Page 1: Table Of Contents
All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means— electronic or mechanical, including photocopying or recording; or any other information storage and retrieval system—without express written permission from Hillphoenix.
Page 2: Important Notices
AdaptaPAK® Parallel Refrigeration System Thank You! The Hillphoenix AdaptaPAK® refrigeration system provides customers with a compact refrigeration package designed to remove heat from both medium- and low-temperature loads. Such a system, as selected by the customer, is built to closely match the necessary heat removal capacity. It is a DX system with a refrigerant charge matched to the needs of the facility where it is installed.
Page 3: General Information
• Hillphoenix Part Barcode Quantity of parts • Part Number located at bottom left. Ship-to location. • If Hillphoenix Service Parts decides that a part must be returned instead of scrapped, you will be issured a Return Material Authorization number.
Page 4 AdaptaPAK® Parallel Refrigeration System...
Page 5: Adaptapak ® Product Information
Hillphoenix AdaptaPAK® parallel systems are available in a 2 fan unit, a 3 fan unit, and a 4 fan configuration. The compressors would be arranged in up to two suction groups, with one loop per suction group.
Page 6 AdaptaPAK® Parallel Refrigeration System Whether a 2 fan unit or a 3 fan unit, the AdaptaPAK® system will arrive fully designed for your load configuration, and ready for placement at the site in your designated pad or roof location. Placement would most commonly be performed with a cable/rope with proper rigging (refer to drawings for details).The remaining tasks would include charging with refrigerant, making electrical connections, and completing the connection of the AdaptaPAK®...
Page 7 In addition to the standard equipment detailed in the list above, customer-selectable options may have been include on the unit being installed. Please check the customer order or the Hillphoenix acknowledgement to determine which custom options have been provided for your specific unit. These options are detailed below.
Page 8: Two Fan Adaptapak® Unit
AdaptaPAK® Parallel Refrigeration System Two Fan AdaptaPAK® Unit As noted earlier, this unit has two condenser fans and up to two condensers sized appropriately for the design- specified refrigeration heat removal loads. The dimensions of the two fan unit, as well as the required clearances for operation and serviceability were provided earlier in this section.
Page 9 AdaptaPAK® Parallel Refrigeration System The layout drawing provided below shows the front view of the two fan unit, as well as the two end views. Two Fan AdaptaPAK® Unit LEFT END VIEW FRONT VIEW RIGHT END VIEW Also, as previously noted. a drawing is supplied which depicts the lifting points on the two fan AdaptaPAK® unit, and details an appropriate lifting jig and the necessary rigging for the cable/rope to perform a level lift and successful placement of this unit.
Page 10: Three Fan Adaptapak ® Unit
AdaptaPAK® Parallel Refrigeration System Three Fan AdaptaPAK® Unit This unit has three condenser fans and two condensers sized appropriately for the design-specified refrigeration heat removal loads. The dimensions of the three fan unit, as well as the required clearances for operation and serviceability were provided earlier on page two.
Page 11 AdaptaPAK® Parallel Refrigeration System The layout drawing provided below shows the front view of the three fan unit, as well as the two end views. Three Fan AdaptaPAK® Unit LEFT END VIEW FRONT VIEW RIGHT END VIEW Also, as previously noted. a drawing is supplied which depicts the lifting points on the three fan AdaptaPAK® unit, and details an appropriate lifting jig and the necessary rigging for the cable/rope to perform a level lift and successful placement of this unit.
Page 12: Four Fan Adaptapak® Unit
AdaptaPAK® Parallel Refrigeration System Four Fan AdaptaPAK® Unit This unit has four condenser fans and two condensers sized appropriately for the design-specified refrigeration heat removal loads. The dimensions of the four fan unit, as well as the required clearances for operation and serviceability were provided earlier on page two.
Page 13 AdaptaPAK® Parallel Refrigeration System The layout drawing provided below shows the front view of the four fan unit, as well as the two end views. Four Fan AdaptaPAK® Unit LEFT END VIEW FRONT VIEW RIGHT END VIEW Also, as previously noted. a drawing is supplied which depicts the lifting points on the four fan AdaptaPAK® unit, and details an appropriate lifting jig and the necessary rigging for the cable/rope to perform a level lift and successful placement of this unit.
Page 14: Adaptapak ® Models Overview
AdaptaPAK® Parallel Refrigeration System...
Page 15 AdaptaPAK® Parallel Refrigeration System Model Overview continued... Model Overview...
Page 16: Key To Codes In Adaptapak Model Numbers
AdaptaPAK® Parallel Refrigeration System Key to Codes in AdaptaPAK Model Numbers ADP-MXXXX-LXXXX- ______ ADP = AdapatPAK Platform (X) - Number of Condenser Fans MXXXX = Medium Temperature Load in KBTUs LXXXX = Low Temperature Load in KBTUs SUFFIX - KEY TO OPTIONS SPLIT COATED HAIL...
Page 17: Dx Refrigeration Systems
The Hillphoenix® AdaptaPAK® units utilize DX refrigeration to remove heat from store display cases and walk-in coolers/freezers, and transfer it to an outdoor location where it can be rejected.
Page 18 AdaptaPAK® Parallel Refrigeration System Compressor The compressor in a mechanical, vapor compression refrigeration system performs a basic function. It generates the pressure differential to move the refrigerant through the complete refrigeration cycle. It accomplishes its function in several simple steps. These steps are: •...
Page 19 AdaptaPAK® Parallel Refrigeration System Metering Device (Expansion Valve) After the condenser, the high pressure liquid refrigerant reaches the metering device (expansion valve). The metering device meters, or controls, the flow of refrigerant from the high pressure, high temperature side of the system to the low pressure, low temperature evaporator.
Page 20 AdaptaPAK® Parallel Refrigeration System...
Page 21: Multimax Tm Controller For Adaptapak
It also records system conditions and provides for alarm logging for easy troubleshooting and system documentation. The Hillphoenix® multiMAX™ controller can perform a large number of different functions. Hillphoenix multiMAX™ Controller...
Page 22 Controller for AdaptaPAK® Parallel Rack AdaptaPAK® The following items apply to the control of the Hillphoenix AdaptaPAK® parallel rack refrigeration system. Compressors: Two suction lines with control by pressure or temperature • Compressors can be controlled with neutral zone band management •...
Page 23: Multimax Tm Controller I/O Connections
Controller for AdaptaPAK® Hillphoenix® multiMAX™ Controller (showing input and output connections) Definitions of Inputs and Outputs corresponding to the multiMAX™ Controller I/O. J12 and J13 - Compressor Enable, Normally Open Relays J12: Compressors 1, 2, 3 and J13: Compressors 4, 5, 6 Compressor Enable = a Normally Open (NO) relay that is used by the controller to energize one or more compressors in a given suction group.
Page 24 multiMAX™ Controller for AdaptaPAK® J18 - Optional, Air Heat Reclaim, Normally Open Relay J18: Air Heat Reclaim Valve With this option, controller would close the relay and thus opening a valve to heat air in a heat exchanger. J21 - Rack Alarm Output, Normally Open Relay J21: Air Heat Reclaim Valve If any rack alarm conditions are met, the controller will close the relay, activating rack alarms.
Page 25 Controller for AdaptaPAK® HILLPHOENIX multiMAX™ CONTROLLER INSTALLED IN AN ADAPTAPAC CONTROL PANEL SEE NEXT PAGE FOR A FULL TWO-PAGE SPREAD OF HILLPHOENIX multiMAX CONTROLLER WIRING...
Page 26 Controller for AdaptaPAK® Hillphoenix AdaptaPAK - multiMAX™ Controller Input-Output Schedule - left side...
Page 27 Controller for AdaptaPAK® Hillphoenix AdaptaPAK - multiMAX™ Controller Input-Output Schedule - right side...
Page 28 multiMAX™ Controller for AdaptaPAK®...
Page 29: Adaptapak ® Installation
® Hillphoenix warrants all refrigeration systems and equipment it manufactures. In order for Hillphoenix to honor this warranty, it is essential that the systems and equipment be properly installed and started up by a qualified refrigeration technician. This section goes through the proper installation practices for AdaptaPAK®...
Page 30 AdaptaPAK® Installation The piping connects the refrigeration circuit together so that compressors are connected to cases or other types of refrigeration loads, and cases are connected to other cases. The type of piping material that is used to connect the circuits must have the capacity to perform one of three refrigeration system functions: Suction •...
Page 31 AdaptaPAK® Installation Phosphorus/copper and silver/phosphorus/copper alloys are used to braze copper to copper and copper to brass. Characteristics of Common Brazing Alloys. The phosphorus content in these alloys makes them self-fluxing on copper. The characteristics of certain alloys provided by one manufacturer are shown in the table on the previous page. Pipe Fittings Pipe fittings are used to route pipe runs in different directions.
Page 32 AdaptaPAK® Installation Other types of insulation that are used include: Rigid cellular phenolic foam • Cellular glass closed-cell • Polyisocyanurate closed-cell rigid • A number of considerations go into selecting the type of insulation to use for a particular application. These include: The application (fluid) temperature •...
Page 33 TEVs come in a wide variety of configurations, including SMS (Superheat Management System) used on Hillphoenix Coolgenix™ cases Check – (including pressure relief) allow flow in only one direction and prevent flow in the opposite •...
Page 34 AdaptaPAK® Installation Defrost Differential — on Hillphoenix systems, located on hot gas racks • Filter and Filter/Driers Filters are used to protect components in refrigeration systems from contaminants and other foreign material that accumulate in the system. A particular type of filter, called a filter/dryer, also removes moisture from the system.
Page 35 AdaptaPAK® Installation temperatures and pressures. Liquid refrigerant and oil are said to be completely miscible—that is, that they can be mixed in any proportions. When mixed, they exist in a single phase. The extent to which they are miscible depends on the type of oil and refrigerant that are mixing together.
Page 36 Installation plans usually include a penetration detail that indicates the type of penetration required. Piping Practices Hillphoenix refrigeration systems are always piped in accordance with ASHRAE refrigeration piping principles and practices. These can be found in, among other codes, ASHRAE 15, Safety Code for Mechanical Refrigeration.
Page 37 2. Adhere to legend line sizes and use only clean dry piping—only use those line sizes shown on the legend for the system; any discrepancies in the line size, as well as the refrigeration loads, must be brought to the attention of the customer and Hillphoenix. 3. Properly size: a.
Page 38 AdaptaPAK® Installation b. Line lengths that are subject to expansion and contraction—suction, liquid and remote condenser lines are subject to expansion and contraction and must be sized accordingly—depending on design considerations (typically long runs or hot gas), an expansion loop may need to be installed (may be indicated on the plan, but not always).
Page 39 AdaptaPAK® Installation Pipe Turns Turns in refrigeration piping should always be accomplished by the use of long radius 90 degree elbows. Short radius elbows and 45 degree elbows should be avoided due to higher pressure drops. 45 degree elbows have thinner walls due to the manufacturing process.
Page 40 AdaptaPAK® Installation Evacuation The system should be able to hold a vacuum for 24 hours with no micron increase and no vacuum pump attached. The vacuum should then be broken with refrigerant type used in the system from a factory filled cylinder. Always follow acceptable industry practices and customer specifications when evacuating systems.
Page 41 AdaptaPAK® Installation Set and Install Unit A basic part of the installation process is setting the unit for the system. As part of this process, an adequate number and type of vibration isolation units, or pads, should be installed to ensure that unit vibration is not transmitted to the rest of the store through the building’s structure.
Page 42 AdaptaPAK® Installation On both the suction and liquid sides of the system, considerations for hot gas defrost (if part of the system) should include the use of return headers. Complete Piping for Condensers and Heat Reclaim Insulation, vibration eliminations, ball valves, check valves, hangers and clamps, risers, and building penetrations should be installed in accordance with customer and manufacturer specifications for condensers and heat reclaim systems.
Page 43: Systems Start-Up Checklist
AdaptaPAK® Installation Startup Procedures As with other aspects of installing a system, following proper startup procedures is of critical importance to the eventual safe and effective operation of the system. Although unique characteristics of every installation may require some variation, the following procedures should be followed as closely as possible. All refrigeration startups should be performed by a qualified refrigeration technician.
Page 44 If problems continue, despite whatever immediate action is taken to address them, the troubleshooting steps described in the next lesson should be followed to address the situation. Contact Hillphoenix concerning any problems that persist.
Page 45: Adaptapak ® Maintenance And Troubleshooting Procedures
In those cases, there are troubleshooting procedures that aid in determining the causes of various problems. This section presents the maintenance and troubelshooting procedures for Hillphoenix AdaptaPAK® refrigeration systems. Maintenance Procedures Refrigeration equipment has been noted to account for approximately 50% of the total electrical power consumption of the typical supermarket.
Page 46 Safety and Operating Controls As should be clear by now, the safe and efficient operation of Hillphoenix refrigeration systems is of the utmost importance to the company. Therefore it is essential that the safety and operation controls installed on each system are functioning correctly.
Page 47 AdaptaPAK® Maintenance and Troubleshooting The T-Stat senses the changes in temperature that cause the control to open and close through a device called a sensing bulb. The sensing bulb is mounted so that it reacts to the evaporator inlet air. Due to the continuous operation of the evaporator fan, the temperature of the recirculating air in the cooler is an average of the product temperature, the wall temperature, and any infiltrated air and any other loads such as those caused by a person entering the cooler.
Page 48 AdaptaPAK® Maintenance and Troubleshooting High Pressure Control Another control commonly found on most systems is for high pressure. High Pressure Controls work exactly opposite of LPCs. Often the two kinds of controls are combined into a single unit called a dual pressure control. The two sections of the control can be easily recognized due to fact that the low pressure side requires a larger bellows assembly since it must react to a lesser amount of force than the high pressure side.
Page 49 AdaptaPAK® Maintenance and Troubleshooting 2. Check liquid line sight glass and expansion valve operation—if there are indications that more refrigerant is required, leak test all connections and system components (including cases) and repair any leaks before adding refrigerant 3. Using suitable instruments, carefully check line voltage and amperage at the compressor terminals; voltage must be within +/- 10% of that indicated on the compressor nameplate—if high or low voltage is indicated, notify the power company;...
Page 50 AdaptaPAK® Maintenance and Troubleshooting Other Checks All electrical connections (including those at the compressor terminals) should be periodically checked for tightness. Loose connections contribute to low-voltage conditions that may cause motor failure. Refrigerant connections should be inspected to insure that they have not loosened. Whenever it is necessary to add refrigerant, a careful leak check of all refrigerant connections should be made.
Page 51 AdaptaPAK® Maintenance and Troubleshooting c. Look for oil stains on headers, return bends, and coil fins. Check any suspect areas with an electronic leak detector. d. Check drain pan to ensure that drain is clear of debris, obstructions or ice buildup, and is freely draining. 2.
Page 52 AdaptaPAK® Maintenance and Troubleshooting Air-Cooled Condensing Units A number of checks should be performed at the intervals listed below. Quarterly On a quarterly basis visually inspect the unit to: 1. Look for signs of oil stains on interconnection piping and condenser coil. Pay close attention to areas around solder joints, building penetrations and pipe clamps.
Page 53 AdaptaPAK® Maintenance and Troubleshooting c. Verify that all motors are mounted securely. d. Lubricate motors, if applicable. Do not lubricate permanently sealed, ball bearing motors. 4. Inspect electrical wiring and components a. Verify that all electrical and ground connections are secure; tighten as required. b.
Page 54 AdaptaPAK® Maintenance and Troubleshooting Air-Cooled Condensers At every six month interval, or sooner if local conditions cause clogging of air passages through the finned surface, the following items should be checked. 1. Visually inspect unit. a. Look for signs of corrosion on fins, cabinet, copper tubing and solder joints. b.
Page 55 Hillphoenix recommends cleaning once a week by performing the following procedures: 1. To avoid shock hazard, be sure all electrical power to the case (or other type of refrigeration unit) is turned off before cleaning.
Page 56 AdaptaPAK® Maintenance and Troubleshooting Troubleshooting Procedures Supermarket refrigeration systems are complex configurations of equipment. Like any other types of complex machinery, regardless of the care and attention given to their installation and startup, refrigeration systems will occasionally run into problems. In most cases, the safety and operating controls with which the system is equipped will give some indication of the problem.
Page 57 AdaptaPAK® Maintenance and Troubleshooting 1 - TROUBLESHOOTING - COMPRESSOR WILL NOT RUN SYMPTOMS SYMPTOMS POSSIBLE ACTIONS Compressor will 1. Main switch open 1. Close switch not run 2. Blown Fuses 2. Check electrical circuits and motor winding for shorts or grounds Investigate for possible overloading...
Page 58 AdaptaPAK® Maintenance and Troubleshooting 1 - TROUBLESHOOTING - COMPRESSOR WILL NOT RUN (continued) SYMPTOMS SYMPTOMS POSSIBLE ACTIONS Compressor will 9. Loose wiring 9. Check all wire not run junctions and tighten all terminal screws. 10. Phase loss monitor 10. Turn power off at inoperative disconnect switch Swap any two of the...
Page 59 AdaptaPAK® Maintenance and Troubleshooting 3 - TROUBLESHOOTING - COMPRESSOR HIGH DISCHARGE PRESSURE SYMPTOMS SYMPTOMS POSSIBLE ACTIONS High compressor 1. Non-condensables in 1. Remove the non- discharge the system condensables pressure 2. System is overcharged 2. Remove excess with refrigerant 3. Discharge shutoff valve 3.
Page 60 AdaptaPAK® Maintenance and Troubleshooting 6 - TROUBLESHOOTING - COMPRESSOR LOW SUCTION PRESSURE SYMPTOMS SYMPTOMS POSSIBLE ACTIONS Low compressor 1. Lack of refrigerant 1. Check for leaks; repair suction pressure and add charge 2. Evaporator dirty or iced 2. Clean/Check Remote 3.
Page 61 4. Dirty condenser coil 4. Clean coil 5. Overcharged system 5. Reduce charge If, after performing the steps above, problems persist and you are not able to determine their cause, you may need to contact Hillphoenix Field Service for assistance.
Page 62 AdaptaPAK® Maintenance and Troubleshooting Evaporator Troubleshooting Evaporators, because of where they are located in the cases (or walk-ins), may experience problems that affect the performance of the case. Many of these problems can be addressed at the source—the evaporator. EVAPORATOR TROUBLESHOOTING CHART SYMPTOMS SYMPTOMS POSSIBLE ACTIONS...
Page 63 AdaptaPAK® Maintenance and Troubleshooting EVAPORATOR TROUBLESHOOTING CHART Coil not clearing 1. Coil temperature not 1. Check heater operation getting above freezing frost during point during defrost 2. Adjust timer for more defrost cycle 2. Not enough defrost defrost cycles cycles per day overload conditions 3.
Page 64 AdaptaPAK® Maintenance and Troubleshooting Defrost Troubleshooting Although the defrost system is relatively simple and trouble-free in operation, there are certain basic components that may cause problems. For systems with electric defrost, the components to check when problems occur include the following: Timer •...
Page 65 Finally, after correcting any faulty condition, it is essential that the coil and case be free of ice before placing the case back into the automatic mode of operation. If you should have questions about the steps or procedures listed in this manual, be sure to contact your Hillphoenix Field Service Representative.

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