Parallel Rack Systems
Installation & Operation Manual
IMPORTANT P/N 0427598_E Keep in store for August 2018 future reference!
MANUAL- I/O PARALLEL RACK
P/N 0427598_E iii
TABLE OF CONTENTS INSTALLATION
Shipping Damage...... 1-1 Equalizing Line ...... 2-5 General Rack Description...... 1-1 Condenser Piping w/ Heat Reclaim. . . . . 2-6 General Rack Components...... 1-1 Split Condenser Piping ...... 2-7 Remote Satellite Components ...... 1-2 Split Condenser Piping (3-Way Valve). . . . 2-8 Legend, Labels & Wiring Diagrams. . . . . 1-2 Rack to Heat Reclaim...... 2-9 Setup Sheet...... 1-2 Rack to Remote Header ...... 2-9 Machine Room Requirements...... 1-3 Rack to Remote Satellite...... 2-9 Handling...... 1-4 Discharge Lines for Two Satellites...... 2-9 Rack Unit Placement...... 1-5 Oil Lines for Remote Satellites ...... 2-9 Minimum Allowable Distances ...... 1-5 Offset and Expansion Loop Const ...... 2-10 Maximum Allowable Distances...... 1-5 Branch Line Piping...... 2-11 Ventilation ...... 1-6 Koolgas Defrost...... 2-12 Floor Drain ...... 1-6 Remote Condenser Placement...... 1-6 Installing Vibration Pads...... 1-7 REFRIGERATION Rack Sizing Charts...... 1-8 Overview...... 3-1 Basic Refrigeration Cycle...... 3-1 COMPONENT PIPING & LINE SIZING Rack Diagram ...... 3-2 Thermostatic Expansion Valve ...... 3-3 Rack Piping Overview...... 2-1 Superheat ...... 3-3 Refrigeration Line Runs ...... 2-1 Heat Reclaim Cycle ...... 3-3 Insulation...... 2-3 Heat Reclaim Valve...... 3-4 Special Piping for Open Rooms...... 2-3 Flooding Valve and Receiver Pressure Connecting Parallel 3-Way Valves . . . . . 2-3 Regulating Valve...... 3-4 Run Lengths and Equivalent Feet...... 2-3 Koolgas Defrost Cycle...... 3-5 Rack to Condenser Piping...... 2-4 Oil System...... 3-5 Purge Valve Location...... 2-4 Y825 Valve Adjustment...... 3-6 Receiver Safety Relief Valve ...... 2-4 Ambient Subcooling...... 3-7 Connecting to Two Manifolds...... 2-5
Continued on Page iv
IMPORTANT KEEP IN STORE FOR FUTURE REFERENCE Quality that sets industry standards!
12999 St . Charles Rock Road • Bridgeton, MO 63044-2483 U S. . & Canada 1-800-922-1919 • Mexico 01-800-890-2900 www.hussmann.com © 2018 Hussmann Corporation
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack iv
Mechanical Subcooling ...... 3-7 Temperature Controls...... 4-5 Two Stage Mechanical Subcooling. . . . . 3-7 Refrigeration Thermostat (Alternate) ...... 4-5 Liquid Injection...... 3-8 Case Probe (Alternate)...... 4-5 EPR Valve ...... 3-9 Defrost Termination Thermostat...... 4-5 CPR Valve ...... 3-10 Master Defrost Valve...... 4-5 Main Liquid Line Solenoid Valves . . . . . 3-11 Alarm Control ...... 4-6 Branch Liquid Line Solenoid Valves . . . . 3-11 Alarm System ...... 4-6 3-Way Split Condensing Valves...... 3-12 Alarm Control (Electronic)...... 4-6 Surge Receiver Valves ...... 3-12 Alarm Systems...... 4-6 Subcooling with Plate Heat Exchanger . 3-12 Inverter Control...... 4-6 Liquid Line Differential Valve Unit Cooler Fan Wiring...... 4-7 Adjustment ...... 3-13 Evaporator Mounted Liquid Line Solenoid . . . . 4-7 SORIT Evap Pressure Reg Adjustment. . . 3-13 Cooler Door Switch Wiring...... 4-7 Low Pressure Controls...... 3-13 Sizing Wire and Overcurrent Protectors . . . . . 4-7 Control Settings General Description. . . . 3-15
START-UP ELECTRICAL Leak Testing...... 5-1 Electrical Overview...... 4-1 Pre-Charge Check List...... 5-1 Field Wiring...... 4-1 Charging...... 5-2 For Remote Header Defrost Assembly...... 4-1 Oil Levels ...... 5-2 For 208-230/3/60 Compressor Units ...... 4-1 Evacuation...... 5-3 Required Field Wire Size...... 4-1 Final Checks...... 5-3 Merchandiser Electrical Data ...... 4-2 Thermostat Settings ...... 5-3 Merchandiser Field Wiring...... 4-2 Liquid Drier Core Replacement ...... 5-3 Electrical Connections...... 4-2 Suction Filter Core Replacement ...... 5-3 Identification of Wiring...... 4-2 Electrical Diagrams ...... 4-3 Unit Cooler Fan Wiring...... 4-3 MAINTENANCE Cooler Door Switch Wiring...... 4-3 Component Wiring Guidelines ...... 4-3 Compressor Replacement ...... 6-1 Sizing Wire and Overcurrent Protectors. . . . . 4-3 Winter Condensing Pressure Controls . . . . 6-2 Other Controls ...... 4-3 General Maintenance...... 6-3 Compressor Control...... 4-3 Drier and Filter Cores Replacement. . . . . 6-4 Electronic Controller...... 4-4 Time Delay...... 4-4 Pressure Switches...... 4-4 SERVICE Switchback Control (Optional)...... 4-4 Crankcase Heaters (Optional)...... 4-4 Trouble Shooting Information ...... 7-1 Oil Failure Relay ...... 4-4 Trouble Shooting Guides ...... 7-2 Current Relay (Optional)...... 4-4 Supermarket Equipment ...... 7-4 Defrost Controls...... 4-5 Refrigeration Mode...... 4-5 Defrost Mode ...... 4-5
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E v
REVISION HISTORY
Revision E - Updated with California Warning
Revision D - moved Nomenclature, vi, Added, Page 1-4 Lifting Details, Updated Page 1-6, Revised Drawings in Section 2; Removed Line Sizing Charts Revision C - Added Trouble Shooting Guide Revision B - Revised Vibration Pad Table, Page 1-6
ORIGINAL ISSUE — February 2013
* * * * * * * * * * * * * * * * * * * * * * * * * * August 31, 2018
ANSI Z535.5 DEFINITIONS This warning does not mean that Hussmann products • DANGER – Indicate[s] a hazardous will cause cancer or reproductive harm, or is in situation which, if not avoided, will violation of any product-safety standards or result in death or serious injury . requirements. As clarified by the California State government, Proposition 65 can be considered more of a ‘right to know’ law than a pure product safety law. • WARNING – Indicate[s] a hazardous When used as designed, Hussmann believes that our situation which, if not avoided, could products are not harmful. We provide the Proposition result in death or serious injury . 65 warning to stay in compliance with California State law. It is your responsibility to provide accurate • CAUTION – Indicate[s] a hazardous Proposition 65 warning labels to your customers when situation which, if not avoided, could necessary. For more information on Proposition 65, result in minor or moderate injury . please visit the California State government website.
• NOTICE – Not related to personal injury – Indicates[s] situations, which if not avoided, could result in damage to equipment .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack vi
Rack Nomenclature
CS 0 1 03 S L K
Voltage (K=208/3/60, M-460/3/60, P=575/3/60, U=380/3/50) Temperature Application {L=Low, M=Medium, H=High, D=Dual (Split Header), T=Two Stage Refrigerant Type (F=R407F, J=R134A, P=R507, Q=R407A, R=R449A, S=R404A, T=R448A) Total number of compressors (Must be two digit i.e. 7 compressors = 07
Number of suction groups
Number of satellite Compressors
Compressor System Designation {C = parallel compressor system, R = Refrigeration System Solution}
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 1-1 INSTALLATION
SHIPPING DAMAGE
All equipment should be thoroughly Concealed Loss or Damage examined for shipping damage before and When loss or damage is not apparent until while unloading . This equipment has been after equipment is uncrated, a claim for carefully inspected at our factory and the concealed damage is made . Upon discovering carrier has assumed responsibility for safe damage, make request in writing to carrier for arrival . If damaged, either apparent or con- inspection within 15 days, and retain all cealed, claim must be made to the carrier . packaging . The carrier will supply an Hussmann parallel compressor systems are inspection report and required claim forms . cling wrapped and taped prior to shipping via flatbed trailer . GENERAL RACK COMPONENTS Apparent Loss or Damage If there is an obvious loss or damage, it must Each parallel/custom rack contains the be noted on the freight bill or express receipt following components: and signed by the carrier’s agent, otherwise, carrier may refuse claim . The carrier will As many as fourteen Copeland Scrolls, or supply the necessary claim forms . 2-10 Copeland, or 2-10 Carlyle semi-hermetic, or 2-10 Bitzer, or 2-10 Bitzer or Carlye screw compressors with: GENERAL RACK DESCRIPTION • high and low pressure controls The Hussmann parallel rack operates with • oil pressure safety control up to ten reciprocating or screw compressors • primary overload protection or fourteen scroll compressors in parallel • compressor cooling fans on low design . The compact design reduces space temperature application requirements, and its open construction provides convenient access to components for Factory piping with: easy maintenance and service . • suction, discharge, liquid header Typically, all supermarket refrigeration needs • defrost header (if applicable) are handled by low and medium temperature • oil separator and return system racks . • receiver • suction filters on each compressor An average low temperature rack runs below • liquid filter drier and sight glass 0°F and may have a satellite operating as • liquid level indicator low as -40°F . Common medium temperature • liquid level switch racks operate between 0°F and 40°F .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 1-2
Control Panel: The control panel contains Factory piping with: all the necessary energy management compo- • suction and discharge stubs nents and motor controls factory-wired to the • oil systems with connections compressors . The interconnected compressors • suction filter are cycled on and off, via low-pressure settings, by a central controller to match Factory control panel with: refrigeration capacity with load requirements . • pre-wired distribution power block • individual component circuit breakers Factory-wired control panel has: • compressor time delay relays • pre-wired distribution power block • individual component circuit breakers and contactors LEGEND, LABELS & WIRING DIAGRAMS • compressor time delays • color-coded wiring system Each parallel rack is shipped with a detailed legend that identifies the specialized compo- Items supplied separately for field nents used such as compressors, valves, oil installation: separators, etc . The legend details line sizing • liquid dryer cores requirements, BTUH loads, control valves, • vibration isolation pads circuit information and suction temperatures . • loose shipped items for accessories • suction filter cores Type of refrigerant and lubricant to be used are prominently displayed on the front of the rack . REMOTE SATELLITE COMPONENTS All racks include complete wiring diagrams Although the satellite is a separate compressor, (control, primary power, board and point its liquid refrigerant is supplied by the rack layout ). All wiring is color coded . liquid manifold . The suction gases pulled by the satellite are discharged into the rack discharge manifold . The satellite components SETUP SHEET include: All set points are to be on a setup sheet One compressor with: mounted inside the door of the rack’s • high and low pressure controls electrical cabinet . This sheet includes all set • oil pressure safety control points for field-adjusted components . • primary overload protection (i e. . suction pressure, discharge pressure, • compressor cooling fans on low temp subcooler setting) .
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 1-3
MACHINE ROOM REQUIREMENTS
Equipment must be located in a dedicated A concrete base must be built on the operating area to provide enough working mezzanine floor to keep mechanical space for service personnel and meet electrical vibrations and noise to an acceptable level. codes. NOTE Hussmann recommends ventilation should Recommended spacing is site specific. It is the be a minimum of 65 cfm per compressor unit installer’s responsibility to check local codes horse power . The air inlet should be sized for and standards. a maximum of 500 fpm velocity . Ventilation fans should cycle by thermostatic control .
Proper ventilation provides needed air flow across the compressors that helps maintain the operation of the rack . Duct work may be necessary . All ventilation equipment is field-supplied and installed . Check national and local codes for ventilation requirements before installation.
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 .
6 in. Concrete Base for Mezzanine
Mezzanine Floor
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 1-4
HANDLING
Each compressor rack has lower base frame brackets for rigging and lifting . It is important to use the spreader bar to prevent the rigging from damaging the rack . Before placing the rack in the machine room, remove the ship- ping skid . For units with vertical receivers, be aware of the level sensor on top of the receiver . Lifting cables and other equipment must not come in contact with any unit piping or electri- cal components .
LIFTING DETAILS
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 1-5
RACK UNIT PLACEMENT Maximum Allowable Distances Remote satellites: Observe the minimum and maximum should not be placed below the level of the distances as described below for setting the custom or parallel rack . The satellite may be rack in relation to other refrigeration positioned above the rack . The maximum equipment: allowable elevation is 6 feet from the bottom of the rack . Minimum Allowable Distances Water-cooled Condenser: Remote Header: The minimum allowable elevation is one foot The maximum allowable piping equivalent from the outlet to the receiver inlet . is 50 feet when piping from the rack to the remote satellite . Piping should be given Air Cooled Condenser: special consideration when going from the The minimum allowable distance is 4 1/2 ft rack to the remote header . with no flooding valve from the mounting surface of the air-cooled condenser to the Condenser: mounting surface of the custom rack . The maximum allowable piping equivalent The minimum allowable distance is 6 feet is 100 feet when piping from the rack to the with a flooding valve from the mounting sur- condenser . face of the air-cooled condenser to the center of the flooding valve . NOTE: Piping equivalent is not the same
Condenser length as linear distance .
Condenser
W/ Flooding Valve Water Cooled 6 ft. Min. Remote Satellite Condenser Rack Remote Header W/O Flooding Valve 1 ft Min. 4.5 ft. Min. Flooding 6ft Max Valve
Piping Equivalent 50ft Max
Piping Equivalent 50ft Max
Piping Equivalent 100ft Max
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 1-6
VENTILATION REMOTE CONDENSER PLACEMENT
Cooler climates generally need less ventilation Locate the condenser with at least three feet than warmer climates . A warm machine room of clearance on all sides to provide adequate is going to need a good amount of ventilation . air circulation if not otherwise specified by Compressors with head fans can dissipate the condenser manufacturer . If roof mounted, as much as 20 percent of the heat (or input place on column-supported beams or load- watts) . Air intake should pass over the top of bearing walls . The mounting surface for the the units where most of the heat remains . See condenser should be at least six feet higher machine room requirements for additional than the rack flooding valve . When a information on ventilation and sizing . flooding valve is not used, the minimum distance from the base of the rack to the mounting surface of the condenser is 4 5. ft . If a FLOOR DRAIN Krack Microchannel (MX) is used, sufficient room on the right side of the unit must Provide a floor drain for disposal of conden- be available to remove the micro channel sate that may form on the compressor unit or slabs . At least nine feet of clearance must be header defrost assembly . available .
Typical Condenser Roof Mount Arrangement Typical Condenser Roof Mount Arrangement
Single Riser Double Riser
Condenser Condenser
Receiver Receiver
Be careful when moving or lifting rack. Serious bodily injury or death could occur from falling equipment.
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 1-7
Vibration Pad Quantities INSTALLING VIBRATION PADS 3 in. x 3 in. x 2 in.
Each rack must be located in the machine # of compressors Reciprocating Screw room so that it is accessible from all sides . A per pack or Scroll Compressor minimum of 36 in . clearance is recommended 2 Compressors 4 Each 6 Each to provide easy access to components . 3 Compressors 4 Each 6 Each Vibration isolation pads are supplied with 4 Compressors 6 Each 8 Each each rack . The entire weight of the rack must 5 Compressors 6 Each 8 Each rest on these pads . The pads should be located 6 Compressors 6 Each 8 Each* as shown in the image below . Cross-level 7 Compressors 8 Each ------the compressor unit so all compressors are 8 Compressors 8 Each ------level with each other . To ensure both proper 9 Compressors 8 Each ------leveling and vibration isolation, perform the 10 Compressors 10 Each ------following: *10 for Bitzer and Vertical Receiver 1 . Lift the rack in accordance with procedures detailed on Pages 1-3 .
2 . Place minimum 15 gauge 3 in . by 3 in . galvanized or stainless steel shims to compensate for uneven floors . (Shims must be field supplied ).
3 . Place vibration isolation pads on top of shims . See vibration pad quantities in the table at right to determine the number of pads to be used .
4 . Pads should be placed over structural joist members when rack is placed on sub-floor .
Vibration Pads
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 1-8
Standard Rack Sizing Chart with Horizontal Receiver # of Scroll # of Reciprocating Maximum number Length of Approximate Operating Compressors Compressors of circuits Rack (in.) Weight of Rack 3 or 4 3 11 98 3330 5 4 15 114 4290 6 5 19 138 5230 7 6 21 150 5720 8 7 24 178 6270 9 or 10 8 28 200 6870 11 9 32 222 7470 12 10 36 244 8070
Standard Rack Sizing Chart with Vertical Receiver # of Scroll # of Reciprocating Maximum number Length of Approximate Operating Compressors Compressors of circuits Rack (in.) Weight of Rack 3 or 4 3 11 128 3330 5 4 15 144 4290 6 5 19 168 5230 7 6 21 180 5720 8 7 24 208 6270 9 or 10 8 28 230 6870 11 9 32 252 7470 12 10 36 274 8070
Note: Standard rack width is 39 in. Standard rack height is 78.5 in.
The charts above are acceptable for most compressor models except screw compressors
Dimensions may vary if optional accessories such as inverters, suction accumulators, electric defrost panels, etc . are applied
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 1-9
Remote Refrigeration Circuit Header Planning (Floor Mount) # of Length Width Height Approx. Circuits (inches) (inches) (inches) Weight 4 52 36 60 312 6 64 36 60 405 8 76 36 60 489 10 88 36 60 582 12 100 36 60 666 14 112 36 60 750 16 124 36 60 843 18 136 36 60 927 20 148 36 60 1011 22 160 36 60 1104 24 172 36 60 1188
Remote Refrigeration Circuit Header Planning (Hanging Mount) # of Length Width Height Approx. Circuits (inches) (inches) (inches) Weight 4 52 34 36 262 6 64 34 36 351 8 76 34 36 431 10 88 34 36 520 12 100 34 36 600 14 112 34 36 680 16 124 34 36 769 18 136 34 36 849 20 148 34 36 929 22 160 34 36 1018 24 172 34 36 1098
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack P/N 0427598_E 2-1 COMPONENT PIPING & LINE SIZING RACK PIPING OVERVIEW
This section provides information for installing the refrigeration lines for a rack . The compo- nents are piped as completely as practical at the factory . Field piping requires only interconnec- tion of the major components and the coolers, freezers and display cases . Piping must also be supported to minimize vibration . Pulsation of the refrigerant and compressor vibration can cause piping to vibrate . This vibration can cause line breakage and damage to components . Ceiling Run with Supports
Use only clean, dehydrated, sealed refrigeration grade copper tubing . Use dry nitrogen at low pressure in the tubing during brazing to prevent the formation of copper oxide . All joints should be made with a 15 percent silver alloy brazing material . Use a 45 percent silver solder for dissimilar metals .
Floor Piping Run
Always use a pressure regulator when Through Walls or Floors operating nitrogen tanks. Refrigeration lines that are run through walls REFRIGERATION LINE RUNS or floors must have a waterseal installed, and the lines must be properly insulated . Avoid Liquid Lines and suction lines must be free to running lines through the refrigeration cases . expand and contract independently of each When this is done the lines must be adequately other . Do not clamp or solder them together . insulated using a closed-cell elastomeric foam Supports must allow tubing to expand and insulation . contract freely . Do not exceed 100 feet without a change of direction or/and offset . Plan Riser proper pitching, expansion allowance, and waterseal at the base of all suction risers . Use Insulation Insulation 2nd Layer long radius elbows to reduce line resistance and breakage . Avoid the use of 45 degree Floor elbows . Install service valves at several locations for ease of maintenance and reduc- tion of service costs . These valves must be UL approved for the minimum design working pressure of the system . Insulating a Riser
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 2-2 Component Piping & Line Sizing
From Machinery to Solid Object Waterseal Construction When mounting lines from machinery to a Waterseals must be installed at the bottom of solid object allow line freedom for vibration to all suction risers to return oil to the compres- prevent metal fatigue . sors to avoid trapping oil .
Using Elbow Riser
Clamp Here
Factory Clamp 10 x Pipe Keep this distance Diameter short as possible
Using Waterseal Riser
Don’t over support piping that is in contact Waterseal Construction with the compressor racks . The machinery must not be tightly stressed from piping that does not allow for some vibration . If piping is Reduced Riser too tight metal fatigue will occur . When a reduced riser is necessary, place the reduction coupling downstream of the waterseal .
Clamp
WRONG Avoid this Piping Arrangement
Clamp Clamp Reduces Riser
Protecting Valves and Clamps CORRECT When brazing near factory installed clamps Good for short piping runs Clamp or valves be sure to protect them with a wet rag to avoid overheating . Insulate all reduced Clamp Clamp Clamp risers .
All clamps must be properly anchored . Rubber CORRECT Good for long piping runs Clamp gromets must be installed to prevent chafing of the lines .
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Elbows evaporator(s) . And the installer is responsible Only use long radius elbows . Long elbows for proper adjustment of the valve . (See CPR have been shown to have less pressure drop Valve Section for adjustment procedures ). and greater strength . It is especially important to use long radius elbows to hot gas discharge lines . CONNECTING PARALLEL 3-WAY VALVES Factory Supplied Stubs Stub sizes provided from the manifolds do Due to the size limitations of 3-way valves, not automatically correspond to the line sizes some of the larger Koolgas systems will require necessary . It is the installer’s responsibility to parallel connection to 2 suction stubs at the supply reduction couplings . header using an offset tee construction . Do not use a bull head tee .
INSULATION
All suction lines and subcooled liquid lines must be insulated. Subcooled liquid in the liquid line will warm if the lines are left unprotected, resulting in energy loss . Overtime Connection to Parallel this can lead to the liquid changing into a gas Suction Stubs before it ever reaches the expansion valves . This is known as flashing . Flashing causes RUN LENGTHS AND EQUIVALENT FEET irregular flow through valves . If this occurs significant refrigerant loss and poor energy When figuring run lengths, angle valves and 90 performance will occur . Compressor motors degree elbows are figured as additional straight will fail if the suction line gas is too warm pipe . The chart below gives equivalent lengths as it enters the compressors . For gas defrost for these . applications, insulated suction lines help maintain temperature during defrost . Insulated Equivalent Feet for lines also prevent sweating of the lines, thus Angle Valve and 90°Elbow eliminating drops of water on the floor below Tubing Size Angle Valve Long Radius the line runs . Elbow 90% 1/2 6 0.9
5/8 7 1. 0 SPECIAL PIPING FOR OPEN ROOMS 7/8 9 1. 4 1 1/8 12 1. 7 An open food preparation room allows heat 1 3/8 15 2.3 infiltration from the rest of the store at a 1 5/8 18 2.6 rate which may jeopardize total refrigeration 2 1/8 24 3.3 performance . To protect the rest of the 2 5/8 29 4.1 refrigeration system, open preparation 3 1/8 35 5.0 evaporators must be piped with a crankcase 3 5/8 41 5.9 pressure regulating valve (CPR) . The CPR is 4 1/8 47 6.7 field installed in the suction line(s) from the
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 2-4 Component Piping & Line Sizing
RACK TO CONDENSER PIPING RECEIVER SAFETY RELIEF VALVE
Discharge line will be routed directly to the The receiver safety relief valve must be properly condenser inlet stub with a purge valve at the vented in accordance with local codes . highest point . Liquid return line will be pitched downstream, and purge valve location will NOTE: provide trapless drainage to the rack . Liquid return lines must be free draining with no traps . Install solenoid valves inside PURGE VALVE LOCATION equipment room . All interconnecting valving to be field supplied and installed . The purge valve will be installed at the highest point of an inverted waterseal, with at least a 6 in . rise . (Use with approved recovery vessel ).
Discharge Supply Condenser
6 in. Min Rise
6 Ft Min Drop before tee to main liquid line
Liquid Return To Heat Reclaim From Heat Reclaim Field Piping Factory Piping
Rack to Condenser Piping
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CONNECTING TO TWO MANIFOLDS EQUALIZING LINE
The discharge line will be “tee’d” upstream of An equalizer line is piped between the parallel the manifolds into expansion offsets with at rack and the condenser . A check valve least a one foot drop to the manifolds . Provide allowing flow only to the condenser and a a purge valve at the highest point . The liquid shut off valve downstream of the check valve return lines will be “tee’d” into the main liquid will be field supplied and installed . return line after six feet of vertical drop from the outlet stubs . The liquid return line will be pitched downstream, and provide trapless drainage to the rack .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 2-6 Component Piping & Line Sizing
Condenser PipingPiping w/w/ HeatHeat Reclaim Reclaim
Condenser 6”6" MinMin RiseRise 1”1" Min Min Drop Drop AfterAfter Tee Tee fromfrom Main Main Discharge Discharge Line Line
6 Ft Min Drop BeforeBefore Tee Tee From Heat toto Main Main From Heat Reclaim LiquidLiquid Line Line Reclaim Return ToTo HeatHeat Return All Piping and Valves ReclaimReclaim All Piping and Valves aboveabove thisthis line line are are fieldfield suppliedsupplied andand installed installed
HS Flooding ValveValve Oil Separator Oil Separator
Receiver Pressure Regulator
Condenser Manifold Discharge Lines Lines BallBall Valve Valve Condenser Manifold Valve Solenoid Liquid Return Return Lines Lines CheckCheck Valve Valve Valve Solenoid Service Valve EqualizEqualizinging Line Line Service Valve HS = Heat ReclaimReclaim
PurgePurge Valve Valve Note:Note: Liquid Return LinesLines mustmust bebe freefree draining draining with with no no Traps Traps InstInstallall Ball valves toto isolateisolate Condenser Condenser (Field (Field Supplied Supplied and and Installed) Installed) All InterconnectingInter-connecting Valving Valving to to be be Field Field Supplied Supplied and and Installed Installed INST & SER - 10
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Split Condenser Piping 2 Solenoid Valve Method w/Heat Reclaim
6” Min Rise
1” Min Drop
Condenser
6 Ft Min Drop All Piping Before and Valves From Heat Tee to above this line Reclaim Main are field To Heat Liquid Reclaim Liquid Return Line supplied and Bleed Line w/ installed Boil off Loops Return
Suction Manifold Flooding Oil Valve Separator
Discharge Lines Ball Valve Condenser Manifold Liquid Return Lines Check Valve Valve Solenoid Equalizing Line Service Valve HS = Heat Reclaim PD = Pump Down 1/4” Tubing Purge Valve SS = Split Condenser Note: Liquid Return Lines must be free draining with out Traps Install Solenoid valves to isolate Equipment Room Pump down Line should not enter the Suction Manifold over a Compressor Inlet Install Ball Valves to isolate condenser All Interconnecting Valving to be Field Supplied and Installed
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 2-8 Component Piping & Line Sizing
Split Condenser Piping 3-Way Valve Method w/Heat Reclaim
6” Min Rise
1” Min Drop
Condenser
6 Ft Min Drop All Piping Before and Valves From Heat Tee to above this line Reclaim Main are field To Heat Liquid Reclaim supplied and Line installed Return Pump Out
Suction Manifold Flooding Oil Valve Separator
Receiver Pressurization Valve
Discharge Lines Ball Valve Condenser Manifold Liquid Return Lines Check Valve Valve Solenoid Equalizing Line Service Valve HS = Heat Reclaim PD = Pump Down 1/4” Tubing Purge Valve SS = Split Condenser Note: Liquid Return Lines must be free draining with no Traps Install Solenoid valves to isolate Equipment Room Pump down Line should not enter the Suction Manifold over a Compressor Inlet Install Ball Valves to isolate condenser All Interconnecting Valving to be Field Supplied and Installed
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 2-9
RACK TO HEAT RECLAIM RACK TO REMOTE SATELLITE
Because of the variety of heat reclaim systems, The compressor discharge line may be piped refer to the instructions accompanying the through a vibration absorber to its stub on the system to be installed at the site . discharge header . The compressor suction line will be piped one of two ways depending on whether a low-end or high-end satellite is used . RACK TO REMOTE HEADER A low-end satellite suction line is piped to its check valve on the suction header, and from Separates compressors from defrost and there to the evaporator . (If Koolgas defrost is temperature controls . The rack suction stub is used pipe through the proper Koolgas valve ). connected as directly as possible to the suction A high-end satellite is piped directly to the header . The rack liquid line stub is connected evaporator . as directly as possible to the liquid header . If equipped with Koolgas defrost the rack Discharge Lines for Two Satellites Koolgas stub is connected as directly as Installations having two Satellites are “tee’d” possible to the Koolgas header manifold . together upstream of the discharge manifold . Note: The remote header may use a double Use an offset tee construction . Do not use a suction riser to aid in oil return . bullhead tee .
Oil Lines for Remote Satellites All oil lines are run in 3/8 copper . Lines will be installed securely and run under tapered cover plates when crossing walkways .
Offset Tee Construction
Satellite Piping
HUSSMANN CORPORATION • BRIDGETON, MOFig ure 63044-2483 3-9 Satellite U.S.A. Piping Parallel Rack
Piping 3-5 2-10 Component Piping & Line Sizing
OFFSET AND EXPANSION LOOP CONSTRUCTION Example: The smallest “Inches Expansion” equal to or For low temperature applications multiply the greater than 1 4196. is 1 5. . The 1 5. column length of the run in feet by 0 0169. . intersects with the 1 3/8 line at 21 . Use “L” value 21 . For an offset multiply the “L” value For medium temperature application multiply by 3 to determine the length of the offset . the length of the run in feet by 0 0112. . The product will be inches of linear expansion for Example: An “L” value of 21 would mean the length of run . 3L = 3 X 21 or 3L = 63 .
Examples: Low temperature application, a run of 84 ft of 1 3/8 in . OD .
84 ft x 0169. = 1 4196. inches expansion .
Select the smallest “Inches Expansion” figure Offset Construction equal to or greater than the product in step one from the table below . Follow that column down until it intersects the OD line size of the The offset distance required for low run . The number listed at the intersection is temperature application for an 84 ft run of 1 the “L” valve for figuring offset an expansion 3/8 line is 63 inches . For an expansion loop loop sizes . multiply the “L” value by 2 if hard copper and long radius elbows are used . If the expansion loop is formed in soft copper the loop diameter equals “L ”.
Equivalent Feet for Example: For the same 84 ft run, a hard Angle Valve and 90°Elbow copper loop is 42 by 42 inches . A soft copper Inches Expansion loop is 21 by 21 inches . 0.5 1. 0 1. 5 2.0 OD Line Size 10 15 19 22 7/8 11 16 20 24 1 1/8 11 17 21 26 1 3/8 12 18 23 28 1 5/8 14 20 25 31 2 1/8 16 22 27 32 2 5/8 18 24 30 34 3 1/8 1 20 28 34 39 4 /8 Expansion Loop Piping
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 2-11
1/2 in. lines to case 7/8 in. Header
Point tees down
Application Do not exceed a straight run for 100 feet 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 . Suction Line Return
NOTE: Sizing of all refrigerant lines is the responsibility of the installing contractor . Contact Hussmann, Application Engineering if assistance is needed .
3-In. Loop (76 mm) Liquid Line Take Off BRANCH LINE PIPING
Suction line Liquid Line - Off-time and Electric Defrost Pitch in the direction of flow . Line size may May be reduced by one size after one half be reduced by one size at one third of case other case load run . Do not reduce below run load and again after the second third . Do evaporator connection size . Take-offs to not reduce below evaporator connection size . evaporators exit the bottom of the liquid line . Suction returns from evaporators enter at the Provide an expansion loop for each evaporator top of the branch line . take-off . (Minimum 3-inch diameter ).
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 2-12 Component Piping & Line Sizing
KOOLGAS DEFROST
Maximum of 24 ft of case per branch system, except for island / coffin cases — never more Branch Size In Case Size than 24 ft . Increase the liquid line size inside 1/2 7/8 the case by two sizes over the branch size . 5/8 1 1/8 7/8 1 3/8 Take-offs to evaporators exit the bottom of 1 1/8 1 5/8 the liquid line . Provide an expansion loop for 1 3/8 2 1/8 each evaporator take-off . (Minimum 3 in ).
Koolgas Defrost Liquid Line Two Sizes Larger in Merchandiser From Liquid Manifold
Electric of Offtime Defrost Liquid Line
To Suction Manifold
Refrigeration Line Stub Outs *Note: This formula applies only to remote condenser Stub sizes do not match line sizes . Reduction lines, and only to longer runs of these lines . A 25 ft run fittings are field-supplied and installed . These does not necessarily have double the capacity of a 100 ft run . are general guidelines . The installer is respon- sible to account for any factors which may Gas Defrost Systems affect the system . 1 Do not use liquid lines smaller than ⁄2 inch OD on any type of Gas Defrost system . Condenser Line Sizing A Condenser Line Sizing chart is established for an equivalent pipe run of 100 feet . For longer runs, use the following formula:
*Table Capacity x 100 Longer Length
= Longer Line Capacity
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 3-1 REFRIGERATION OVERVIEW The flooding valve maintains head pressure This section details the refrigeration process in low ambient conditions by restricting liquid by tracking the refrigerant flow through the refrigerant flow from the condenser . rack components . Oil separation and return is explained as well .
The rack is designed with an adequately-sized receiver for proper refrigerant management . The compact design reduces height and width requirements as well as providing convenient access to components for easy maintenance Flooding Valve and service . In the diagrams refrigerant flow direction is generally clockwise and indicated by directional arrows . Electrical solenoid This causes liquid refrigerant flow to be valves carry the same initial abbreviations as backed up in the condenser, thus reducing in the electrical schematics . available heat transfer surface and causing the discharge pressure to rise . The receiver is Refrigeration lines not actually in the cycle a holding vessel for liquid refrigerant . The being discussed are shown closed or removed . receiver compensates for fluctuations in Pressure oil lines will retain a fixed pattern . liquid requirements during changing loads, defrosts and weather .
BASIC REFRIGERATION CYCLE The main liquid pressure differential valve functions during gas defrost to reduce pres- Beginning with the parallel compressors, sure to the liquid header . The reduced refrigerant vapor is compressed and flows to pressure allows reverse flow of refrigerant the oil separator and returned to the gas through the evaporator necessary for an compressors . A 3-way valve directs the super- effective defrost . heated discharge gas to either the condenser or a heat reclaim device when energized . The liquid header distributes liquid When the reclaim solenoid is de-energized the refrigerant to all branch liquid lines . The valve directs the refrigerant to the condenser . branch liquid line solenoid valve closes off The condenser rejects the heat that must be refrigerant supply to the evaporator . The removed from the refrigerant to cause it to valve also allows back flow of refrigerant condense . into the liquid header .
Oil Separator It is the installing contractor’s responsibility to consult local agencies for local code requirements.
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 3-2 Refrigeration
Heat Reclaim Condenser
Field Piping Factory Piping
Evaporator Hr Valve Off-Time Discharge Header
Oil Separator Evaporator Suction Header Koolgas
Koolgas Header
Liquid Header
Custom System Refrigeration
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 3-3
THERMOSTATIC EXPANSION VALVE (TEV) OR
The Thermostatic Expansion Valve (TEV) (2) Read the gauge pressure at the suction regulates refrigerant flow into the evaporator valve of the compressor . by responding to the temperature of superheated vapor at the outlet of the • Add the estimated pressure drop through evaporator, and in some cases where a TEV the suction line between bulb location and is used with and external equalizer . The TEV compressor suction valve . The sum of the also responds to the pressure at the outlet of gauge reading and the estimated pressure the evaporator . drop will equal the approximate suction line pressure at the bulb . The TEV, located in the merchandiser, meters liquid • Convert the pressure obtained in (1) or (2) refrigerant through its above to saturated evaporator temperature orifice to the low pressure by using a temperature-pressure chart . side of the system where it absorbs heat from the Thermostatic • Subtract the two temperatures obtained coil causing the liquid to Expansion Valve from these — the difference is superheat . evaporate .
An evaporator pressure regulator (EPR) may Secondary Method for Setting be used to control the evaporator Expansion Valve Superheat: temperature by preventing the evaporator • Before attempting to set a TEV be sure the pressure from dropping below a preset merchandiser is within 10°F of its normal pressure . operating range .
At critical locations along the refrigerant path, • Attach temperature probes at both the service valves or ball valves allow TEV bulb location (under the clamps) and isolation of components . between the TEV and the evaporator inlet .
• While the valve is hunting the temperature Primary Method for Setting Expansion Valve difference between the two probes should Superheat: not exceed 3-5°F . The differential may fall • Measure the temperature of the suction to zero . To reduce differential, turn the line at the point the bulb is clamped . adjusting stem counter clockwise and wait at least 15 minutes before checking results . • Obtain the suction pressure that exists in the suction line at the bulb location or by either of the following methods: HEAT RECLAIM CYCLE
The heat reclaim system returns heat to (1) If the valve is externally equalized, a gauge the store that has been removed from the in the external equalizer line will indicate refrigeration units . This heat, which would the desired pressure directly and accurately . otherwise be wasted, is returned in useable form through a heat reclaim coil .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 3-4 Refrigeration
The heat reclaim 3-way valve energizes during There are three types of heat reclaim water, reclaim mode diverting discharge gas to a air, glycol . Water uses a special water tank remote mounted air reclaim coil or water that pre-heats water to 140°F . This helps heating coil or other heat exchanger . After the reduce electric output of gas fired hot water discharge gas passes through the reclaim coil, heater . Air heat reclaim allows the waste heat it returns to the system through a check valve to be used to either heat the store ambient air and then to the condenser . The check valve or to preheat air prior to air-conditioning . assures no back flow and flooding when heat Glycol heat reclaim allows glycol to heat a reclaim cycle is off . During heat reclaim, the cold aisle or a side walk-in or fryer, etc . heat reclaim coil rejects superheat from the refrigerant vapor and the condenser coil rejects latent heat and produces quality liquid for the FLOODING VALVE AND RECEIVER refrigeration process . The heat reclaim coil PRESSURE REGULATING VALVE should not be oversized . The Flooding Valve and the Receiver Pressure Regulating Valve work together, the operation HEAT RECLAIM VALVE of one effects the operation of the other . The flooding valve responds to upstream pressure A 3-Way Heat Reclaim Valve directs the from the condenser . The receiver pressure refrigerant to either the Condenser or a Heat regulating valve responds to downstream Reclaim Coil . When the solenoid is de-ener- pressure in the receiver . gized the valve directs the refrigerant to the condenser . The Pressure Regulator Valve responds to receiver pressure . If the receiver pressure drops below its set point, the valve opens, directing hot high pressure vapor to the receiver .
Heat Reclaim Valve
When the solenoid is de-energized the high pressure inlet is stopped and the passage between suction and valve chamber is open . When the solenoid is energized the suction Pressure Regulator Valve outlet is stopped and the passage between high pressure and the valve chamber is open . Some manufacturers of the valve has a bleed port through the drive piston to the suction manifold . The bleed port provides a vent for fluids trapped in the heat reclaim circuits during normal operation .
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 3-5
The Flooding Valve maintains head pressure When defrost is called for, the suction line con- in low ambient conditions by reducing the trol valve closes and a two-way Koolgas valves available condensing area . Restricting liquid opens the line from the Koolgas header to the refrigerant flow from the condenser, the evaporator . flooding valve prevents the liquid refrigerant from leaving the condenser as fast as it is forming, so the condenser floods with its own OIL SYSTEM condensate . Discharge refrigerant carries droplets of oil from the compressors’ lubrication system . The KOOLGAS DEFROST CYCLE Turba-shed or other oil separator returns the oil from its reservoir along a high pressure line Beginning with the receiver the Koolgas cycle to the oil pressure differential regulator valve . splits in two directions – receiver vapor and This valve reduces the oil pressure to between receiver liquid . The high pressure liquid flowing 20 and 25 psig above the crankcase pressure of from the receiver is throttled by the main liquid the compressor, providing even flow of oil to line solenoid valve causing a pressure reduction the oil level regulators or floats . in the liquid header . To balance oil level among the compressors If a branch liquid line solenoid valve is used on an equalizing line returns any excess oil in one a Koolgas circuit, the liquid circuit is designed oil level regulator to the rest of the system . to allow backflow into the reduced pressure A check valve is placed in the equalizing line liquid header by an external parallel check between the low end satellite and the rest of the valve or by a special solenoid valve designed system . The check valve is necessary to keep to allow reverse flow . When a branch of the low end satellite from filling up with oil . refrigeration cases enters the defrost cycle its With a high end satellite, note that the satellite branch valve allows refrigerant to flow into the has no equalizing line . liquid header . Regulation Valve The receiver vapor flows directly into the The special oil pressure differential valve is Koolgas header . This Koolgas Vapor used to reduce the high pressure in the maintains the same high pressure as the combination oil separator and reservoir to a receiver . A 3-way valve closes the suction line pressure slightly above the suction pressure to the suction header and opens the Koolgas to prevent overfeeding of the compressor line to the evaporator . Koolgas vapor flows float . The valve has an adjustment range of 3 backward through the evaporator, giving up to 30 psi differential pressure . Typically, this heat to the evaporator for defrost . pressure should be approximately 20 to 25 psig above the suction pressure . 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 header . If a suction stop or EPR with suction stop is used to control evaporator temperature, the 3-way valve is not used .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 3-6 Refrigeration
Y825 VALVE ADJUSTMENT
NOTE: Every suction group or satellite com- 1) Close all the oil float service valves . This is pressor should has its own pressure differential done by turning the valve stem in the clock valve . wise direction until they bottom out .
Adjustments are made at the bottom of the 2) Connect a low pressure gauge to the valve . To adjust, remove the valve cap and suction header . turn the stem with a valve wrench . To increase the differential, screw the stem in; to decrease 3) Connect the low side gauge hose of a gauge the differential, screw the stem out . One turn manifold set to the schrader connection at gives 4 psi of adjustment . the end of the supply oil manifold .
NOTE: An increase in differential means 4) Connect the center hose of the gauge mani higher oil pressure into the floats . fold set to the suction header .
Oil Level Regulators 5) Open the hand wheel on the gauge mani For any brand of oil level regulator to work fold set for a few seconds then close it off accurately the unit and each compressor must again . be level . Both Sporlan and AC & R regulators may be damaged by over adjusting . Do not 6) Subtract the suction header pressure from exceed 175 psig when testing to prevent the oil header pressure . damage to the floats . A sightglass filled with oil may indicate a damaged regulator . Before 7) If adjustment is necessary, turn Y825 valve beginning adjusting, isolate the compressor by adjustment stem in the clock wise direction turning off its control circuit . to increase pressure and turn it counter clockwise to reduce pressure . Always open Sporlan Oil Level Control OL-1 Series the hand wheel on the gauge manifold for a The Sporlan Oil Level Regulator comes preset few seconds and recalculate oil pressure to maintain oil level at the center line of the after every adjustment . sightglass . If there is any question as to the actual set point of the regulator, turn the 8) Remove all gauges from the system . adjustment stem counterclockwise until the top stop is reached . Then adjust the oil level 9) Open all the oil float service valves . down to the desired height by turning the stem clockwise . Each full turn will represent about 05. inches change in oil level . Do not exceed nine turns from the top, or the control may be damaged .
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 3-7
AMBIENT SUBCOOLING TWO STAGE MECHANICAL SUBCOOLING The surge valve directs flow of refrigerant from the condenser through the receiver (flow Due to wide ranges of load requirements, a through), or around the receiver (surge) in two stage subcooling control will be used . In response to ambient subcooling obtained in two stage subcooling, there are two expansion the condenser . During low ambient conditions valves piped in parallel; one valve approximately the receiver pressure regulator will aid in main- one-half the size of the other . taining pressure in the liquid header . The surge valve reacts to liquid temperature from the The largest valve will be in operation during condenser . full load conditions . When the load require- ments are reduced, the smaller valve will be When the liquid temperature is below 75°F, the turned on . At this time, the larger valve will be surge valve will open allowing subcooled liquid shut off . When the liquid drop leg reaches the to bypass the receiver into the liquid header . subcooled liquid design point, both valves will When the liquid temperature is above 75°F, be shut off . the surge valve will close forcing liquid into the receiver and then into the liquid header . Two-Stage Mechanical Subcooler Control Electrically, a thermostat responding to liquid The Surge Valve is controlled by a t’stat that drop leg temperature will turn on the closes on drop of liquid drain temperature . The subcooler . The setpoint of this control will be correct setting may have to be adjusted due to the subcooling temperature design point . lower flooding valve settings . The setpoint of the control for the one-half or full expansion valve is the liquid drop leg as MECHANICAL SUBCOOLING well . This setpoint is determined by the expan- sion valve selection and will vary from store to By lowering the temperature of the liquid store . 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 . 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 .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 3-8 Refrigeration
LIQUID INJECTION
The Liquid Injection System is designed to Component Testing inject saturated refrigerant into the suction Remove power to the system . Unplug the cavity when the compressor internal head Temperature Sensor from the Module . The temperature reaches the cut-in point . Injection Sensor should ohm out between 1,600 ohms continues until the temperature reaches the and 100,000 ohms . cut-out point . If the temperature remains above 310°F for one minute the control shuts Leave the Sensor unplugged and restart the down the compressor . After correcting the system . There should be no voltage between cause of shutdown, manual reset is required . terminals “S” and “L2” on the Module . The inlet and outlet sides of the injection valve The System Parts: should feel the same temperature . After one minute, the alarm relay should trip . Remove Temperature Sensor Control Module Injection power to the system . Press the manual reset on Valve. the Module .
The Temperature Sensor employees a Negative Using a small piece of wire jump the Sensor Temperature Coefficient (NTC) Thermistor circuit at the female plug in the module . to provide signals to the Control Module . The Restart the system . There should be voltage NTC resistance drops on temperature rise . between terminals “S” and “L2” on the module . The outlet side of the Injection Valve °F Reading should feel colder than the inlet side . After one 77 90,000 minute the alarm relay should trip . 282 2,420 292 2,110 Remove power to the system . Press the manual 310 1,660 reset on the Module . Remove the jumper wire and plug in the Temperature Sensor . Control Module responds to the Temperature Restart the System . Sensor input by energizing the Injection Valve Solenoid when the cut-in temperature is Alarm Circuit reached . Too high or too low a resistance from The Alarm Circuit has three terminals in the the thermistor circuit will cause the Module to Control Module: “L” – Common; shutdown the compressor after one minute . “M” – Normally Closed; and“A” – Normally Open . “L” and “M” are wired into the Injection Valve meters saturated refrigerant compressor control circuit so an alarm into the suction cavity of the compressor . condition removes the compressor from the The valve orifice is carefully sized to meet the line and power to the Module . A manual requirements of a specific compressor . Valve reset is required to call attention the alarm sizes correspond to the four compressor condition . bodies – 2D, 3D, 4D and 6D by Copeland Compressor . Newer compressors equipped with “Core Sense” will not heed this option .
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 3-9
Alarm Relay 6) Turn off the compressor again, remove The Alarm Relay is activated after a one jumper and push reset button on the liquid minute delay under the following three injection module . conditions: 7) Plug the sensor back into the demand Compressor discharge temperature exceeds cooling module then turn compressor back 310°F . A shorted circuit or very low on . Thermistor resistance . An open circuit or very high thermistor resistance . Operational notes liquid injection does NOT replace head EPR VALVE cooling fans which are still required on low temperature applications . Temperature Sensor Evaporator pressure regulator valves respond cable must not touch any hot surfaces or the to upstream pressure and are used to maintain cable will be damaged . a minimum evaporator temperature .
Two key points when working with rack Liquid Injection Test mounted EPRs: 1) Turn off the compressor whose demand cooling module you want to test . • Pressure drop from the merchandiser to the machine room . The final test for setting an 2) Unplug sensor from liquid injection module EPR should always be evaporator discharge then turn compressor back on . air temperature or product temperature .
3) Once the compressor starts it should run for • The second is that low pressure drop EPR about one minute before locking out on valves, like those used on the rack, require liquid injection . an external high pressure supply to power the main piston chamber . This high pressure 4) Turn off the compressor again, this time supply must maintain a positive jump the temperature sensor at the demand cooling module .
5) Push the reset on the liquid injection module . When the compressor starts the liquid injection solenoid should be energized . The compressor should run for about one minute then lock out on demand cooling .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 3-10 Refrigeration
CPR VALVE
differential of at least 50 psig above the The Crankcase Pressure Regulator protects the down stream side of the valves . Lower rest of the system from the large loads caused pressure differentials may cause valve by open prep rooms . Installed in the suction malfunction . line, this valve prevents down stream pressure from rising above a given point . Basically all EPR and ORI valves open on upstream suction pressure rise . Achieve To set the CPR Valve: the desired suction pressure by balancing Adjustment Spring (#1) against Upstream • Attach compound gauges up and down Suction Pressure (#2) and Fixed Pressure stream of the valve and as closely as Counter Spring (#3) . As upstream pressure possible to the valve . rises it closes the high pressure inlet to the Main Valve Chamber (#4) . The downstream • Set the prep room temperature control low bleed off reduces the Main Chamber pressure enough to be calling for cooling . Manually to the point that piston spring (#5) and turn off one or more compressors on the Upstream Pressure (#6) open the main valve . rack to cause a suction pressure rise .
• Set the CPR to throttle at 35 psig, maintaining that pressure down stream . The up stream pressure will increase above 35 psig . Set the temperature control to 45°F discharge air temperature, or local codes .
NOTE: If a CPR Valve does not operate or leaks around the adjustment screw, it generally must be replaced .
FigureFigure 6-1 EPR VValvealve with SuctionSuction St Stopop Solenoi Solenoidd
Note: EPR Valves equipped with a Suction Stop Solenoid are used with Koolgas Defrost . When de-energized, this solenoid causes the Main Valve to close .
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 3-11
MAIN LIQUID LINE SOLENOID VALVES
The Sporlan Main Liquid Line Solenoid Valve 4 goes into differential mode when the coil is de-energized or fails . When the Pilot Port (1) 3 opens, upstream pressure (2) fills the Main Valve Chamber (3) and forces the Main Valve 5 towards a closed position . The downstream pressure (4) falls to the point that the Pilot 2 Valve Spring (5) can not keep the downstream 1 outlet closed . The Main Valve Chamber starts to empty and upstream pressure forces the main valve towards open .
DiffDifferentialerential Mode Mode - -coil Coil De-energi De-energizedzed DownstreamDownstream pressure ++ pilotpilot springspring pressure == upstreamupstream pressure BRANCH LIQUID LINE SOLENOID Energizedenergized VALVES
1 5 The Branch Liquid Line Solenoid Valve closes off refrigerant supply to the evaporator, yet 3 allows back flow of refrigerant into the Liquid Manifold for Koolgas Defrost .
2 4 When the Solenoid is de-energized the Valve Port (1) is held closed . Higher Pressure (5) Figure 6-6 Sporlan main Liquid Line Solenoid Figure 6-6 Sporlan main Liquid Line Solenoid upstream fills the Valve Chamber (3) through the Equalizing Port (4), keeping the Valve Differential Mode Quick Test closed . • Connect pressure gauges up- and downstream of the valve . In refrigeration the Valve Port (1) opens, • All branches on the rack must be in emptying Valve Chamber (3) through the refrigeration mode . Check Valve (2) faster than the Equalizing • Disconnect power to Solenoid . Port (4) can fill it . Higher Pressure (5) • Check gauges for differential . upstream forces the Valve open .
NOTE: Low refrigerant demand may prevent During Defrost, Valve Port (1) opens, the differential from building up to the valve’s removing kick spring force from the valve . real setting — upstream pressure . Higher Pressure (5) downstream back flows, closing the Check Valve (2) and forcing the Valve up . Equalizing Port (4) allows Valve Chamber (3) pressure to escape upstream .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 3-12 Refrigeration
NOTE: The refrigerant flow is then directed to the The Solenoid of the branch valve is energized condenser coil that is set to operate all year . during refrigeration and from back flow The “B” version of this valve has a small bleed during defrost . port that pumps out the condenser coil that is not operating when the valve is energized .
ValveValve Port Upstream Hussmann’s racks will have a split condenser EqualizingEqualizing PortPort pump-out on the liquid drop leg that consists of a solenoid valve in series with a small orifice Check ValveValve expansion valve . When the split condenser ValveValve DetailDetail valve is also energized, this solenoid valve De-energizedDe-energized is energized allowing for a quick pump-out 1 3 through the expansion valve and through the 2 4 bleed port of the 3-way valve . 5
Branch Liquid Line Solenoid VaValvelve SURGE RECEIVER VALVES
EnergizedEnergized When the refrigerant temperature returning 1 3 from the condenser drops below its set point, 2 4 the surge valve directs the flow of refrigerant 5 around energized (open) directing refrigerant flow around the Receiver (Surge) in response RefrigerationRefrigeration - Forward Flow to ambient subcooling obtained in the condenser . EnergizedEnergized 1 3 2 4 SUBCOOLING WITH PLATE HEAT 5 EXCHANGER
DefrostDefrost -- Back Flow The TEV should be set with the highest possible superheat that will still maintain the 3 –WAY SPLIT CONDENSING VALVES desired liquid temperature . EPR setting is listed on the store legend . A 3-Way Split Condenser Valve directs the refrigerant to either both coils of a split Electrically, a thermostat responding to condenser or one coil of a split condenser . main liquid line temperature immediately When the solenoid is de-energized, the seat down stream of the plate subcooler controls disc is in the position that evenly splits the a solenoid valve on the liquid supply line flow between both coils of the condenser . from the liquid manifold . This circuit When the solenoid is energized, the seat disc is supplied with power through parallel moves to close the upper port . auxiliary contactors on the compressor motor contactors .
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 3-13
SORIT EVAPORATOR PRESSURE A liquid line solenoid valve and a TEV control REGULATOR ADJUSTMENT refrigerant flow to the plate heat exchanger . An EPR on the return suction line prevents the 1) Connect a low pressure gauge to the suction subcooler temperature from dropping below manifold . desired liquid temperature . 2) Connect a low pressure gauge to the Thermostat setting is 50°F with minimum evaporator side of the SORIT valve in need differential, or customer specifications . of adjustment .
3) Make sure the suction header pressure is 5 LIQUID LINE DIFFERENTIAL VALVE to 10 psig lower than the desired set point . ADJUSTMENT 4) Turning the SORIT valve adjustment stem 1) Shut off the Kool/Hot gas ball valve on the in the clock wise direction will cause the first gas defrost circuit and put that circuit evaporator pressure to go up . Turning the in defrost . Make sure that no other circuits stem in the counter clock wise direction will that are gas defrost, are in, or will go in cause the evaporator pressure to go down . defrost while adjustments are being made . 5) Wait a few minutes to allow system 2) Connect two high side gauges, one on each pressures to stabilize then recheck the side of the liquid line differential valve . SORIT valve set point .
3) Subtract the outlet pressure from the inlet 6) Remove the low side gauges . pressure, this is your differential pressure .
4) If adjustment is necessary, turn valve LOW PRESSURE CONTROLS adjustment stem in the clock wise direction to increase the deferential pressure and 1) Turn off the control circuit for the turn it counter clock wise to reduce the compressor that needs it’s low pressure deferential pressure . control set .
5) Remove the high side gauges . 2) Bypass any time delays, electronic rack control relay, electronic overload module 6) Take the first gas defrost circuit out of with built in time delay and switch back defrost and open the Kool/Hot gas ball relay if used . valve for that circuit . 3) Connect a low pressure gauge to the suction header .
4) Front seat oil supply and oil equalizer line service valves on the compressor whose low pressure control is being adjusted .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 3-14 Refrigeration
5) Make sure rack suction pressure is above 13) Slowly open the suction service valve the desired cut in point of the low pressure while watching the gauge connected to control . You may have to turn off the other the suction service valve . Repeat until the compressors to raise the suction pressure . desired cut in point is reached . When you are finished adjusting the cut in of the low 6) Connect a low pressure gauge to the pressure control open the suction service compressor suction service valve on the valve fully . compressor whose low pressure control is being adjusted . 14) Turn the deferential adjustment on the low pressure control to a value greater than 7) Front seat the suction service valve . your desired cut out point .
8) Jump out the low pressure control and 15) Slowly front seat the suction service valve turn on the compressor . Look at the gauge while watching the gauge connected to the connected to the suction service valve, suction service valve . When the desired cut when the pressure reaches 0 psig turn off point is reached stop turning the suction the compressor . service valve .
9) Adjust the cut in point of the low pressure 16) Slowly turn the deferential adjustment control 20 to 25 psig above the desired on the low pressure control towards cut in point by looking at the scale on low the desired cut out point . When the pressure control . compressor turns off you have reached your desired cut out point . 10) Slowly open the suction service valve and watch the low pressure gauge . When the 17) Open the suction service valve fully then pressure reaches the desired cut in close off begin to front seat it while watching the the suction service valve . gauge connected to the suction service valve . Make sure the compressor cuts out 11) Remove the jumper on the low pressure at the proper pressure . If fine tuning of the control . Turn the compressor control low pressure control is needed, adjust the circuit on . Slowly turn the cut in cut out on the low pressure control . Repeat adjustment toward the desired cut in this step until the desired cut out point is point . When the compressor turns on you reached . When you are finished adjusting have reached your desired cut in point . the cut out of the low pressure control open the suction service valve fully . 12) Slowly open the suction service valve and watch the gauge connected to the suction service valve . Make sure the compressor cuts in at the proper pressure . If fine tuning of the low pressure control is needed, front seat the suction service valve again then adjust the cut in on the low pressure control .
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 3-15
CONTROL SETTINGS GENERAL DESCRIPTION
18) Disconnect the low pressure gauges from There are ten potential control settings the system . required to be set up prior to startup . They are as follows: 19) Open oil supply and oil equalizer line • Low Pressure Controls service valves that were closed during • Satellite Pressure Controls Step 4 . • Compressor Oil Failure Controls • Heat Reclaim Lockout 20) Turn off the control circuit on the • Split Condenser Control Settings compressor whose low pressure control • Condenser Settings you set . • Winter Condensing Pressure Controls • EPR Pressure Settings 21) Remove any jumpers you installed during • Defrost Timer Settings Step 2 . • Inverter Settings
22) Turn the compressor control circuit back on .
High Pressure Control Adjustment
1) Set the cut out of the high pressure control to the desired set point . Use the scale on the high pressure control to set cut out point .
2) Set the cut in of the high pressure control to the desired set point . Use the scale on the high pressure control to set cut in point .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 3-16 Refrigeration
NOTES:
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 4-1 ELECTRICAL ELECTRICAL OVERVIEW
Custom wiring schematics are located on the For 208-230/3/60 Compressor Units: doors of each rack . Racks are wired for To each parallel rack compressor, provide one 208-230/3/60 or 460/3/60 . Other voltages are 208-230/3/60 branch circuit, one 120V or one available upon request . The control circuit is 208V, 1PH and 15A circuit . Omit when single typically 208VAC but racks can be ordered point connection kit is used . with a single point connection (optional) . Refer to the serial plate located on the control Provide one 208-230/3/60 branch circuit to panel to determine MCA MOPD . each remote air-cooled condenser . Dry contacts are made available upon request at Refer to merchandiser Data Sheets for the rack control panel . Contacts will close in electrical supply requirements for cases . alarm state . Contact rating is 10A at 208V . Alarm status may be configured through an electronic controller . FIELD WIRING
Rack components are wired as completely REQUIRED FIELD WIRE SIZE as possible at the factory with all work completed in accordance with the National Based on the full load amps of the system, Electrical Code (NEC) . All deviations select the largest connectable wire size from required by governing electric codes will be the table . (Based on no more than three the responsibility of the installer . wires in the wireway and 30°C environment per NEC ). Total Connected FLA Largest The lugs on the circuit breaker package in the Connectable Wire: compressor control panel are sized for copper wire only . All wiring must be in compliance 140A (max) 00 per with governing electrical codes . 248A (max) 350 mcm 408A (max) 2x (250 mcm) per For Remote Header Defrost Assembly: 608A (max) 2x (500 mcm) per To the defrost control panel, provide one 208V, 1PH and 15A branch circuit, or one Include control circuit amps if single point 120V, 1PH and 15A branch circuit for control connection transformer option is used . 12A for power only . One 208V 3PH branch circuit for 208V systems 6A for 460V systems (Refer to electric defrost power, one communications NEC for temperature duration factors ). circuit for electronic controller output/ input boards . The 120V and 208V circuits may originate at the parallel rack or from a separate source .
Consult the store legend or electrical plans for each installation .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 4-2 Electrical
MERCHANDISER ELECTRICAL DATA ELECTRICAL CONNECTIONS
Technical data sheets are included with this All wiring must be in compliance with NEC manual . The data sheets provide merchandiser and local codes . All electrical connections are electrical data, electrical schematics, parts lists to be made in the electrical wireway or Handy Box . and performance data . Refer to the technical data sheets and merchandiser serial plate for electrical information . IDENTIFICATION OF WIRING
Leads for all electrical circuits are identified by MERCHANDISER FIELD WIRING colored plastic bands . These bands correspond to the color code sticker (shown below) located Field wiring must be sized for component inside the merchandiser’s wireway cover . amperes stamped on the serial plate . Actual ampere draw may be less than specified . Field The defrost heaters, defrost termination wiring from the refrigeration control panel to thermostats and refrigeration thermostats on the merchandisers is required for defrost the wide island models are tagged with termination thermostats and for optional identification as being either front or rear refrigeration thermostats . When multiple merchandiser display section defrost and merchandisers are on the same defrost circuit, refrigeration controls . the defrost termination thermostats are wired in series .
a l w a y s c h e c k t h e s e r i a l p l a t e f o r c o m p o n e n t a m p e r e s .
WIRING COLOR CODE Leads for all electrical circuits are identified by a colored plastic band: neutral wire for each circuit has either White insulation or a White plastic sleeve in addition to the color band.
Pink...... Refrig. Thermostat Low Temp. Orange or Light Blue.. Refrig. Thermostat Norm Temp. Tan...... Lights Dark Blue.. Defrost Term. Thermostat Maroon.....Receptacles Purple...... Condensate Heaters Yellow...... Defrost Heaters 120V Brown...... Fan Motors Red ...... Defrost Heaters 208V Green*...... Ground *Either colored Sleeve Or Colored Insulation
ELECTRICIAN NOTE: Use copper conductor wire only. CASE MUST BE GROUNDED
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ELECTRICAL DIAGRAMS
All electrical schematics reflect the standard wiring should refer to the controller manufacturer’s ladder diagram . Electrical schematics are literature . Check field wiring requirements for included with each rack . Please keep in mind appropriate quantity of wires . all diagrams in this manual are only examples! Wiring may vary, refer to the diagram Sizing Wire and Overcurrent Protectors included with each rack . To focus on circuit Check the serial plate for minimum circuit logic the diagram may separate a relay coil and ampacity (MCA) and maximum overcurrent it’s contacts . Electrical terminal connections protective devices (MOPD) . Follow NEC are clearly numbered and aid in trouble guidelines . shooting should a problem arise . Other Controls Unit Cooler Fan Wiring Refer to the wiring schematics included with See manufacturer’s literature for wiring the rack, when other controls are used . requirements . Evaporator mounted liquid line solenoid power for a liquid line solenoid can be picked up at the rack on terminals C and R COMPRESSOR CONTROL for each respective circuit . Each control panel is wired with independent Cooler Door Switch Wiring compressor control circuits so any compressor Check the store legend for door switch can be electrically isolated without causing requirements . The switch must be mounted to the other compressors to be shut down . A the cooler door frame, and must be wired to typical compressor control will consist of the control the field installed liquid line solenoid following: and the fan circuit . For Koolgas applications, install a check valve to bypass the liquid line • Electrical control solenoid valve . • Switchback relay contacts (optional) • Switchback time delay (optional) • Low pressure switch COMPONENT WIRING GUIDELINES • High pressure switch • Oil pressure switch Check the store legend for components • Overload contact (if used) requiring electrical circuits to either the panel, • Contactor coil which may include: • Demand cooling control (if used) • Remote alarm • Crankcase heater (optional) • Electronic temperature probe • Lighted toggle switch • Defrost termination thermostat Terminal pins will be used between control • Thermostat controlling a liquid line points for easy testing and troubleshooting . solenoid • Satellite control • Heat reclaim contact or 24V supply All thermostat wires should be sized for rack control circuit breaker . Temperature sensor
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 4-4 Electrical
ELECTRONIC CONTROLLER *For proper setting of switches see control The electronic controller uses a suction settings section . transducer to “read” the suction manifold pressure . From this, sequence compressors on or off through a relay board to achieve the SWITCHBACK CONTROL (OPTIONAL) target suction pressure . During “normal” operation, the switchback relay will be de-energized allowing the TIME DELAY electronic controller to be in full control . When the controller looses power or malfunctions . Automatic time delays are built into most the switchback relay will energize which in electronic controllers . This helps avoid short turn will bypass the control power around cycling . A solid state time delay will be used the electronic controller and through the low for backup in the unlikely event of a electronic pressure switch and time delay . controller failure . The time delay will only be in the circuit during switch back, if the system uses switch back control . CRANKCASE HEATERS (OPTIONAL)
If the system does not have optional switch A crankcase heater is used to alleviate liquid back control then it will be wired in series with migration to the compressor during off cycle the operating controls . Awareness of time periods . The crankcase heater is interlocked delays will reduce frustration and confusion through the compressor contactor to be when starting or troubleshooting the system . powered when the compressor is not running .
PRESSURE SWITCHES OIL FAILURE RELAY
There are basically three pressure switches This relay is used during an oil failure to in the compressor control circuit . A low jump the electronic controller relay . This pressure switch is used to close the control will eliminate multiple alarms if the suction circuit during high suction and open the pressure drops and the compressor control circuit during low suction pressure . A high point opens without the oil failure relay, the pressure switch is used to open the control suction pressure would eventually rise causing circuit during a critical high discharge pressure another oil failure alarm . state . The high pressure switch is available in automatic or manual reset . An oil pressure switch senses the supply oil pressure when the CURRENT RELAY (OPTIONAL) compressor is running . A current relay is wired in series with the oil If the oil pressure falls below the preset setting, failure control heater . This will prevent a false the control circuit will open . Oil pressure oil trip if the compressor circuit breaker should switches are preset for 6 5. psig differential trip or if the compressor goes off on internal (Carlyle) and 9 psig differential (Copeland) . overload . The oil failure time delays are preset for 45 seconds (Carlyle) and 120 seconds (Copeland) .
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 4-5
DEFROST CONTROLS TEMPERATURE CONTROLS
There are many types of defrost circuits and Refrigeration Thermostat (Alternate) they are shown on the Defrost diagram in If it is desired to have the refrigeration the rack . These circuits may be repeated in thermostat operate the branch liquid line multiple and intermixed in any one store . solenoid on the compressor unit, wire it to Each control panel is wired with independent the control panel in the following manner . defrost control circuits so any circuit can be Determine the system number from the store electrically isolated without causing the other legend . The system will be on the suffix of the circuits to be shut down . appropriate “T” and “B” terminals .
A typical defrost circuit will consist of the a . Remove the jumper from the T and B terminal . following: b . Connect one thermostat wire to the T terminal . c . Connect the other thermostat wire to the B • Lighted toggle switch . terminal . • Pins R and C for refrigeration power circuit . Case Probe (Alternate) • Pins D and C for defrost power circuit . If it is desired to monitor case temperature • N C. . contacts for refrigeration . and operate a branch liquid line circuit, wire • N O. /N. C. . contacts for defrost . a case probe from the case to an analog point • Pins E and F for defrost termination . (Dry on the electronic controller . Provisions for case contact only) probes may be made from the field or factory . • Pins T and B for temperature control Refer to the controller manual for setup . thermostat (Dry contact only) or Temperature probes can be used for Defrost Termination Thermostat electronic controllers . For each system using defrost termination thermostats, run a two-wire control circuit Refrigeration Mode: from all termination thermostats (in series, During refrigeration, both the defrost point one per case) to the E_ and F_ terminals in the and refrigeration point are de-energized control panel with a suffix corresponding to allowing L1 power to flow to the SV valve the system number . (Sorit or Liquid Solenoid) . If case probes are used with the controller the refrigeration Note: The defrost termination thermostat must point will open when a system reaches proper supply a dry contact closure . An isolation operation temperature . Thus closing the relay must be used for a “hot” termination refrigeration valve . thermostat .
Defrost Mode: Master Defrost Valve The defrost point will energize opening The master defrost valve is used during a hot/ power to the SV valve, refrigeration point . kool gas defrost cycle to create a reverse flow and closing power to the Kool/Hot gas valve through the evaporator . (HGV) or defrost contactor (DC) .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 4-6 Electrical
ALARM CONTROL The controller can display actual refrigerant level with the analog type (optional) . Phase Alarm System loss, oil failure, and the compressor failure The rack basic alarm package includes alarms alarms are connected to the rack controller for: through a digital input . An optional modem • Oil Failure (each compressor) can be installed to allow the rack controller to • Phase Loss call out any refrigeration alarms . • Low Liquid Level* • High Suction* Alarm Systems • High Discharge The following alarms are available for use with • Compressor Failure the parallel rack system:
*Time Delayed 1 . Refrigerant Loss Alarm/Indicator: An alarm trips if the refrigerant level in the A dry set of contacts are supplied to control receiver drops below a set level . This alarm a remote bell or other alarm device . These automatically compensates for changes in contacts are rated at 10 0. amps, 120V . An liquid level occurring during heat reclaim . indicator light signifies what alarm condition has been activated . 2 . Single Phase Protection: This shuts down the control circuit during single phasing Note: If an electronic rack controller is of the power circuit; automatically resets utilized, then the above alarms will performed when three phase power is restored . by the rack controller . 3 . Remote Alarm: In event of a power Ladder diagrams emphasize the circuit outage or any alarm condition, an alarm continuity and logic . They aid troubleshooting will sound at another location, such as and testing by identifying point-to-point a burglar alarm monitoring station or connections, and color coding rather than just answering service . physical location . A ladder diagram normally moves from left to right so the user can “read” the series of switches, relays, terminals and INVERTER CONTROL components that make up a circuit . An inverter is used to vary the speed of a Alarm Control (Electronic) compressor which in turn varies the capacity When an Electronic Rack Controller is utilized of that compressor . With the ability to vary all alarm functions are performed by the rack the capacity of a compressor, refrigeration controller . High suction and high discharge requirements can be better matched to the pressures are “read” by transducers connected load . to the rack controller . The liquid level can either be a digital input (standard) or an analog type input .
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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 merchandiser can be picked up from the fan circuit . (Check fan motor and solenoid voltages first ).
Cooler Door Switch Wiring Check the store legend or electrical plans, for door switch kits . The switch must be mounted to the cooler door frame, and must be wired to control the field-installed liquid line solenoid and evaporator fans . Door switches are wired in series . 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 .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 4-8 Electrical
NOTES:
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 5-1 START-UP LEAK TESTING the pressure is the same throughout the assembly . Check connections and NOTE: accessories for any leaks . Use an electronic Leaks harm the ozone layer and can be very leak detector . Inspect all joints . If the expensive . It is very important to follow pressure drops sharply, this is an indication EPA Greenchill Installation Leak Tightness of a leak . Visually inspect all lines and Guidelines as well as Greenchill Leak joints for proper piping practices . Prevention and Repair Guidelines .
• Once the system has been thoroughly tested, evacuate the system to 1500 microns for the first evacuation . Know whether a circuit is open at the power supply or not. Remove all power before • The evacuation is repeated . Install liquid opening control panels. Note: Some equipment has more than one power supply. and drier cores before the second evacuation . Suction filter cores are factory installed . After each evacuation, the system must be Check that the compressor’s primary pressurized to 2 psig with dry nitrogen . ON-OFF switch are all in the OFF position . • Now evacuate the system to 500 microns NOTE: for the second evacuation . Perform three Do not start any compressors without ensuring evacuations in all . there is oil in them . Serious damage to the compressors may result from not having oil in them . Parallel racks are shipped with the oil PRE-CHARGE CHECK LIST loose . While the system is being evacuated Always use a pressure regulator with a nitrogen preparation for charging can begin . During tank. Do not exceed two pounds of pressure any of the pull downs check: and vent lines when brazing . Do not exceed 350 pounds of pressure for leak testing high • Merchandiser’s electrical requirements and side . Do not exceed 150 pounds of pressure power supply electrical connections are for leak testing low side . tight and clean • Check for proper fan operation and To check for system leaks do the following: thermostat setting . • Walk-in coolers and freezers electrical • Leave all valves closed to allow pressure requirements and power supply into the rack . Close the suction, liquid • Damper operation, if equipped . or hot gas manifolds . Each rack system • Heat Reclaim and other systems is shipped with dry Nitrogen . Build the pressure in the rack unit until it reaches 150 psi . Each individual circuit should be checked .
• Each circuit can be leak checked as the pressure increase to 150 psi . Ensure that
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 5-2 Start-up
CHARGING
• Open compressors – backseat service valves If the oil is low, add the appropriate oil or on suction and discharge . lubricant to match the refrigerant used . • Open oil supply line immediately down stream of the oil separator . • Pressure transducers – open angle valves . connect defrost time clock and set proper Additionally, check for the following time . during leak test: • Leave open ball valves – to branches, condenser, heat reclaim, receiver . Isolate compressors – front seat service valves on suction and discharge . close oil • Main liquid line solenoid valve – now supply line immediately downstream of under control of defrost clock . the oil separator . • Branch liquid line solenoid valve – Back out manual open screws . Pressure transducers – close angle valves . • Suction stop EPR – under control of Open ball valves – to branches, condenser, defrost clock . heat reclaim, receiver . • Split condenser – operation under pressure controls . Main liquid line solenoid valve - solenoid should be non regulating position . Note: Branch liquid line solenoid valve - Remember to reinstate control to unit solenoid should be energized or manual components jumpered to make test . open used . Set all mechanical pressure controls . Compressors Suction stop EPR valves – suction stop should still be isolated from the rest of the EPR requires energized solenoid to be system . Set all electronic compressor controls open . into switchback so the mechanical controls Split condenser – both sides open . are in command of all system functions . De-energize valve solenoid .
During the last evacuation look up and make Defrost time clock – disconnect power a list of the required control settings for the to the clock or set electronic controllers system . A copy of the equipment legend will in manual . Be sure all branches are in be needed to determine the system’s design refrigeration mode . operating points . High and low pressure, heat Verify refrigerant requirements for system, reclaim lockout, winter control settings, and Compressors, and TEVs in merchandisers other controls on the system should be noted . and coolers .
Electrical supply and component Oil Levels requirements . Check oil levels for each compressor and the Turba-shed or other oil separator: Always recapture test charge in approved Compressor sight glass 1/8 to ½ full, oil recovery vessel. separator between two lower sight glasses . See legend for oil types used in parallel rack system .
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Evacuation Thermostat Settings Nitrogen and moisture will remain in the Adjustments to electronic controls: system unless proper evacuation procedures are followed . Nitrogen left in the system Thoroughly inspect all field piping while may cause head pressure problems . Moisture the equipment is running and add supports causes TEV ice blockage, wax build up, acid where line vibration occurs . Be sure additional oil and sludge formation . supports do not conflict with pipe expansion and contraction . • Do not simply purge the system . This procedure is expensive, harmful to the When merchandisers are completely stocked, environment, and may leave moisture and check the operation of the system again . At 48 nitrogen behind . hours of operation replace the liquid drier and suction filter cores . • Do not run the compressors to evacuate . This procedure introduces moisture into At 90 days recheck the entire system, the compressor’s crankcase oil and does including all field wiring . Change the oil filter . not produce adequate vacuum to remove Future maintenance costs may be reduced if moisture from the rest of the system at an oil acidity test is run at this time . Replace normal temperatures . acidic oil .
LIQUID DRIER CORE REPLACEMENT
Replace liquid drier cores 24 hours after initial Never trap liquid refrigerant between closed startup . valves as this could cause a hydraulic explosion. After 48 hours of operation, replace the drier cores again . Any time the system is opened Final Checks after this point, the dryer cores shall be Once the rack is up and running, it is the replaced . responsibility of the installer to see that all the fine adjustments are made so the rack delivers maximum temperature performance and SUCTION FILTER CORE efficiency for the customer . REPLACEMENT
These adjustments include: Replace suction filter cores 24 hours after initial startup . • Defrost scheduling and timing • Condenser controls After 48 hours of operation, inspect suction • Winter controls filter cores and replace and repeat if they are • Sub-cooling Compound System Operation full of dirt and debris . EPR, and ORI settings • TEV superheat adjustment • CPR settings High and low pressure controls Main liquid line solenoid differential
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 5-4 Start-up
NOTES:
Intentionally venting or discharging CFC, HFCand HCFC refrigerant violates Federal Law. All CFC, HFC and HCFC refrigerants must be reclaimed and recycled in accordance with all state, federal and local laws.
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 6-1 MAINTENANCE
COMPRESSOR REPLACEMENT Remove oil supply and equalizing lines . Remove externally mounted components Since each machine room tends to be unique, which will be re-used on the replacement plan carefully as to how you will move the compressor . Plug holes to compressor compressor without harming personnel, manufacturer’s specifications . equipment or the building . Before beginning removal of an old compressor make Remove bolts from suction and discharge service replacement unit ready to install: valves .
Verify Replacement compressor electrical Remove mounting bolts . requirements, refrigerant, application, When moving the compressor, use a come- capacity, piping hookup location and design along, hoist or hydraulic lift to carry the suction and discharge gaskets . weight .
Mounting requirements: Do not use the rack piping or panel to support Have compressor in an easily accessible a hoist or come-along . position, uncrated and unbolted from shipping pallets . Do not use ceiling trusses to support a hoist or come-along . Disconnect electrical supply: Turn off motor and control panel power The rear support channel on the rack or a supplies to the Rack . Turn off control circuit properly constructed ceiling rail may be used and open all compressor circuit breakers . Tag to support a hoist or come-along . and remove electrical wires and conduit from the compressor . To make hookup and lifting easier, an eye bolt may be installed in the rear top of the Isolate compressor from rack: compressor head . Front seat suction and discharge service valves . Close oil supply and equalizing lines . Bleed compressor pressure through both discharge and suction access ports into an approved recovery vessel .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 6-2 Maintenance
If a compressor removal table is used, slide the Replacing Drier and Filter Cores: compressor fully on to the table, then roll table Shut down the system . Isolate the core to to overhead hoist or hydraulic lift area . be replaced and bleed off pressure into an approved recovery vessel . Open housing, When the old compressor has been removed, replace core and close up . Pressurize, leak test clean the suction and discharge service valve and bring back into line . gasket surfaces to shiny metal . Clean the gasket surfaces on the new compressor to shiny metal . Be careful not to groove or round WINTER CONDENSING PRESSURE the surfaces . Gasket surfaces must be clean to CONTROLS prevent leaking . Five methods are used to control condensing Install the new compressor in reverse order of pressure during cold weather operation . removal . Do not open the new compressor to the system until after it has been leak tested 1) Flooding valves must be applied to the and triple evacuated . compressor unit when winter temperatures Note: Oil level regulator sight glasses are are expected . designed to provide a hermetic seal when internally pressurized . Some leaking may occur 2) Temperature Control: Fans are when a deep vacuum is pulled . thermostatically controlled and cycled accordingly to outside temperature . Can be Cleaning the Turba-Shed (Oil Separator) applied to single circuited condensers . Should the oil separator require cleaning, first shut down the system . Isolate the oil separator 3) Thermal Fantrol: Used with multi-circuited and bleed off pressure into an approved condensers . Fans are cycled according to recovery vessel . Remove the top and bottom outside temperatures . sight glasses and the oil supply line . With a clean, dry, regulated pressure source like 4) Split Condensers (factory or field installed): nitrogen, blow out any sludge or dirt . Install Used on dual circuit condenser with or the sightglasses using new o-rings . without heat reclaim, where a four-way
solenoid valve (controlled by ambient Parker Number 2-23, Compound 557 Precision Rubber, number sensing temperature control or pressure 023, control) activates to cut off one half of Compound 2337 the condensers . Field-installed situations will require double discharge and double Leak test, evacuate, and charge with fresh oil condenser leg return piping . refer to legend for oil type . Open valves closed to isolate the oil system and bring the rack back on line .
P/N 0427598_E0427598_C U.S. & Canada 1-800-922-1919 • Mexico 01-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 6-3
GENERAL MAINTENANCE
Regular inspection and upkeep is critical Generally, the following items should be checked to operation of the rack . Because of the on a quarterly basis: numerous options and accessories that are unique to each store, it is impossible to list all Investigate operating conditions for the of the maintenance guidance for individual following: systems . • Suction, liquid, and discharge pressures and Maintenance must be performed by a well temperatures qualified technician to diagnose and prevent • Sub-cooling, superheat and ambient problems before they may occur. The temperatures information below is a general guideline. • Safety controls, operating controls and alarms Recommended service intervals in your area may • Amperage coming from Compressors vary depending on the operating environment and equipment used. Contact your Hussmann representative for further information. Each year, check the following:
Generally, the following items should be checked • Clean the condenser coil on a weekly basis: • Straighten or replace all fan blades • Change the filter drier and suction cores • System Pressures • Get an oil sample and determine the quality • Main Power Voltage and change if required • Oil Levels • Refrigerant Charge DRIER AND FILTER CORES REPLACEMENT Generally, the following items should be checked on a monthly basis: Replacing Drier and Filter Cores Shut down the system . Isolate the core to be replaced and • System pressures bleed off pressure into an approved recovery • System leak tests vessel . Open housing, replace core and close • All filters and drier cores up . Pressurize, leak test and bring back into • Insulation, conduit, electrical boxes and line . control panels • Secondary systems, and accessories • Fan motors, contactors and electrical connections • Check for tightness of fittings, fan blades and motor mounts
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 6-4 Maintenance
NOTES:
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 01-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 7-1 SERVICE
TROUBLE SHOOTING INFORMATION
SPORLAN http://www .sporlanonline .com
EMERSON Fault Finder app http://www .emersonclimate .com/en-us/ Resources/Mobile_Apps/Pages/mobileapps . aspx
SQUARE D HOTLINE 888-SQUARED (888-778-2733) Tech Support Line . Level One provides product initial Tech Support and can connect the Caller to Level 2, if required .
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack
7-2 Service
4
Compressor Starts Compressor
Runs Continuously Runs
Verify System Operation System Verify
8,4
5
Fan & Motor, Refrigerant Overcharge, etc. Overcharge, Refrigerant Motor, & Fan
Check for Blown Gasket or Damaged Discharge Reeds Discharge Damaged or Gasket Blown for Check
Refer to 3 Phase Voltage Monitor Section of Controls Module Controls of Section Monitor Voltage Phase 3 to Refer
-- Worn Electrical Contacts Electrical Worn --
-- Bad Transformers Bad --
-- Loose Electrical Connections Electrical Loose --
-- Power Supply/Utility Grid Supply/Utility Power --
-- Undersized Cable Undersized --
-- Excessive Cable Length Cable Excessive --
Correct Voltage Supply Check Supply Voltage Correct
Refer to Motor & Basic Wiring Section Wiring Basic & Motor to Refer
Yes
6
8 Condenser, Defective Condensers, Dirty for Check
7Control Faulty or Restriction Charge, of Loss for Check
5Module Controls of Section Control Pressure See
4Worksheet Operation System Complete See
3Components Appropriate Replace
1
2
HPC
Seated?
Verify System Operation System Verify
Do Not Replace Compressor Replace Not Do
No
Backseat It Backseat
7,4
3
Is the Discharge Service Valve Back Back Valve Service Discharge the Is
5
No
No
Range?
Verify System Operation System Verify
LPC
Do Not Replace Compressor Replace Not Do
DANGER!
Yes
Voltage Application, Temp Temp Application, Voltage
Is the Compressor Properly Properly Compressor the Is
Applied? Proper Refrigerant, Refrigerant, Proper Applied?
Still Short Cycling? Short Still
6
Resolve Application Issues Application Resolve
LPC from the Compressor! the from LPC
Yes
Valve if Doing so will Isolate the the Isolate will so Doing if Valve
Frontseat Suction Service Valve Service Suction Frontseat
Do Not Frontseat Suction Service Service Suction Frontseat Not Do
4
4
Short Cycle Short
Short Cycling? Short
Which Control is is Control Which
4,2
Yes
OK?
Compressor
Compressor Starts Compressor
Inspect/Replace
Trouble Shooting Guide Shooting Trouble
Replace
Compressor
Are The Start Components Components Start The Are
(i.e. Relays, Motor Starters, Starters, Motor Relays, (i.e.
Does Not Restart Not Does
Contactors, and Capacitors) and Contactors,
No
4
Thermostat
Replace Components Replace
Good
Verify System Operation System Verify
Fix Voltage Issues Voltage Fix
Restart While Observing Amps Observing While Restart
Verify System Operation System Verify
Do Not Replace Compressor Replace Not Do
Verify System Operation System Verify
Do Not Replace Compressor Replace Not Do
Balance System Pressure and Attempt to to Attempt and Pressure System Balance
Connections
Check Electrical Electrical Check
1
Not High Amps High Not
Fix
Bad
Voltage
Improper
Verify System Operation System Verify
Connections
Do Not Replace Compressor Replace Not Do
Compressor
(If Accessible) or or Accessible) (If
Replace Protector Protector Replace
Normal Amps Normal
Protector
Restarts
Wired
Check Voltage at at Voltage Check
Correctly
1
Draw
Compressor Terminals Compressor
Proper
Voltage
Check
Wiring
Proper
Check Amp Amp Check
Resistance
Amps
Check Winding Winding Check
Resistance and and Resistance
Wired
High or Excessive Excessive or High
Wiring
Resistance to Ground to Resistance
Incorrectly
Fix Replace Replace Fix
Replace
Improper
Replace
High Amps High
Compressor Resistance
Compressor
Protector to Reset to Protector
Compressor Starts Compressor
Allow Time for Compressor Compressor for Time Allow
Immediately Trips on Protector on Trips Immediately
© 2004 Copeland Corporation Copeland 2004 © Form No. 2004CC-126 No. Form
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 01-800-890-2900 • WWW.HUSSMANN.COM P/N 0427598_E 7-3 Replace Compressor Refer to Motor & Basic Wiring Module See Complete System Operation Worksheet Replace Appropriate Components Check External Wiring Correct Voltage Supply Check -- Excessive Cable Length -- Undersized Cable -- Power Supply/Utility Grid -- Loose Electrical Connections -- Bad Transformers -- Worn Electrical Contacts Refer to 3 Phase Voltage Monitor Section of Controls Module Check Fuses, Circuit Breakers, Control Circuit/Safety Controls Thermostat, Contactors, etc. 1 5 6 3 4 2 Windings Not OK 1 4,2 3 No Ohmmeter Check Winding Resistance Using an Windings OK Yes No Does Not Start Is Compressor Grounded? Check Components Range? Instantly Blown Fuses Verify System Operation Do Not Replace Compressor Replace Compressor Voltage Application, Temp Yes Is the Compressor Properly Resolve Application Issues Applied? Proper Refrigerant, Yes Trouble Shooting Guide 6 Replace 2 Compressor Does Not Restart OK? 2 No Voltage 2 Relays, Motor Starters, Contactors, and Capacitors) re The Start Components (i.e. A Restart While Observing Amps No Fix Voltage Issues Balance System Pressure and Attempt to 1 5 Verify System Operation Do Not Replace Compressor Good stem Operation y Replace Components Compressor S Voltage (If Accessible) or Verify System Operation Not High Amps y Improper Replace Protector Do Not Replace Compressor Did Not Reset erif V Do Not Replace Compressor Check Voltage at Connections Protector to Reset Check Electrical Compressor Terminals Restarts Protector to Reset Allow Time for Compressor Compressor Not Running Allow Time for Compressor Reset No Amps Fix Bad Wired Connections Correctly 1 Draw Check Wiring Proper Proper Voltage Resistance Check Amp Fix Wired Replace Replace Incorrectly High Amps High or Compressor Excessive Check Winding Resistance and Resistance to Ground Improper Replace Resistance Compressor Form No. 2004CC-126 © 2004 Copeland Corporation
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Parallel Rack 7-4 Service
THERMOSTATIC ELECTRIC VALVES EXPANSION VALVES SER SERIES
CATCH-ALL FILTER-DRIERS PRODUCT INFORMATION PRODUCT
REFRIGERANT ELECTRIC VALVES DISTRIBUTORS CDS SERIES
HEAD PRESSURE CONTROL VALVES
SOLENOID VALVES PRESSURE TRANSDUCERS XSP SERIES & TEMPERATURE SENSORS
EVAPORATOR PRESSURE REGULATING VALVES
GLYCOL SOLENOID VALVES KELVIN II SERIES
DEFROST DIFFERENTIAL VALVE
SOLENOID VALVES PSK CONTROLLERS MODEL 214 SUPERMARKET EQUIPMENT SUPERMARKET
Form 5-422
Additional Sporlan Resources SPORLAN APPS SPORLAN SELECTION PROGRAM
www.sporlanonline.com
P/N 0427598_E U.S. & Canada 1-800-922-1919 • Mexico 01-800-890-2900 • WWW.HUSSMANN.COM To obtain warranty information or other support, contact your Hussmann representative. Please include the model and serial number of the product.
Hussmann Corporation, Corporate Headquarters: Bridgeton, Missouri, U.S.A. 63044-2483 01 October 2012