valve Chamber starts to empty and upstream pressure forces the main valve towards open Revised August 1 1996 Differential Mode Quick Test 1 Connect pressure gauges up and down stream of th
61. ctor Coil Elapsed Time Meter This meter is wired to run when the Motor Contactor Coil is energized Crankcase Heater The normally closed 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 Bk Coa toll cna E 5 T i Eehy Figure 4 16 Circuits Parallel to the Compressor Motor Contactor Coil HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL 4 22 DEFROST CIRCUIT BOARDS Revised August 1 1996 GI BRANCH ON DEFROST EPR SOLENOD ER SOLEN GD Defrost Control Circuit Switch ON OFF shuts off all power to the defrost branch cir cuit Branch On Green LED indicates that there is 120VAC to the system branch circuit If the switch is off the light will turn off Defrost Yellow LED indicates the system is in 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 li
62. d The Koolgas Vapor condenses and flows into the reduced pressure liquid line through a Bypass Check Valve around the TEV From there it is returned to the Liquid Line Manifold If a Suction Stop EPR Valve is used to control Evaporator temperature the 3 Way Valve is not used When defrost is called for the suction line control valve closes and a two way Koolgas Valve opens the line from the Koolgas Manifold to the Evaporator HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA REFRIGERATION PROCESS 2 8 OIL CYCLE Discharge refrigerant carries droplets of oil from the compressors lubrication system The Turba shed returns the oil from its reservoir along the high pressure line to the Oil Pressure Differential Regulator Valve This valve reduces the oil pressure to between 10 and 15 psig above the crankcase pressure providing even flow of oil to the Oil Level Regulators e Oil Fiker Angle Valve BE Vay Valve on Pressure Regulator ob Dil Le vel Fe gubtor Check Yabe Gil Lines High Pressure Relwed Pressure Equaliz Broken Field supphed Revised August 1 1996 To 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
63. d Filter Cores 9 6 No 7538 April 18 1997 TO Region Vice Presidents Account Executives District Managers Sales Managers Sales Representatives Branch Managers Hussmann Distributors International SUBJECT Update for SuperPlus Fibertronic Manual P N 340272 Rev A The Super Plus Installation Manual has been updated as follows e Addendum Condenser Installation provides information on installing condensers with SuperPlus systems place behind index and in front of warranty page e 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 settings discard pages 8 9 through 8 18 and replace with pages 8 9 through 8 20 dated March 1 1997 Revised August 1 1996 P N 340272A 1 1 INSTALLATION INSTRUCTIONS mi uussmunrmn Figure 1 1 Super Plus System OVERVIEW This section is limited to the information needed to set the Super PlusTM Compressor Rack Power Supply requirements are found under Electrical piping under Piping and charging under Startup and Mainte nance Auxiliary units are found in the sections devoted to them or in the manuals accompanying them SUPER PLUS COMPONENTS Each Super Plus contains the following 1 Two to eight Copeland or two to seven
64. e being discussed are shown closed or removed Each specific refrigerant state and pressure maintains the same fill pattern throughout the instruction Pressures in oil lines will also retain a fixed pattern HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA REFRIGERATION PROCESS Revised August 1 1996 2 2 Heat Reclaim Coil T HS super Plus Fibertronic i Refrigeration m ul system 2 _ S S DUI TCR a gt v z z 7 Twhashead fet 2 2 i 2 mE 5 2 ee z E 2 5 5 on P4 7 vu i 7 i Batellihe 5 2 4 8 Compressor 2 5 14 7 2 Suction Manifold 2 2 2 E Evaporator a A 2 LET Lt pn A 2 j 2 Vale 2 1 pj 2 2 A A AV 2 2 2 7 oy n 7 4 7 A 7 A 2 2 2 2 a a E a p 5 5 2 Eu pil SASS i e t 010017208 Er eT PACD A SATA Figure 2 1 Super Plus Refrigeration System ST eh HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed USA Revised August 1 1996 gt 5 boe M gue Ball Valve Check Valve Compressor Service Valve 2 Way Valve 3 Way Valve Valve Solenoids 2 SS Si
65. e 2 wire control circuit placing all termination thermostats in series and connected between the R_ and F_ termi nals in the control panel with the suffix corresponding to the system number Check the store legend for system number Merchanl er Thermostats One per Unit Figure 4 26 Widing Defrost HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 PYCL 400 4R UND ER VOLTAGE P N 340272A 4 33 CONTACTS M0VAC ingel Phase Monitor POWER MONITOR The single phase monitor detects phase loss phase reversal low voltage and phase imbalance It opens the control circuit when any of these conditions occurs When the fault is corrected it will automatically reset The normally open contacts will close when 3PH voltage is applied to the three input ter minals The 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 1596 below the nominal line voltage at power source voltmeter should be used to establish actual supply voltage The monitor controls a two pole bypass relay BP making and breaking power to the control panel HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 5 1 REMOTE CONDENSER REMOTE SATELLITE OVERVIEW
66. e 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 2483 Printed in USA Revised August 1 1996 Precision Alarm Switch The timer is provided with two motors and an alarm switch which is normally open Both motors operate continuously If one motor fails the other motor will continue to drive the timer the alarm switch will close warning that the timer requires service P N 340272A 6 3 To reset the alarm switch 1 2 Push gear A toward the motor or lever B will be broken Using a non metallic object depress the plastic cam until it snaps into position holding the switch open Figure 6 4 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 MECHANICAL DEFROST TIMERS 6 4 To T T Petros Cre Da bo Inliator Seating Knob 1 clang Time Time fekhng Dial 24 cur C ck Defrozt Program DP al 24 cur C ck Figure 6 5 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 PARAGON DEFROST TIMER The Paragon Defrost Timer Consists of three components These are 1 The Frame holds a Drive Motor Module and as many Program Modules as needed for the defrost systems 2 The D
67. e only clean dehydrated sealed refriger ation grade copper tubing Use dry nitrogen in the tubing during brazing to prevent the formation of copper oxide All joints should be made with silver alloy brazing material use 35 silver solder for dissimilar metals Fbor Run REFRIGERATION LINE RUNS Liquid lines and suction lines must be free to expand and contract independently of each other Do not clamp or solder them together Run supports must allow tubing to expand and contract freely Do not exceed 100 feet without a change of direction or an offset 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 2483 Printed in USA COMPONENT PIPING Revised August 1 1996 3 2 Through Walls or Floors P Trap Construction Refrigeration lines run through walls or floors P Trap must be installed at the bottom of all must be properly insulated Avoid running lines suction risers to return oil to the compressors through the refrigeration cases When this is done the lines must be adequately insulated Armaflex or equivalent Using Elbows f Rimr Keep this ditame as shor
68. e 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 real setting Downstream pressure pilot spring pressure upstream pressure HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 The Alco Main Liquid Line Solenoid Valve goes into differential mode when the coil is de energized or fails Upstream liquid D is forced through the modulating valve when the upstream pressure exceeds downstream pres sure plus the spring pressure In refrigeration mode the solenoid valve is held open allowing flow around the modulating valve Downstream pressure spring pressure upstream pressure 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 P N 340272A 7 5 Refrigeration Mode Coil Energized HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL VALVES Revised August 1 1996 7 6 BRANCH LIQUID LINE SOLENOID VALVES Valve Port Upstream Equalizing Port The Branch Liquid Line Solenoid Va
69. eceivers to 60 on the liquid gauge Disconnect refrigerant tank and open the ball valve CAUTION The remaining charge must be added only as vapor through the suction header Charge the system to approximately 30 of the receiver on the liquid gauge Turn on compressor number one to speed up charging Its suction pressure should remain below 20 psig for low temperature and below 45 psig for medium temperature units If necessary turn on more compressors Monitor the oil levels carefully At the first sign of trouble or unusual compressor operation shut off the system After 30 charge is achieved check oil levels Bring on each compressor one at a time Check Suction and discharge pressure Oil Pressure Voltage differential and balance Ampere draw and balance Allow the full rack to operate until it stabi lizes If the Receiver charge drops below 15 add more vapor until a 15 level is obtained Watch oil levels receiver liquid level and possible flood back from evaporator Shut off all compressors and recheck oil levels in each compressor and the Turba shed Leak testing evacuation and initial charging are now completed Revised August 1 1996 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 Defrost
70. echnique Unmounted legs and lifting channels are fur nished with necessary bolts nuts and washers for mounting to the unit Mount each leg and plate with the bolts provided Under no circumstances should the condenser coil manifolds control panel or return bends be used for lifting or moving the unit Locating Locate the 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 Addendum April 15 1996 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 requirement is reduced to 4 feet for installations not using condensing pressure control valves Refer to Section 1 Installation Requirements for details Leveling Cross level the coil section carefully then bolt the condenser legs to the support beams For multi circuit condensers consult the store legend and refer to the metal identification tag on the manifold end of the condenser to deter mine which compressor unit to connect to each set of condenser circuits Route and support all piping in a manner that relieves stress caused by vibration thermal expansion and gradual base or building movement Construct a pitch box to weather proof the opening where piping is routed th
71. essure Control 8 2 7 Koolgas 7 2 Oil System 7 20 21 2 7 9 2 Flooding 7 10 Power Monitor 4 33 2 4 Prep Room Special Piping 3 8 Heat Reclaim 7 9 2 4 Receiver Capacity 1 2 Main Liquid Line Solenoid 7 4 5 Satellite 5 6 2 5 Shipping Damage Oil Pressure and Level 7 20 21 Remote Header 5 6 2 8 Remote Satellite 9 Super Plus 1 2 Receiver Pressure Regulator 7 10 2 6 Single Phase Protector 4 33 TEV 4 T Solder 3 1 2 5 2 Way 7 3 Subcooling 2 9 Ambient 2 9 7 12 3 Way 7 4 9 Mechanical 2 10 7 15 Addendum April 15 1997 P N 3402724 1 ADDENDUM CONDENSER INSTALLATION Figure A 1 Roof Mounted Condenser with field installed split condenser valving CONDENSER INSTALLATION General Description The SuperPlus Fibertronic system is available for use with three types of condensers remote air cooled water cooled and evaporative water cooled Refer to specific manufacturer s instructions for the installation of these com ponents See the store legend for manufacturer and model number Remote Air Cooled Condensers When air cooled condensers are used general ly there will be individual condensers for each rack Split condenser valving is an option to reduce the refrigerant charge During certain conditions the valving will automatically valve off one half of the condenser to mini mize the refrigerant charge The valving may be field or factory installed If any of the following conditions exist split condenser val
72. essure too low raise head pressure of TEV Liquid supply line not exiting 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 and ambient influence Moisture or dirt Clean and dehydrate and install new liquid line holding valve open filter dryer Oversized TEV Install correct size Valve damage or Repair or replace valve seat leak Poor Uneven circuit load on Balance load lightly loaded evaporator is Performance multiple evaporators controlling TEV starving loaded evaporator Moisture or Dirt Clean and dehydrate and install new liquid line filter dryer TEV mis sized Install correct size HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 HEAT RECLAIM A 3 Way Heat Reclaim Valve directs the refriger ant to either the Condenser or a Heat Reclaim Coil When the solenoid is de energized the valve directs the refrigerant to the condenser The pilot valve a check valve is directional When the solenoid is de energized the high pres sure inlet is stopped and the passage between suction and valve chamber is open When the
73. gged Clean or replace If oil filled repipe so high pressure line is not an oil trap Sleeve or piston scored allowing high pressure leak from piston chamber Replace Dirt in piston chamber causing drag Clean or replace High pressure supply lower than defrost vapor pressure Repipe Sporlan Faulty T seal or Gasket Replace KOOLGAS VALVES Koolgas valving is piped in one of two ways With a stop suction EPR a simple 2 way solenoid valve is used Without a 3 way solenoid valve is used Unless there is damage to the valve body itself both the 2 way and 3 way valve may be disassembled and repaired in the field HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Low high pressure supply 50 psig or more required in differential between high pressure and down stream suction Increase pressure supply Condensation in long high pressure line To Evaporator Insulate and or relocate to higher pressure source Revised August 1 1996 P N 340272A 7 3 a Evaporator FA j 2 af Both the EPR and the 2 way solenoid valves are normally closed so the EPR must be powered only during refrigeration and the 2 way valve only during defrost From Koolgas Manifold The 3 way valve is normally in refrigeration mode Energizing the solenoid opens the pilot valve port which directs high pressure Evaporator Koolgas vapor to the piston cham
74. ghly examined for shipping damage before and while unloading This equipment has been carefully inspected at our factory and the carrier has assumed responsi bility for safe arrival If damaged either apparent or concealed claim must be made to the carrier Apparent Loss or Damage If there is an obvious loss or damage it must be noted on the freight bill or express receipt and signed by the carrier s agent otherwise carrier 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 compressor is pulled down on shipping blocks Before piping loosen mount ing spring by turning spring nuts one full turn counterclockwise Shipping blocks can then be removed and spring tension is correct Revised August 1 1996 Lifting and Leveling Single tier Satellites require three straps front and two sides supported Two tier Satellites are provided with lifting eyes Use a spreader bar and observe minimum rigging angle of 45 Figure 5 2 Satellite Rigging and Lifting Remote Satellite Dimensions Satellite Length Height Depth in in in Single tier 38 40 29 5 Two tier 38 85 29 5 Remo
75. ght Glass Suction Filter Liquid Line Drier Thermal Expansion Valve TEV _ R Pressure Regulating Valve 8 for Condenser 9 for Receiver EPR for Evaporator Main Liquid Line Pressure Differential Valve Autosurge Valve Optional Heat Exchanger Optional P N 340272A 2 3 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 REFRIGERATION PROCESS 2 4 rrr BASIC REFRIGERATION CYCLE Beginning with the Parallel Compressors vapor refrigerant is compressed into the Discharge Manifold and flows to the Turba shed The Turba shed separates the vapor refrigerant from liquid oil by centrifugal force and screen baffles The oil is stored in the bottom of the Turba shed and returned to the compressors Heat Reelam 3 Way Vakre Revised August 1 1996 A 3 Way Heat Reclaim Valve HS directs the refrigerant to either the condenser or a Heat Reclaim Coil When the HS solenoid is de energized the valve directs the refrigerant to the condenser LET iy The Condenser discharges the unwanted heat from the system The Flood
76. h is closed Run Refrigeration Mode Voltmeter Voltmeter Action Lead Placement Readings Lead 1 Lead 2 1 T7 T8 120 Go to 2 0 Check Power Supply to Board 2 5 8 120 Go to 3 0 Check Power Supply to 5 from X1A 3 T6 T8 120 Go to 4 0 Alarm Circuit open correct cause and reset 4 T4 T8 120 Go to 5 0 Failed connection between T7 and T4 Repair 5 1 8 120 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 2 2 T8 120 Go to 10 0 Board Failure 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 Go to 13 120 High Pressure Alarm Correct cause and reset 13 P1 7 T8 0 Go to 14 120 Oil Alarm Correct cause and reset 14 P2 3 T8 120 Go to 15 0 If K1 Contacts are open correct and reset If closed Board Failure 15 P2 5 T8 0 Circuit Complete End Test 120 Board Failure HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 10 111 pi E 7 8 5 4 8 2 1 E 3 E EE O O c HUSSMANN CORPORATION B
77. igure 4 4 Compressor Cim uit Board Connection P2 connects to the contactor supplying output to the contactor coil and receiving input from the compressor auxiliary contacts Pin num bers run right P2 1 to left P2 5 P1 connects to the compressor harness pro viding input to the board from the oil failure high pressure and low pressure controls Pin numbers run right P1 1 to left P1 8 Fuse 1 provides overload protection T10 and T9 provide input to the board from Koolgas or Interlock contacts P N 340272A 4 7 DORF FED ER TECH 1 0042 T3 provides power to the K2 Relay Circuit T1 and T2 provide input to the board from EPC compressor contacts for the K2 Relay 5 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 input during normal operation when the EPC is in control 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 po 5 221 S 7 d h 4 Z 2 1 or mue Ir pz HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 4 9 Troubleshooting Compressor Board Mechanical Low Pressure Control or Series Switchback Be sure Board Switc
78. ing 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 from leaving the Condenser as fast as it is forming so the Condenser floods with its own condensate HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 The Twin Receivers act as a vapor trap and supply the Main Liquid Solenoid with quality liquid refrigerant Sufficient liquid vapor and pressure are critical to the operation of the system The system maintains these balances in the Twin Receivers for use as needed The Main Liquid Pressure Differential Valve MS functions during Koolgas defrost to reduce pressure to the Liquid Manifold This solenoid operated valve never closes completely but restricts the liquid line reducing the pressure in the Liquid Manifold The reduced pressure allows reverse flow of refrigerant necessary for Koolgas Defrost Figure 2 6 Main Liquid Line Pressure The Liquid Manifold distributes liquid refrigerant to all Branch Liquid Lines P N 340272A 2 5 The Branch Liquid Line Solenoid Valve S_ closes off refrigerant supply to the evaporator yet allows back flow of refrigerant into the Liquid Manifold Figure 2 7 Liquid Branch The TEV located in the merchandiser meters liquid refrigerant through its orifice to the low pressure side
79. ing may begin If the 500 micron vacuum does not hold the cause must be determined and corrected Repeat the entire evacuation procedure from the first step HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 Pre charge Check List Preparation for charging can begin while the system is being evacuated During any of the pull downs check Merchandisers Electrical requirements and power supply Electrical connections tight and clean Proper fan operation Thermostat setting Walk in coolers and freezers Electrical requirements and power supply Electrical connections tight and clean Proper fan operation Thermostat setting Condensers Electrical requirements and power supply Electrical connections tight and clean Proper fan operation Thermostat or pressure settings Damper operation if equipped Heat Reclaim and other systems Electrical requirements and power supply Electrical connections tight and clean Component operation Note Remember to reinstate control to unit components jumpered to make tests Set all mechanical pressure controls Compressors should still be isolated from the rest of the system Set all electronic compres sor controls into switchback so the mechanical controls are in command of all system func tions During the last evacuation look up and make a list of the required control settings for the sys tem A copy of the equipment legend will be needed to determi
80. ing to the gauge face R 22 would have a saturated liquid tem perature of 108 F If the Liquid Return Line Temperature Reading 1 is 98 F the refriger ant has 10 F of subcooling Because of the 5 F accuracy of the pilot valve the system may be in Surge as soon as 103 F is reached or not until 93 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 pressure reading at the Liquid Return Line of 220 psig Reading 2 and an Mechanical Surge Valve Chamber Pressure of 215 psig should place the system in Flow through the Receiver Revised August 1 1996 Main Valve To test the Main Valve isolate the Pilot Valve and connect the Autosurge Schrader Valve to the center hose of a manifold Connect the high and low side hoses to respective pressure sources Operate the main valve through the gauge set 10 F Eubenolinz Operation Range ieee Filot Valve Refrigerant E 22 Pressure Reading 220 psig Baturated Liquid Temperature 108 F 10 TF Subeooling 98 F Operation of Pilot Valve between 93 and 103 Figure 7 177 WARNING When entering a system s high side through a Schrader Valve use a High Side Schrader Valve Adapter between the Schrader Valve and the gauge speed coupling This will prevent excessive refrigerant loss into the
81. iquid manifold This circuit is supplied with power through parallel auxiliary contactors on the compressor motor contactors A liquid line solenoid valve 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 Zu boo liig Liquid Line fokmi Yale Revised August 1 1996 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 temperature EPR setting is listed on the store legend Line Pressure Differeztml Thermostat ee Contactors Liquid Line Bok noii 2 ne per Compressor Figure 7 19 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 DEMAND COOLING COPELAND The Demand Cooling System is designed to inject saturated refrigerant into the suction cavity when the compressor internal head temperature exceeds 292 F Injection contin ues until the temperature is reduced to 282 F If the temperature remains above 310 F for one minute the control shuts down the compressor After correcting the cause of shutdown manual reset is required The System Parts Temperature Sensor Control Module Injection Valve Module Injection valve P N 340272 7217 The Tem
82. ite 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 CONTROLS Thermostat setting is 50 F with minimum dif ferential or customer specifications SUBCOOLING 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 COMPOUND RACK ADDITIONAL SETTINGS High Pressure Safeties Ist Stage 230 psig 2nd Stage 395 psig EPC Interlock Factory Set Below 90 psig Liquid Injection TEV Superheat Factory Set 25 F Ist Stage Discharge Thermostat 50 to 65 F Not adjustable HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL SETTINGS 8 2 EPR SETTINGS The pressure settings are based on a normal 2 psig pressure drop in the suction line when the EPR control is mounted in the machine room Evap EPR Pressure Setting psig Temp Refrigerant Application F R404A R507 R22 25 22 13 7 20 14 8 15 18 12 6 37 2 9 41 30 12 44 33 15 47 36 18 51 39 21 55 42 25 60 47 30 68 53 NOTE The final test for proper EPR setting must be discharge air temperature or product temperature
83. keep the Low End Satellite from filling up with oil With a High End Satellite note that the Satellite has no Equalizing Line Note Certain Carlyle compressors do not require an oil equalizing line en aula ane enc HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 SUBCOOLING Autosurge for Ambient Subcooling The A9B needs to be working properly for the Autosurge Valve to function during Koolgas Defrost The Autosurge Valve directs the flow of refrigerant either through the Receiver Flow Through or around the Receiver Surge in response to ambient subcooling obtained in the condenser High Pressure Hot Vapor High Pressure Warm Liquid High Pressure Warm Vapor Cut Away Hot Shown Empty P N 340272A 2 9 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 temperature returning from the condenser drops below its condensing temperature the system has ambient subcooling The valve is factory set at 10 F of subcooling and is not field adjustable Conlenser Figur 2 16 Awtoszuree HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA REFRIGERATION PROCESS 2 10 Mechanical Subcooling By lowering the temperature
84. l turn liquid refrigerant flow from the Condenser H clockwise increase of TO psig the Flooding Valve prevents the liquid refrigerant from leaving the Condenser as fast as it is forming so the Condenser floods with its own condensate A6 Valve Operation Upstream Pressure from the condenser must be sufficient to hold Diaphragm off Valve Port so main Valve Chamber 2 stays filled and holds Main Valve open When upstream pressure falls below Adjustment Spring set point the valve port closes the main Valve Chamber empties through the bleed port closing the main valve 4 Turn 35 psig change Troubleshooting Malfunction Cause Action Fails to Open Set too high Reduce spring tension Dirt blocking Valve Port Clean or replace Diaphragm dirty or misaligned Clean replace or align Fails to close Set too low Increase spring tension Dirt in bleed port Clean or replace Installed backwards Re install with direction of flow HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 9 Valve Operation Downstream Pressure must be sufficient to keep Adjustment Spring 2 from opening Valve Port G If receiver pressure falls below the spring set point the valve port opens allowing Upstream Pressure to fill the Valve Chamber opening the Main Valve one full turn 25 psig change A9B Valve Racks equipped with a A9B Valve have no By
85. le tongues and grooves are vertical red tabs will be directly above the axle Loosen the hex head bolt next to the motor And slide the module up until the three locator studs clear the key slots P N 340272A 6 7 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 Axle Tongue Drive Gear Axle Groove Must be in Vertical Position Before Module be 814 Upwarnl Figure 6 8 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA MECHANICAL DEFROST TIMERS Revised August 1 1996 6 8 Figure 6 9 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 7 1 CONTROL VALVES OVERVIEW This section deals with the operation and maintenance of the major valves which may be found with the Super Plus System EPR VALVE Evaporator Pressure Regulator Valves respond to upstream pressure and are used to maintain a minimum evaporator temperature Remem ber two keys when dealing with rack mounted EPRs The first is the pressure drop from the merchandiser to the machine room The final test for setting an EPR should always be evap orator discharge air temperature or product temperature The second is that low pres
86. lest R404A R507 Design Compressor Capacity Suction Largest to Smallest Temp 1 2 Temp 1 2 5 6 F F 33 30 28 33 30 28 10 10 10 10 10 11 12 14 15 17 Note These Fanal Westinghouse Low Pressure Controls have a fixed 10 psig differential HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL SETTINGS Revised August 1 1996 8 4 Other Mechanical Low Pressure Control Settings R404A R507 Low Temperature Design Compressor Compressor Compressor Compressor Compressor Compressor Suction Number6 Number5 Number4 Number3 Number2 Number 1 Temp CO co CO co CO CO F psig psig psig psig psig psig psig psig psig psig psig psig Suction Number5 Number 4 Temp F Design Compressor Compressor Compressor Compressor Suction Number3 Number2 Number 1 Temp CO F Caution Never run the compressors in a vacuum HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 8 5 R404A R507 Medium Temperature Design Compressor Compressor Compressor Compressor Compressor Compressor Suction Number 6 Number5 Number4 Number3 Number2 Number 1 Temp CI Design Compressor Compressor Compressor Compressor Compressor Suction Number 5 Number4 Number3 Number2 Number 1 Temp CI Design Compressor Compressor Compress
87. ling F Defrost Frequency 24 Hrs 24Hrs 24 Hrs 8 Hrs 8 Hrs 8 Hrs Electric Temp Failsafe Min Reverse Air Temp Term F 48 F Failsafe Min 50 Koolgas Duration Min 14 16 Min 12 Min 12 Min Offtime Temp Duration Min 100 Min 90Min 110 Min 50 Min 50 Min HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed USA Revised March 1 1997 P N 340272A 8 19 MERCHANDISER SETTINGS Concluded Application Low Temp Coolers Models Frozen Food For all Merchandisers with Gravity Coils the Temperature listed in the Discharge Air row is Product Temperature Refrigeration Discharge Air Temperature F Return 5 F Evaporator Temperature F Fan Cycling F Defrost Frequency Electric Temp Failsafe Min Reverse Air Temp Failsafe Min Koolgas Duration Min Offtime Temp Duration Min Walk in and Prep Room Data Medium Temp Coolers Dairy Beverage Return 36 F Prep Areas Return 55 F 120 Min HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA P N 340272A 9 1 Revised August 1 1996 START UP AND MAINTENANCE Warning Know whether a circuit is open at the power supply or not Remove all power before openi
88. lve closes off refrigerant supply to the evaporator yet allows back flow of refrigerant into the Liquid Manifold for Koolgas Defrost Check Valve Valve Detail When the Solenoid is de energized the Valve Port is held closed Higher Pressure upstream fills the Valve Chamber through the Equalizing Port keeping the Valve closed In refrigeration the Valve Port opens emptying Valve Chamber through the Check Valve faster than the Equalizing Port can fill it Higher Pressure upstream forces the Valve open During Defrost Valve Port opens removing kick spring force from the valve Higher Pressure downstream back flows closing the Check Valve 2 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 Defrost Back Flow Troubleshooting Branch Liquid Line Figure 7 7 Solenoid Valves Branch Liquid Line with Back Flow Malfunction Cause Action Fails to Open Dirt plugging valve port Disassemble and clean or equalizing port Solenoid not energized bad solenoid Replace solenoid circuit open Find and repair open Fails to close Dirt in valve port Clean or replace or equalizing port Barrel or piston scored Replace Dirt in piston chamber causing drag Clean or replace HUSSMANN CORPORATION BRIDGETON MO 6304
89. m original factory setting P N 340272A 7 21 Cap Oil Inlet Adjusting Stem Compre 5301 oi and Sight Glass qualizing Port Figure 7 24 Seporlan Oil Level Regulator Cap Locking Disc Compressor Oil Inet and Sight Glass Flanges Figure 7 25 AC amp R Oil Level Regulator HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 8 1 CONTROL SETTINGS OVERVIEW This section is limited to the control settings required prior to and during start up These include Compressor Failure 1 Pressure Sett 1 Plate Subcooling Controls 1 Shell and Tube Subcooling Controls 1 Compound Rack Additional Settings 1 EPR 2 Winter Condensing Pressure Controls 2 Mechanical Low Pressure Controls 2 2 4 Condenser Sett ngs 8 Merchandiser Settings 9 PRESSURE SETTINGS Compressor Oil Failure Safety requires manual reset Compressor Cutin Cut out Time Delay psig psig seconds Copeland 12 14 7 9 105 135 Carlyle 8 11 4 8 45 75 High Pressure Safety for both R22 and R404A 507 is 395 psig Differential is fixed High Suction Pressure is set at 50 above Design Pressure or to customer specification Satellite Low Pressure Controls Low end Satellites Low Temperature Cut out 1 psig High end Satell
90. ne 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 P N 340272A 9 3 Warning Never trap liquid refrigerant between closed valves Hydraulic explosion may result Charging Open Compressors Backseat Service Valves on Suction and Discharge Open oil supply line immediately downstream of the Turba shed Pressure Transducers Open Angle Valves Leave Isolated Autosurge Pilot Valve Leave Angle Valves closed on suction and discharge manifolds until system stabilizes Connect Defrost Time Clock Connect power to the clock and set to proper time Leave Open Ball valves to branches condenser heat reclaim receiver Main Liquid Line Solenoid Valve Now under control of defrost clock Branch Liquid Line Solenoid Valve Back out manual open screws Suction Stop EPR or CDA Valves Suction Stop EPR under control of defrost clock CDA Valves replace fuse in panel board to place under control of defrost clock Split Condenser Operating under pressure controls Check Oil levels for all compressors and Turba shed HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA START UP and MAINTENANCE 9 4 Close the Ball Valve immediately downstream of the Receiver and connect the proper refrigerant to its Access Port Slowly open the liquid valve on the refrigerant tank and charge the R
91. ng control panels Note Some equipment has more than one power supply Always use a pressure regulator with a nitrogen tank Do not exceed 2 pounds of pressure and vent lines when brazing Do not exceed 350 pounds of pressure for leak testing high side Do not exceed 150 pounds of pressure for leak testing low side Always follow current EPA regulations and guidelines START UP Note Regardless of which refrigerant will be used for the operating charge R22 may be used for leak checking and pressure testing at startup Leak Testing Visually inspect all lines and joints for proper piping practices Isolate Compressors Front seat Service Valves on Suction and Discharge Close oil supply line immediately downstream of the Turba shed Pressure Transducers Close Angle Valves e Autosurge Pilot Valve Close Angle Valves on suction and discharge manifolds Open Ball valves to branches condenser heat reclaim receiver Main Liquid Line Solenoid Valve Solenoid should be energized Branch Liquid Line Solenoid Valve solenoid should be energized or manual open used Split Condenser Both sides open Energize valve solenoid Disconnect Defrost Time Clock Disconnect power to the clock Be sure all branches are in refriger ation mode and ensure that the defrost clock cannot initiate a defrost during start up procedure Verify Refrigerant requirements for System Compressors
92. nsive harmful to the environment and may leave moisture and nitrogen behind Do not run the compressors to evacuate this procedure introduces moisture into the compressor s crankcase oil and does not produce adequate vacuum to remove mois ture from the rest of the system at normal temperatures Setup Using all copper lines and packless valves connect an eight CFM or larger vacuum pump to a inch header and from the header to at least 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 Revised August 1 1996 Procedure Pull a vacuum to 1500 microns If the vacuum fails to hold determine the cause and correct Begin again with the first of the three required evacuations Break the vacuum with R22 vapor to a pressure of about 2 psig Do not exceed the micron gauge transducer s maximum pressure limit Liquid refrigerant may cause damage to components through thermal shock or a pressure surge to the transducer of the micron gauge Repeat first two steps Install the suction and liquid drier cores Pull a vacuum to 500 microns Close vacuum header valves and allow system to stand for a minimum of 12 hours If the 500 micron vacuum holds charg
93. onnected to its power supply check to see that the supply coming to the condenser disconnect is acceptable according to the serial plate Be sure the dis connect is open and jumper the fan controls Close disconnect and check the following Volt drop and ampere draw Leg balance for volts and amperes Fan discharge from the 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 NOTE Before starting any compressor s be sure the condenser serving that unit has power and that all isolation valves are open HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 5 3 Physical Data Weight w Max Flood Inlet Outlet No FLA 3PH Max Flood Charge Connections Model Fans lbs Ibs OD R404A R404A 208V 230V 460V R22 R507 R22 R507 1 1 2 8 2 6 1 3 205 221 19 35 11 HLCVB 1 2 56 5 2 2 6 410 445 40 75 1 3 8 N 1x3 8 4 7 8 3 9 615 666 59 110 1 3 8 E 1x4 11 2 10 4 5 2 925 1002 88 165 5 8 1x5 14 0 13 0 6 5 1039
94. oper winter condensing 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 ther mostatic fan cycling of all fan banks with a pressure control override of the first cycling fan bank requires flood ing controls or 2 Control B pressure controlled fan cycling of all fan banks and gravity dampers for each fan flooding controls may be required in severe winter climate 4 Adjust controls to the settings specified on the wiring diagram These are approximate settings and may be changed to suit local conditions 5 Leave condenser disconnect closed and turn off power at the store distribution panel Evacuate leak test charge and start each sys tem according to the start up section HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA P N 340272A Addendum April 15 1997 A 7 TORO we ST A 9 7 Jo 7HH SIJ unpa 42069 Pele L ng k ag 1201 RUR L E o Hrd HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA
95. or Compressor Suction Number4 Number3 Number2 Number 1 Temp Caution Never run the compressors in a vacuum HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL SETTINGS Revised August 1 1996 8 6 R22 Medium Temperature Design Compressor Compressor Compressor Compressor Compressor Compressor Suction Number6 Number5 Number4 Number3 Number2 Number 1 CO CO CI CO psig psig psig psig psig psig psig psig psig psig psig psig Compressor Compressor Compressor Compressor Compressor Number5 Number4 Number3 Number2 Number 1 CI CO CI CO CO psig psig psig psig psig psig psig psig psig psig Compressor Compressor Compressor Compressor Number4 Number3 Number2 Number 1 Caution Never run the compressors in a vacuum HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 8 7 R22 Low Temperature Design Compressor Compressor Compressor Compressor Compressor Compressor Suction Number6 Number5 Number4 Number3 Number2 Number 1 Temp Cl CO CI CO CO CO CO CI F psig psig psig psig psig psig psig psig psig psig psig psig OANA ANF URN OND NK A 92 Design Compressor Compressor Compressor Compressor Compressor Suction Number5 Number4 Number3 Number2 Number 1 Temp CI CO CI CO CI CO CI CO CO F psig psig psig psig
96. ost Timer Motor 4 28 Series Switchback Controls 4 15 Defrost Control Circuits 4 28 Switchback Controls 4 16 Other Gontrols 4 32 Koolgas and Interlock Relays 4 17 Power a 4 33 Compressor Protection 4 18 Carlyle Internally Compounded Compressor Protection 4 19 Head Cooling Fan and Demand Cooling 4 20 Circuits Parallel to the Compressor Motor Contactor Coil 4 21 Branch Board Faceplate 4 22 Defrost Board Inputs and Outputs 4 23 Defrost Board Mechanical Timer 4 24 Defrost Board Electronic Timer 4 26 Defrost Control Circuit 4 28 Suction Stop Koolgas Defrost 4 29 Electrig Demost 4 30 Cycle Defrost 2 2 eoe dece 4 31 Tables Refrigeration Thermostat w Header Mounted Solenoid 4 32 Required Field Wire Size 4 2 Wiring Defrost Termination Alarm Board Troubleshooting 4 5 Thermostats o ees 4 32 Compressor Board Troubleshooting Power Monitor and Slave Contactor 4 33 coast de eget 4 9 Electrical 4 33 uetus 4 11 Def
97. p systems are tailored to individual customers Check the store legend for component listing Alarm Delays Alarm delays are used where trip points are passed in normal operation yet system damage would result if cause continued beyond the timed delay Compressor oil pressure failure Copeland 120 seconds 15 seconds Carlyle 60 seconds 15 seconds Low liquid level 30 minutes High suction 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 uninterrupted power supply may be used Revised August 1 1996 HEADER MOUNTED LIQUID LINE SOLENOID Wire the thermostat in the following manner Determine the system number from the store legend In the control panel the system num ber matches the suffix of the appropriate and B terminals Remove the jumper between T_ and B_ terminals Connect one thermostat wire to the T_ terminal Connect the other wire to the B_ terminal 5 Amp Fuse 5 Amp F Field Supplied Feld Supplied Figure 4 25 Refrigeration Thermostat Defrost Termination Thermostats For each system using defrost termination thermostats run on
98. pass Solenoid for Koolgas Defrost operation The single A9B valve covers both functions A9B Valve Operation When the 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 P N 340272A 7 11 De energized Figure 7 14 AGB Receiver Pressure Regulator with Malfunction Cause Action Fails to Open Set too high Reduce spring tension Dirt blocking Valve Port Clean or replace Diaphragm dirty or misaligned Clean replace or align Fails to close Set too low Increase spring tension Dirt in bleed port Clean or replace Installed backwards Re install with direction of flow HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL VALVES 7 12 AUTOSURGE AND BY PASS VALVES The A9B Valve needs to be working prop erly for the Autosurge Valve to function during Koolgas Defrost The Autosurge directs the flow of refrigerant either through the Receiver Flow Through or around the Receiver Surge in response to ambient subcooling obtained in the condenser Note Both the Valve s sensing bulb and its equalizer line are located upstream of the Flooding Valve poe EX O High Pressure Hot Vapor Revised August 1 1996 The Autosurge Valve re
99. per Plus Components 1 1 Electrical Clearance Requirements 1 3 Shipping Damage 1 2 Allowable 1 4 Super Plus Frame Dimensions 1 2 Lifting and Leveling the Super Plus 1 5 1 2 Isolation Pad Location 1 5 Receiver Refrigerant Capacities l 2 Dolly 1 6 Machine Room Requirements 1 3 Uit PI3cemebht edet odi 1 4 Lifting and Leveling 1 5 Setting without a 1 6 Revised August 1 1996 P N 340272A CONTENTS Topics Figures VERVIEW situa ste le 2 1 Super Plus Refrigeration System 2 2 Super Plus Refrigeration System 2 2 Refrigeration 2 4 Basic Refrigeration Cycle 22 P rbasslieds s iimsesto ii ete enter 2 4 Heat Reclainn yole o coo edes 2 6 Heat Reclaim Valve ono eee rds 2 4 Receiver Pressure and Vapor Flooding Valve ertet 2 4 Temperature Regulation 2 6 Main Liquid Line Pressure Koolgas Defrost 2 7 Differential Valve 2 5 Beds Searle 2 8 Branch Solenoid Valve 2 5 Subcooling 20
100. perature Sensor employees Negative Temperature Coefficient NTC Thermistor to provide signals to the Control Module The NTC resistance drops on temperature rise Temperature Approximate F Reading 77 90 000 282 2 420 292 2 110 310 1 660 Probe test readings between 100 000Q and 1 600Q usually indicate an operating probe Temperature Sensor Demand Cooling is registered to Copeland Corporation HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL VALVES 7 18 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 Valve meters saturated refriger ant into the suction cavity of the compressor The valve orifice is carefully sized to meet the requirements of a specific compressor Valve sizes correspond to the four compressor bod ies 2D 3D 4D 6D CLT on Hn LE L Injection Valve EN cde ee 22 Revised August 1 1996 Component Testing Remove power to the system Unplug the Temperature Sensor from the Module The Sensor should ohm out between 1 6000 and 100 000Q Leave the Sensor unplugged and restart the system There should be no voltage between terminals 5 and L2 on the Module The inlet and outlet sides of the Injection
101. psig psig psig psig psig psig 2 3 4 5 6 7 9 OND WAU NK A o Design Compressor Compressor Compressor Compressor Suction Number4 Number3 Number2 Number 1 Temp CI CO CI CO CI CO CI CO F psig psig psig psig psig psig psig psig OANA ANH UC OND WAU NK A 92 Caution Never run the compressors in a vacuum HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 CONTROL SETTINGS 8 8 SQ OT Aq SUL 107 88 1 91155924 4 6 Aq 980195 onejsourmqi ISVOIOUL Surjos JATEA SUIPOOT ur ISVOIOUT 0 IOJ 9390N 8150 3154 OST 6 V mod 195 ATBA Surpoo T SOL 591 SOT S9T SOT SOT SOT 9 SOT SOT 591 SOT Sisd 4 sues LOL 210520 061 Sog 061 Sog 061 590 061 E aimvsaduray 8184 oxnssozq Sod juouruzi y Lod MAOTH puo juoqury IAO IH ADATH 6 580 adnssodq Josuopuo LO0S VVOr SEDIA SONILIAS AWOLV Aad NGL ANV 4 WASNAGNOD HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised March 1 1997 MERCHANDISER SETTINGS Application MEAT P N 340272A 8 9
102. quid branch solenoid is ener gized It will turn off when the thermostat no longer calls for refrigeration HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 4 23 Figure 4 18 Defrost Board Inputs and Outputs FUSE 5A on circuit board can only be replaced by removing board from panel Remove the screw on the front and on the top of the faceplate J1 through J5 Jumpers should be clipped for the following conditions if thermostat controls EPR solenoid J2 for Koolgas defrost J3 and J1 for Off time Electric defrost Do not clip J1 if suction stop EPR is used J4 if mechanical defrost time clock is used J5 if Fibertronic Defrost Clock 1000 is used T STAT is input for temperature control ther mostat MECH DEFR CLOCK is input from the normally open contacts on the 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 thermostat when controlling the suction stop solenoid for temperature J1 must be cut EPR SOL is output to the suction stop sole noid valve LIQ BRANCH SOL is output to the liquid
103. r must be level Both Sporlan and AC amp R regulators may be damaged by over adjusting Do not exceed 175 psig when testing to prevent dam age to the floats A sight glass filled with oil may indicate a damaged regulator Tum Stem Clockwise to increase a Differential Figure 7 23 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 Floats may be adjustable or non adjustable For adjustable floats before beginning adjustment isolate the compressor by turning off its control circuit Sporlan Oil Level Control OL 1 Series The Sporlan Oil Level Regulator comes preset to maintain oil level at the center line if the sight glass If there is any question as to the actual set point of the regulator turn the adjustment stem counterclockwise until the top stop is reached Then adjust the oil level down to the 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 amp R Oil Level Regulator The AC amp R Oil Level Regulator comes preset to maintain oil level inch below the center line if the sight glass Turn the adjustment stem counterclockwise to increase the oil level Each full turn will represent about 0 055 inches change in oil level Do not exceed 5 turns clockwise downward 4 turns counterclockwise upward fro
104. re Relay Note Units with Heat Reclaim should Side 3 BL z have the lockout control set to prevent 1 Bleed Line the heat reclaim from being activated Solenoid below the following discharge pressure H C values R 22 135 psig R 507 170 psig R404a 165 psig F Split Condenser Figure A 5 Split Condenser Wiring Diagram Factory and Field Installed Kits HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed USA CONDENSER INSTALLATION A 6 ELECTRICAL AND PRELIMINARY CHECK OUT The following electrical diagrams show the internal wiring Consult motor serial plate for wire sizes After wiring is complete check condenser operation in the following manner prior to compressor start up 1 Be sure the disconnect at the condenser is open then turn on power to the condenser at the store distribution panel Bypass the fan cycling controls so all fans will operate 2 Close the condenser disconnect and check the fans for proper operation The fans should discharge air from the top of the condenser Reverse the rotation of any fans blowing in the wrong direction If the con denser is equipped with gravity dampers check that they open and close freely After fans check out place the fan cycling con trols back into operation Caution Before entering any fan section make sure power to the fan motors is dis connected Addendum April 15 1996 3 Check that the pr
105. ressor 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 others are running The schematic shows a six compressor rack with the 4 Compressor being the first high side unit T4 on Datfrozt Board x ef All Branches CHET wired in Parade thri T4 Eps Sood Clet Ox ror ATEM g Low Voltage i Foolgas 2189 1207 Cl aaa A Interlock Relay L Cu Compin C4 High Side ompessors MES 2 bo EL pel ect Sce rod 15 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 18 Compressor Protection EXCEPT CARLYLE INTERNALLY COMPOUNDED COMPRESSORS Compressor protection is determined by the type of compressor used These controls are l Ed 5 wired between P1 3 and P1 8 Since the con he trols reset automatically an open compressor protector will not cause an alarm situation HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 OSC OOLS Thi 337 Cur OEC Goce Thin 229 IT P N 340272A 4 19 Figure 4 14 Carlyle Inemaly compounded Compressor Protection for Carlyle Internally Compounded Compressors For these Carlyle Compressors the compres sor protection is wired in series
106. rive Motor Module mounts on the frame end and powers the Program Modules through the Main Drive Gear Note that the Drive Motor and the Defrost Circuits do not have to be the same voltage 3 Program Modules contain a Time of Day Dial which rotates once every 24 hours and a Minute Dial which rotates once every defrost cycle The Time of Day Dial is notched to accept defrost start trippers either on the EVEN HOUR or on the ODD HOUR of the 24 hour dial These Modules cannot be substituted for each other or converted to the other type Time of Dav Alignment Mark Black Latching Lever Figure 6 6 P N 340272A 6 5 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 required minutes of defrost Be careful not to bend the lever any further than is necessary to disengage it from the dial teeth DO NOT MOVE THE RED TAB Setting the Time of Day Rotate the Main Drive Gear on the Motor Module with an upward push of the thumb until the correct hour on the black Time of Day Dial aligns with the pointed alignment mark on the modules Time of Day Dial ODD HOUR 24 Hour De frost Tripper Dial witches Minute Axle Groove
107. rost Board Troubleshooting Mechanical Time Clock 4 25 Fibertronic Time Clock 4 27 Revised August 1 1996 P N 340272A CONTENTS Topics Figures CO VOL VIO W t e I UU 5 1 Lifting the 5 2 Remote Condensers esses 5 1 Schematic Ambient Temperature Remote Satellite ient 5 6 Control heini bete 5 4 Schematic Pressure Control 5 5 Satellite Rigging and Lifting 5 6 Revised August 1 1996 P N 340272A CONTENTS Topics Figures OVEL EW aii cado ae E 6 1 Inserting 6 1 Precision Defrost Timer 6 1 Proper Installation 6 1 Paragon Defrost Timer 6 5 Precision 6 2 Resetting Alarm Switch 6 3 Precision Defrost Timer 6 4 Paragon Program ModUule 6 5 Paragon Program Module Removal and Installation 6 6 Motor Module Removal and Installation 6 7 Paragon Defrost 6 8 Revised August 1 1996 P N 340272A CONTENTS Topics Figures OVER VIC 7 1 EPR Valve with Suction Stop Solenoid 7 1 EPR Valve acabaron tuia ta ede vid 7 1 Koolgas Valve
108. rough the roof Shutoff Valves Shutoff valves are highly recommended but are not mandatory These valves should be field supplied and installed in such a manner as to isolate the entire condenser HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Addendum April 15 1997 P N 340272A A 3 LEG ASSEMBLY Figure A 2 Rigging for Leg Assembly and Lifting HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONDENSER INSTALLATION A 4 Control Panel and Electrical Components Typically at Opposite End of Unit Purge Yalve Discharge Line Liquid Return Line Addendum April 15 1996 Figure A 3 Connecting to One Manifold Connecting to One Manifold Route the discharge line directly to its respec tive condenser inlet stub and install a purge valve at the highest point in the line Route the liquid return line in a manner providing free trapless drainage from the condenser to the connection at the compressor unit Horizontal piping runs must be pitched in direction of flow Connecting to Two Manifolds When a compressor unit is served by two sets of condenser circuits an expansion loop must be constructed between the manifolds Note a connection is provided on the rack for inch equalizer line The use of an equalizing line is left to the discretion of the store engi neer It is recommended that the condenser manufacturer s installation instructions be consulted When used the eq
109. round on 4 it Min Re mobe Satellite P N 340272A 1 3 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 Rack Assembly Load Point Dimensions Nomenclature Length Width in in 02VK 04VY 51 30 04VK 05VY 64 5 30 05 06 06 87 30 07 08 07VY 109 5 30 08VY 66 amp 66 30 Note The 08 and other Extended Rack have three cross feet and six load points not the usual two and four For nonstandard racks such as with mechanical subcooling consult Hussmann Engineering Bridgeton Mo Super Plus Rack Live 150 to Ground ft Min rounded Wetal ail Cohete Block Wall HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed USA INSTALLATION INSTRUCTIONS 1 4 UNIT PLACEMENT Revised August 1 1996 When setting the Super Plus Rack plan in relation to the rest of the equipment to be installed Some minimum and maximum distances are listed Note Piping equivalent is not the same as linear distance Minimum Allowable Distances From the Water Cooled Condenser Outlet to the Super Plus Receiver Inlet the minimum allowable elevation is 1 foot With no Flooding Valve from the mounting surf
110. scheduling and timing Condenser controls Winter controls Subcooling Compound System operation EPR ORI and CDA settings TEV superheat adjustment CPR settings High and low pressure controls Main liquid line solenoid differential Thermostat settings Adjustments to electronic controls Thoroughly inspect all field piping while the equipment is running and add supports where line vibration occurs Be sure additional supports do not conflict with pipe expansion and contraction When merchandisers are completely stocked check the operation of the system again At 48 hours of operation replace the liquid drier and suction filter cores At 90 days recheck the entire system including all field wiring Change the oil filter using a Sporlan SF 283 F Future maintenance costs may be reduced if an oil acidity test is run at this time Replace acid oil HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 MAINTENANCE Compressor Replacement Since each machine room tends to be unique plan carefully as to how you will move the compressors without harming personnel equipment or the building Before beginning removal of old compressor make replacement unit ready to install Verify Replacement compressor Electrical requirements Refrigerant application Capacity Piping hookup location and design Suction and discharge gaskets Mounting requirements Have compressor in an easily acces
111. sible position uncrated and unbolted from shipping pallet Disconnect Electrical Supply Turn off motor and control panel power supplies to the Rack Turn off control circuit and open all compres sor circuit breakers Tag and remove electrical wires and conduit from the compressor Isolate Compressor from Rack Front seat Suction and Discharge Service Valves Close oil supply and equalizing lines Bleed compressor pressure through both dis charge and suction access ports into an approved recovery vessel Remove oil supply and equalizing lines Remove externally mounted components which will be re used on the replacement compressor P N 340272A 9 5 Plug holes to compressor manufacturer s specifications 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 a hoist or come along To make hookup and lifting easier an eye bolt may be installed in the rear top of the com pressor head If a compressor removal table is used slide the compressor fully on to the table then roll table to overhead hoist or hydraulic lift area When the old compressor has been remo
112. sure drop EPR Valves used on the Super Plus require an external high pressure supply to power the main piston chamber This high pressure supply 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 D against Upstream Suction Pressure and Fixed Pressure Counter Spring As upstream pressure rises it closes the high pressure inlet to the Main Valve Chamber The down stream bleed off reduces the Main Chamber pressure to the point that piston spring and Upstream Pressure open the main valve EPR Valves equipped with a Suction Stop Solenoid are used with Koolgas Defrost When de energized this solenoid causes the Main Valve to close completely HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONTROL VALVES 7 2 Troubleshooting EPR Valves Malfunction Cause Fails to Open Fails to close Dirt holding pilot port open Revised August 1 1996 Disassemble and clean Solenoid not energized bad solenoid circuit open stuck in defrost mode High pressure inlet strainer plugged Replace solenoid find and repair open correct defrost clock problem Clean or replace High pressure line pinched shut off or plu
113. t Feet 3 8 2 Way 3 5 Branch Line seas edi 3 9 Offset Tee 22 3 6 Remote Satellite Piping 3 6 Offset Construction 3 7 Expansion Loop 3 8 Connecting to Parallel Suction Stubs 3 8 Branch Pipih gioni edv d cide 3 9 Tables EA EE 3 7 Equivalent Bee oue dites crees ds 3 8 Revised August 1 1996 P N 340272A CONTENTS Topics Figures OV OTIC 4 Alarm Board Circuits 4 3 Field Wits rh t pan Santee 4 Alarm oue eodein 4 4 Wiring Guidelines Based on Compressor Board Faceplate 4 6 Various Components 4 2 Compressor Circuit Board Connections 4 7 Using 4 3 Compressor Board Mechanical Alarm Board uus 4 3 Low Pressure Control 4 8 Compressor Controls 4 4 Compressor Board EPC Control 4 10 Compressor Circuit Boards 4 6 K2 and Motor Contactor Circuits 4 12 Compressor Board Related Circuit 4 12 and Compressor Alarm Circuits 4 13 Defrost Circuit Boards 4 22 Parallel Switchback Controls 4 14 Defr
114. t as possible e i Using P Trap Ris Reduced Riser From Machinery to Solid Object When a reduced riser is necessary place the When mounting lines from machinery to reduction coupling downstream of the P Trap solid object allow line freedom for vibration to prevent metal fatigue Clamp Here mg Factory 10 x Pipe Diameter 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 When brazing near factory installed clamps or valves be sure to protect them with a wet rag to avoid overheating HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised April 15 1997 RACK TO CONDENSER PIPING Connecting to One Manifold Discharge Line will be routed directly to the con denser inlet stub with a purge valve at the highest point Liquid Return Line will be pitched downstream and provide trapless drainage to the Super Plus P N 340272A 3 3 WARNING Vent the Receiver Safety Relief Valve properly Header End of Conde nzer a 6 Inch e sn TEE Mini wm 12 Inch Minimum Drop 2 after Tee AE Main Discharge T 8 25 Line 7 2 ded All Piping 2 and Valves 2 above this line 2 ISDEM are field Ay z 7 suppled and instal 5 x
115. te Satellite Weights Shipping Weight the Sum of Compressor Weights 115 pounds HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 6 1 MECHANICAL DEFROST TIMERS OVERVIEW This section deals with the Precision and Paragon Defrost Timers When used these Time Clocks handle defrost periods of 2 hours or less Cycles requiring longer defrost periods must be controlled through supple mental time clocks Hussmann s Electronic Defrost Time Clock carries its own manual Specific guidelines for setting the Time Clocks are in Control Settings General instructions are handled here PRECISION DEFROST TIMER Three main sets of components are involved in setting up a defrost program for the system These are 1 Program Timer Dials rotate once in 24 hours and are slotted at one hour increments The field technician will insert a tripper each time a defrost cycle is to start in the 24 hour clock day 2 Cycle Timer Dials rotate each defrost cycle and stop in refrigeration The field technician will set the length of each defrost 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
116. tors exit the bottom of the liquid line Provide an expansion loop for each evaporator take off Minimum 3 inch diameter HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed USA Revised August 1 1996 P N 340272A 4 1 ELECTRICAL OVERVIEW The scope of this section is limited to main field wiring connections and to the control panel Hussmann s Super Plus Control Panels feature custom wiring schematics Most of the common user choices are detailed in this section For a schematic of the control panel as shipped see the diagrams on the panel There are three Compressor Control Circuit Diagram Defrost Diagram Power and Accessories Diagram The Fibertronic Circuit Boards are discussed at length Both explanation of Board layout and a troubleshooting chart to determine Board continuity are here The Super Plus System is available wired for 208 230 3 60 or 460 3 60 or other international voltages In any case the control circuit is 120V Refer to the serial plate located on the control panel to determine wire size MCA and overcurrent protection MOPD FIELD WIRING Super Plus components are wired as com pletely as possible at the factory with all work completed in accordance with the National Electrical Code NEC All deviations required by governing electric codes will be the responsibility of the installer The lugs on the circuit breaker package in the compressor control panel
117. ualizing line should have a field 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 manifolds Do not route the discharge line directly in front of the control panel 2 Liquid return line Route each liquid return line downward at least 6 feet between outlet stubs before teeing into the main liquid return line Note If split condenser valving is not used drop may be reduced to 2 feet After the tee route the main liquid return line in a manner providing free trapless drainage from the condenser to the connection at the com pressor unit HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Addendum April 15 1997 SPLIT CONDENSERS Remote 340272 5 LL Fil Fping Figliu ppled and Tretaled Hand Valves Recommended Ambient High Pressure Control Settings Thermostat 3 ae ac nn Relay Refrigerant Cut Out Cut In _ 9 R 404a 250 195 n R22 210 160 Condenser 00000777 solenoid or R507 260 200 3 Wav Vale HO el solenoid 5 High Pressu
118. ved clean the suction and discharge service valve gasket surfaces to shiny metal Clean the gasket surfaces on the new compressor to shiny metal Be careful not to groove or round the surfaces Gasket surfaces must be clean to prevent leaking Install the new compressor in reverse order of removal Do not open the new compressor to the system until after it has been leak tested and triple evacuated Note Oil level regulator sight glasses are designed to provide a hermetic seal when internally pressurized Some leaking may occur when a deep vacuum is pulled HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA START UP and MAINTENANCE 9 6 Cleaning the Turba shed Should the Turba shed require cleaning first shut down the system Isolate the Turba shed and bleed off pressure into an approved recovery vessel Remove the top and bottom sight glasses and the oil supply line With a clean dry regulated pressure source like nitrogen blow out any sludge or dirt Install the sight glasses using new O rings Parker 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 repl
119. ving is recommended 1 The difference between summer and winter dry bulb temperatures is greater than 90 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 than 50 of the heat of rejection for the unit 4 The condenser liquid return line is longer than 100 feet 5 The system is equipped for low head pressure operation that seeks to obtain a maximum of subcooling HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA CONDENSER INSTALLATION A 2 Water Cooled Condensers When water cooled condensers are used they generally will be shell and tube construction The water cooled condensers may be factory or field installed Evaporative Water Coolers for Condensers Evaporative water cooled condensers are shipped directly to the job site by the manu facturer REMOTE AIR COOLED CONDENSERS Handling Lifting channels are provided at each corner of the condenser Condensers with three or more fan banks will have additional inter mediate lifting channels Use only these locations for attaching cables during leg assembly and lifting the condensers Rig cables to the lifting channels and position the condenser so the legs can be bolted to the frame If the condenser was shipped on its side the intermediate erection plates for that side should also be installed at this time See illustration for proper rigging t
120. when moving and lifting Figure 1 6 Dolly Placement HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA Revised August 1 1996 P N 340272A 2 1 SUPER PLUS REFRIGERATION PROCESS OVERVIEW This section details the refrigeration process by tracking the refrigerant flow through the system components Oil separation and return is explained Super Plus Refrigeration System 2 Basic 4 Heat Reclaim iiit 6 Receiver Pressure and Vapor Temperature IRE GUL AU OM ense tae ti TRU 6 Koolgas DBTEOSE 7 ede e iis 8 Subcooling ooo ne aede dia ma pie 9 10 Demand Cooling 11 The Super Plus is designed with twin receivers for increased receiver volume The compact design reduces height and width requirements yet provides convenient access to components for easy maintenance and service Because service is 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 electrical schematics Refrigeration lines not actually in the cycl
121. wit Compressor Motor Contactor Coil Cirevit Compressor Run Circuits On call for compressor run the EPC Compressor Controller Contacts energizing the K2 Relay Coil When the Normally Open K2 Contacts close the Compressor Motor Contactor Coil is ener gized cH EHO Lan Fark d Boy Cortos 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 Revised August 1 1996 Compressor Alarm Circuits If the Compressor Motor Contactor fails to complete the motor circuit its Normally Closed Auxiliary contacts energize the Alarm Relay Once energized the K1 Relay maintains its own circuit through the Normally Open K1 Contacts The Compressor Board Switch must be opened to de energize the K1 Relay P N 340272A 4 13 assum K1 Relay Coil Circuit Tracer Compressor Alarm Relay Coil Cirewt Tracer Coat Call The three Normally Closed K1 Contacts are held open during alarm conditions The K1 Contacts between 5 and open the circuit to the Compressor Alarm on the rack s Alarm Board HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL 4 14 EFC Seritechtack Esby 2d Sor Deh F
122. ypass Circuit HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL Revised August 1 1996 4 30 Electric Defrost 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 HUSSMANN CORPORATION 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 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 Printed in USA ELECTRICAL 4 32 OTHER CONTROLS Each control panel is wired with independent compressor control circuits so any compressor can be electrically isolated without causing the other compressors to be shut down Time Delays Automatic time delays on the Super Plus System help avoid electrical overload or com ponent damage Awareness of time delays will reduce confusion in starting and troubleshoot ing the system Hussmann s EPC 2000 provides both anti short cycle and stagger start delays During switchback operation when the EPC 2000 is not controlling the system sensible delays safeties and controls can maintain less efficient operation These backu

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