Page 2 Being Safe is Your Responsibility. Wear proper eye protection whenever working. Wear proper hearing whenever working in a machine room. Stand to one side–never work directly in front of: Any valve you are opening or closing • Manual refrigeration valves Regulator valves on brazing tanks and nitrogen tanks Electrical Circuit Breakers...
Page 3 Congratulations! With the purchase of Hussmann's Super Plus™ System, you are receiving equipment designed to provide the finest refrigeration and temperature control for modern supermarket display equipment and coolers. Since the introduction of Hussmann Central Refrigeration Systems, thousands of installations have confirmed our belief that, as with all fine equipment, good installation and proper adjustment are the keys to customer satisfaction.
Page 4 Super Plus ™ Fibertronic ™ Installation and Service Manual 12999 St. Charles Rock Road • Bridgeton, MO 63044-2483 • (314) 291-2000 August, 1996 Printed in USA...
Page 5: Table Of Contents
Receiver Refrigerant Capacities...1-2 Machine Room Requirements ...1-3 Unit Placement ...1-4 Lifting and Leveling...1-5 Setting without a Crane ...1-6 CONTENTS Figures Super Plus™ System ...1-1 Electrical Clearance Requirements ...1-3 Allowable Distances...1-4 Lifting and Leveling the Super Plus™...1-5 Isolation Pad Location...1-5 Dolly Placement ...1-6...
Page 6 Topics Overview ...2-1 Super Plus™ Refrigeration System...2-2 Basic Refrigeration Cycle ...2-4 Heat Reclaim Cycle...2-6 Receiver Pressure and Vapor Temperature Regulation ...2-6 Koolgas Defrost Cycle ...2-7 Oil System ...2-8 Subcooling...2-9 Demand Cooling...2-11 CONTENTS Figures Super Plus™ Refrigeration System...2-2 Refrigeration Cycle ...2-4 Turba-Shed ...2-4...
Page 7 Topics Overview ...3-1 Refrigeration Line Runs ...3-1 Rack to Condenser Piping ...3-3 Rack to Remote Header...3-6 Rack to Remote Satellite ...3-6 Rack to Heat Reclaim...3-7 Offset and Expansion Loop Construction ..3-7 Special Piping for Open Rooms ...3-8 Connecting Parallel 3-Way Valves ...3-8 Run Lengths and Equivalent Feet ...3-8 Branch Line Piping...3-9 Tables...
Page 8 Topics Overview ...4-1 Field Wiring ...4-1 Wiring Guidelines Based on Various Components ...4-2 Using Schematics ...4-3 Alarm Board...4-3 Compressor Controls...4-4 Compressor Circuit Boards ...4-6 Compressor Board Related Circuit ...4-12 Defrost Circuit Boards ...4-22 Defrost Timer Motor ...4-28 Defrost Control Circuits ...4-28 Other Controls ...4-32 Power Monitor...4-33 Tables...
Page 9 Topics Overview ...5-1 Remote Condensers...5-1 Remote Satellite ...5-6 CONTENTS Figures Lifting the Condenser...5-2 Schematic – Ambient Temperature Control...5-4 Schematic – Pressure Control ...5-5 Satellite Rigging and Lifting ...5-6...
Page 10 Topics Overview ...6-1 Precision Defrost Timer ...6-1 Paragon Defrost Timer ...6-5 CONTENTS Figures Inserting Tripper...6-1 Proper Installation ...6-1 Setting Precision Timer ...6-2 Resetting Alarm Switch ...6-3 Precision Defrost Timer ...6-4 Paragon Program Module...6-5 Paragon Program Module, Removal and Installation...6-6 Motor Module, Removal and Installation...6-7 Paragon Defrost Timer ...6-8...
Page 11 Topics Overview ...7-1 EPR Valve ...7-1 Koolgas Valve ...7-2 Main Liquid Line Solenoid Sporlan ...7-4 Alco ...7-5 Branch Liquid Line Solenoid Valves ...7-6 TEV ...7-7 Heat Reclaim Valve...7-9 Flooding Valve and Receiver Pressure Regulating Valve ...7-10 Autosurge ...7-12 Mechanical Subcooling ...7-15 Demand Cooling ...7-17 Oil System ...7-20 Tables...
Page 12 Revised August 1, 1996 P/N 340272A CONTENTS Topics Overview ...8-1 Pressure Settings ...8-1 Plate Subcooling Controls...8-1 Shell and Tube Subcooling Controls...8-1 Compound Rack, Additional Settings...8-1 EPR Settings...8-2 Winter Condensing Pressure Controls ...8-2 Mechanical Low Pressure Controls...8-2 Alco ...8-2 Others ...8-4 Condenser Settings...8-8 Merchandiser Settings ...8-9...
Page 13 Topics Startup ...9-1 Leak Testing ...9-1 Test Charge...9-1 Oil Levels ...9-2 Evacuation...9-2 Charging ...9-3 Final Checks...9-4 Maintenance ...9-5 Compressor Replacement...9-5 Cleaning the Turba-shed™...9-6 Replacing Drier and Filter Cores ...9-6 CONTENTS...
Page 14 Hussmann Distributors, International SUBJECT: Update for SuperPlus Fibertronic Manual, P/N 340272, Rev. A The Super Plus Installation Manual has been updated as follows: • Addendum – Condenser Installation provides information on installing condensers with SuperPlus systems (place behind index and in front of warranty page).
Page 15: Overview
4. Items supplied separately for field installation a. Liquid Drier Core b. Vibration Isolation Pads (8) ⁄ to 3 HP c. Loose shipped items for accessories. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 1 - 1...
Page 16: Shipping Damage
15 inches to depth. N o t e : For 08VY and other Extended Racks, consult with Hussmann Engineering, Bridgeton, Mo. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA SYSTEM WEIGHTS Base Rack Weight Rack Assembly...
Page 17: Machine Room Requirements
For nonstandard racks such as with mechanical subcooling consult Hussmann Engineering, Bridgeton, Mo. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 1 - 3 Length Width (in.)
Page 18: Unit Placement
1 - 4 UNIT PLACEMENT When setting the Super Plus Rack plan in relation to the rest of the equipment to be installed. Some minimum and maximum distances are listed. Note: Piping equivalent is not the same as linear distance.
Page 19: Lifting And Leveling
NOTE: This unit is slightly front heavy, due to the Control Panel. Take necessary precautions when lifting. Figure 1-4 – Lifting and Leveling the Super Plus™ Vibration Isolation Pads are supplied with each rack. The entire weight of the rack must rest on these pads, with the rack cross leveled.
Page 20: Setting Without A Crane
These racks are supplied with 12 isolation pads and require cross leveling for all six load points. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA SETTING WITHOUT A CRANE In many locations crane lifting may not be practical.
Page 21: Overview
Each specific refrigerant state and pressure maintains the same fill pattern throughout the instruction. Pressures in oil lines will also retain a fixed pattern. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 2 - 1...
Page 22 REFRIGERATION PROCESS Revised August 1, 1996 2 - 2 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 23: Main Liquid Line Pressure Differential Valve
High Pressure Hot Vapor High Pressure Warm Vapor High Pressure Warm Liquid Reduced Liquid Low Pressure Cool Vapor Cut-away not shown (Empty) HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 2 - 3 P ressure Wa r m...
Page 24: Basic Refrigeration Cycle
The oil is stored in the bottom of the Turba-shed and returned to the compressors. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 A 3-Wa y Heat Reclaim Va l v e ( H S ) directs the refrigerant to either the condenser or a Heat Reclaim Coil.
Page 25 At critical locations along the refrigerant path, service valves or ball valves allow isolation of components. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 2 - 5...
Page 26: Heat Reclaim Cycle
E l e c t r i c a l l y, the circuit is supplied with power only during Koolgas Defrost. The circuit is closed by a thermostat responding to Koolgas Manifold temperature. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 27: Koolgas Defrost Cycle
When defrost is called for, the suction line control valve closes and a two-way K o o l g a s Valve opens the line from the Koolgas Manifold to the Evaporator. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 2 - 7...
Page 28: Turba-Shed
10 and 15 psig above the crankcase pressure, providing even flow of oil to the Oil Level Regulators. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 To balance oil level among the compressors An Equalizing Line returns any excess oil in one Oil Level Regulator to the rest of the system.
Page 29: Autosurge For Ambient Subcooling
The valve is factory set at 10˚ F of subcooling and is n o t f i e l d adjustable. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 2 - 9...
Page 30: Mechanical Subcooling
TEV. Since mechanical subcooling uses a direct expansion device, it is not limited by ambient temperature. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 A Liquid Line Solenoid Va l v e and a T E V control refrigerant to the subcooler.
Page 31: Demand Cooling
Module to shutdown the compressor after one minute. The Injection Valve meters saturated refrigerant into the suction cavity of the compressor. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 2 - 11...
Page 32: Super Plus™ Refrigeration System
45˚ elbows. Install service valves at several locations for ease of maintenance and reduced service costs. These valves must be UL approved for 450 psig minimum working pressure. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 3 - 1...
Page 33: P-Trap Construction
When mounting lines from machinery to a solid object allow line freedom for vibration to prevent metal fatigue. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 P-Trap Construction A P-Trap must be installed at the bottom of all suction risers to return oil to the compressors.
Page 34: Rack To Condenser Piping
The purge valve will be installed at the high- est point of an inverted P-trap, with at least a 6-inch rise. Use with approved recovery vessel. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 3 - 3 WARNING...
Page 35 1 foot drop to the manifolds. Provide Purge valve at the highest point HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 •Liquid Return Lines will be teed into the Main Liquid Return Line after 6 feet of verti- cal drop from the outlet stubs.
Page 36 Revised August 1, 1996 P/N 340272A 3 - 5 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 37: Rack To Remote Header
•If equipped with Koolgas Defrost, the Super Plus Koolgas Stub is connected as directly as possible to the Header Koolgas Manifold. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 RACK TO REMOTE SATELLITE •The compressor Discharge Line will be piped through a vibration absorber to its stub on the Super Plus Discharge Manifold.
Page 38: Rack To Heat Reclaim
3L = 3 x 21 or 3L = 63. The offset distance required for low temperature application for an 84 foot run of 1 63 inches. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 3 - 7 Line Size ⁄...
Page 39: Special Piping For Open Rooms
The installer is responsible for proper adjustment of the Valve (see “Control Valve” Section for adjustment procedures). HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 CONNECTING PARALLEL 3-WAY VALVES Due to the size limitations of 3-Way Va l v e s ,...
Page 40: Branch Line Piping
• Ta k e - o ffs to evaporators exit the bottom of the liquid line. Provide an expansion loop for each evaporator take-off. (Minimum 3 inch diameter.) HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 3 - 9 EFROST In Case Size ⁄...
Page 41: Overview
– one 460/3/60 branch circuit. For Alarm Wiring Between the Compressor Control Panel and the in store alarm bell provide – one 120/1/60 10A circuit. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 1...
Page 42: Wiring Guidelines Based On Various Components
*Include control circuit amps if single point connection transformer option is used (Refer to NEC for temperature derating factors.) HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Select Wire Size Based on the serial plate ampacity of the sys- tem, select the largest connectable wire size from Table 1.
Page 43: Using Schematics
B S R Electronic Circuit energizes BSR Coil BSR Contacts open the circuit to Terminal 3 2 BSR Contacts close the circuit for its own power supply. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 3...
Page 44: Alarm Board
ELECTRICAL Revised August 1, 1996 4 - 4 COMPRESSOR CONTROLS Alarm Board HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 45: Alarm Board Troubleshooting
Open Jumper Circuit from X1 to T9A. Press Reset. Go to 1 6 Not Lit Alarm Board Failure Not Lit Test Completed, Power OFF, Re-instate Control. Alarm Board Failure HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 5...
Page 46: Compressor Circuit Boards
120VAC is applied to the board. It can only be turned off at the panel circuit breaker. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 C o m p re s s o r O n – Yellow LED – indicates that there is 120VAC to the contactor coil.
Page 47 T4 is the power input from a switchback con- trol contact. T7 is the power input during normal operation when the EPC is in control. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 7...
Page 48 ELECTRICAL Revised August 1, 1996 4 - 8 Compressor Board using Mechanical Low Pressure Control or Series Switchback HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 49 Oil Alarm – Correct cause and reset Go to 15 If K1 Contacts are open, correct and reset If closed, Board Failure Circuit Complete – End Test Board Failure HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 9...
Page 50 ELECTRICAL Revised August 1, 1996 4 - 10 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 51 Oil Alarm – Correct cause and reset Go to 15 If K1 Contacts are open, correct and reset If closed, Board Failure Circuit Complete – End Test Board Failure HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 11...
Page 52: Compressor Board Related Circuit
When the Normally Open K2 Contacts close the Compressor Motor Contactor Coil is ener- gized. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 If an electronic control other than EPC is applied with Series Switchback, the K2 Circuit is not used.
Page 53 The three Normally Closed K1 Contacts are held open during alarm conditions. The K1 Contacts between T5 and T6 open the circuit to the Compressor Alarm on the rack’s Alarm Board. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 13...
Page 54 T4 on half the boards, plus Time Delay Split Relay. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 After another 24 second delay, the Split Relay closes the circuits to: T4 on the remaining half of the boards.
Page 55 P1,1 and P1,2. A Time Delay Split (TDSP) prevents all the compressors from coming on at once on start- up after the control panel has been off. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 15...
Page 56 EPC in case of EPC failure. The rack will continue to operate less e ff i c i e n t l y, until the EPC is brought back on line. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 57 The schematic shows a six compressor rack with the #4 Compressor being the first high side unit. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 17...
Page 58: Compressor Protection
Compressor protection is determined by the type of compressor used. These controls are wired between P1,3 and P1,8. Since the con- trols reset automatically, an open compressor protector will not cause an alarm situation. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 59 2 .If the compressor does not start, press the reset for the oil safety. If the compressor starts the failure was from Oil Failure. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 19...
Page 60: Head Cooling Fan And Demand Cooling
Compressor Terminal Box. The modules time delayed safety is placed in front of the High Pressure control. If opened by sustained high temperature, it will cause a compressor alarm condition. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 61: Circuits Parallel To The Compressor
The Unloader is controlled by the normally open contacts of the EPC Unloader Board. Figure 4-16 Circuits Parallel to the Compressor Motor Contactor Coil HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 21...
Page 62: Defrost Circuit Boards
This light will turn off if the defrost has been terminated due to time or temperature, and if the branch is in drip cycle. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 EPR Solenoid – Green LED – indicates the suction stop solenoid is energized, which means the valve is open.
Page 63: Liquid Branch Solenoid Valve
EPR SOL is output to the suction stop sole- noid valve. LIQ BRANCH SOL is output to the liquid branch solenoid valve. Q 2 is fiber optic input from Fibertronic Defrost Clock 1000. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 23...
Page 64 ELECTRICAL Revised August 1, 1996 4 - 24 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 65 Go to 4 Defrost timer circuit open – Check and correct Go to 5 Board Failure End Test Board Failure then use standard test procedures. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 25...
Page 66 ELECTRICAL Revised August 1, 1996 4 - 26 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 67: Branch Board Faceplate
Branch Board Voltmeter Reading then use standard test procedures. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 27 Action System OK to Branch Board Go to 5...
Page 68: Defrost Timer Motor
The variations come from tailoring the systems to the customers’ needs by selection of components used to accomplish defrost. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 The basic circuit is controlled by a defrost clock which closes the circuit, energ i z i n g relay coil R1.
Page 69: Suction Stop Koolgas Defrost
Koolgas Relay (KR) power to T4 thru Yellow wire to KR terminal thru Red wire to Koolgas Relay (KR) and thru Brown wire to Bypass Circuit. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 4 - 29...
Page 70: Electric Defrost
Contact 2R1 will turn “ON” Branch Defrost Contactor in the Electric Defrost Panel power to T4 thru Orange wire to D__ terminal thru field wiring to corresponding D__ terminal in Electric Defrost Panel. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996...
Page 71: Off Cycle Defrost
Revised August 1, 1996 P/N 340272A 4 - 31 Off Cycle Defrost When defrost clock energizes Defrost Relay Coil R1 Contact 1R1 will turn “OFF” Liquid Line Solenoid Valve (S). HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 72: Other Controls
Wire the thermostat in series with the liquid line solenoid. Any 120V uninterrupted power supply may be used. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA EADER Wire the thermostat in the following manner. Determine the system number from the store legend.
Page 73: Power Monitor
15% below the nominal line voltage at power source. A voltmeter should be used to establish actual supply voltage. The monitor controls a two pole bypass relay (BP) making and breaking power to the control panel. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 74: Overview
Route and support all piping in a manner that relieves stress caused by vibration, thermal expansion, and gradual base or building movement. Where piping is routed through a roof, construct a pitch box. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 5 - 1...
Page 75: Lifting The Condenser
(To reverse, change L1 and L3 at the motor.) • (If equipped) Gravity dampers moving freely. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Figure 5-1. Lifting the Condenser Preliminary Control Setting Set controls according to the charts in “Control Settings”...
Page 76 • If the coldest expected temperature is above 20˚F, the flooding charg e required will be less than 50% of each condenser circuit. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A Max Flood Inlet/Outlet Charge...
Page 77 REMOTE CONDENSER, REMOTE SATELLITE Revised August 1, 1996 5 - 4 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 78 Revised August 1, 1996 P/N 340272A 5 - 5 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 79: Remote Satellite
Shipping blocks can then be removed, and spring tension is correct. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 Lifting and Leveling Single-tier Satellites require three straps, front and two sides supported.
Page 80: Overview
⁄ inch above the dial face, and is square to it. A misaligned tripper can jam the timer. Figure 6-2 Proper Installation HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 6 - 1...
Page 81: Setting Precision Timer
Time Setting Dial is opposite the Arrow Time Marker. Note that the time indicated on the Time Setting Dial does not match the position of the numbers on the Program Timer Dials. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 82 1. Push gear “A” toward the motor, or lever “B” will be broken. 2. Using a non-metallic object, depress the plastic cam until it snaps into position holding the switch open. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 6 - 3...
Page 83 MECHANICAL DEFROST TIMERS Revised August 1, 1996 6 - 4 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 84: Paragon Defrost Timer
Module with an upward push of the thumb until the correct hour on the black Time of Day Dial aligns with the pointed alignment mark on the modules. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 6 - 5...
Page 85: Paragon Program Module
At the bottom rear of the Module, pull down on the plastic latching lever and out on the bottom of the Module. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 Installation Be sure power is off.
Page 86 (red tabs will be directly above the axle). Place locator studs in key slots and slide down. Tighten hex head bolt. Reconnect wires. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 6 - 7...
Page 87 MECHANICAL DEFROST TIMERS Revised August 1, 1996 6 - 8 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 88: Epr Valve
EPR Valves equipped with a Suction Stop Solenoid are used with Koolgas Defrost. When de-energized, this solenoid causes the Main Valve to close completely. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 7 - 1 a g a i n s t and Fixed .
Page 89: Koolgas Valve
Unless there is damage to the valve body itself, both the 2-way and 3-way valve may be disass embled and repaired in the field. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 Action Disassemble and clean...
Page 90: Troubleshooting Koolgas Valves
Action Disassemble and clean Replace solenoid Find and repair open Correct defrost clock problem Clean or replace Replace Clean or replace Correct defrost clock problem HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 7 - 3...
Page 91: Main Liquid Line Solenoid
Main Valve Chamber starts to empty and upstream pressure forces the main valve towards open. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Differential Mode Quick Test 1. Connect pressure gauges up- and down- stream of the valve.
Page 92: Alco Main Liquid Line Solenoid
4. Check gauges for differential. NOTE: Low refrigerant demand may prevent the differential from building up to the valve's real setting. is forced when the HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 7 - 5...
Page 93: Branch Liquid Line Solenoid Valves
Dirt in valve port or equalizing port Barrel or piston scored Dirt in piston chamber, causing drag HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA t h r o u g h opens, through the u p s t r e a m...
Page 94: Tev
To reduce differential, turn the adjusting stem counter clockwise and wait at least 15 minutes before checking results. Valve Recommended Body Adjustment ⁄ turn ⁄ turn HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 7 - 7...
Page 95 Uneven circuit load on Performance multiple evaporators Moisture or Dirt TEV mis-sized HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 Action Adjust to proper superheat Dehydrate and install new liquid line filter dryer Remove and clean or replace...
Page 96: Heat Reclaim Valve
The bleed port provides a vent for fluids trapped in the Heat Reclaim circuits during normal operation. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 7 - 9...
Page 97: Flooding Va Lve And Receiver Pressure Regulating Va Lv E
Dirt blocking Valve Port Diaphragm dirty or misaligned Fails to close Set too low Dirt in bleed port Installed backwards HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA o ff stays open. W h e n ⁄ Turn =...
Page 98: Troubleshooting Receiver Pressure Regulator
, and open- Action Reduce spring tension Clean or replace Clean, replace or align Increase spring tension Clean or replace Re-install with direction of flow HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 7 - 11...
Page 99: Autosurge And By-Pass Valves
Note: Both the Valve's sensing bulb and its equalizer line are located upstream of the Flooding Valve. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 The A u t o surge Valve reacts to the condensing...
Page 100 5 . Cap Pilot Valve Suction Outlet with a ⁄ -inch flare cap. 6 . Open suction pressure pilot line valve at Suction Manifold. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 7 - 13 ⁄ -inch flare plug (finger...
Page 101 Mechanical Surge Valve Chamber Pressure of 215 psig should place the system in Flow through the Receiver. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Main Valve To test the Main Valve, isolate the Pilot Valve and connect the Autosurge Schrader Valve to the center hose of a manifold.
Page 102: Mechanical Subcooling
The T E V should be set with the highest possible superheat that will still maintain the desired liquid temperature. EPR setting is listed on the store legend. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 7 - 15...
Page 103 Exchanger. An EPR on the return suction line prevents the subcooler temperature from drop- ping below desired liquid temperature. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 Plate Subcooler Controls Thermostat setting is 50˚F with minimum differential, or customer specifications.
Page 104: Demand Cooling
Module. The NTC resistance drops on temperature rise. Temperature ˚F Probe test readings between 100,000 1,600 usually indicate an operating probe. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 7 - 17 Approximate Reading 90,000 2,420...
Page 105 Va l v e sizes correspond to the four compressor bod- ies—2D, 3D, 4D, 6D. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 Component Testing Remove power to the system. Unplug the Temperature Sensor from the Module.
Page 106 Temperature Sensor cable must not touch any hot surfaces or the cable will be damaged. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 7 - 19...
Page 107: Oil System
Do not exceed 175 psig when testing to prevent dam- age to the floats. A sight glass filled with oil may indicate a damaged regulator. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 108: Sporlan Oil Level Regulator
Each full turn will represent about 0.055 inches change in oil level. Do not exceed: • 5 turns clockwise (downward) • 4 turns counterclockwise (upward) fro m original factory setting. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 109: Control
EPC Interlock (Factory Set) Liquid Injection TEV Superheat (Factory Set) 1 psig 1st Stage Discharge Thermostat Cut-in (psig) HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 8 - 1 230 psig 395 psig. Below 90 psig. 25˚F.
Page 110: Epr Settings
2 feet of elevation. Refrigerant Flooding Valve (Liquid) (psig) R404A/R507 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA MECHANICAL LOW PRESSURE CONTROLS Alco The Alco Low Pressure Control comes with a factory set cut-in pressure of 15 psig. Since Setting (psig)
Page 111: Alco
N o t e : These Fanal/Westinghouse Low Pressure Controls have a fixed 10 psig differential. Design Smallest Suction Largest Temp ˚F HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 8 - 3 Compressor Capacity Smallest psig...
Page 112: Others
O t h e r Mechanical Low Pre s s u re Contro l Settings Design Suction Temp ˚F Caution: Never run the compressors in a vacuum. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA R404A/R507 Low Temperature Compressor Compressor Compressor Number 6 Number 5 Number 4...
Page 113 Compressor Design Number 4 Suction Temp ˚F psig psig HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 8 - 5 Compressor Compressor Compressor Number 3 Number 2 Number 1 psig psig psig...
Page 114 CONTROL SETTINGS 8 - 6 Design Suction Temp ˚F Caution: Never run the compressors in a vacuum. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA R22 Medium Temperature Compressor Compressor Compressor Number 6 Number 5 Number 4 psig...
Page 115 Compressor Design Number 4 Suction Temp psig psig ˚F HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 8 - 7 Compressor Compressor Compressor Number 3 Number 2 Number 1 psig psig psig...
Page 116 CONTROL SETTINGS Revised August 1, 1996 8 - 8 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 117: Merchandiser Settings
— — — — — — — — 48°F 48°F 60°F 35 Min 43 Min HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 8 - 9 M3GE M5GE 27°F 28°F 28°F 28°F 21°F 18°F 18°F 21°F —...
Page 118 — O ff t i m e Temp Te r m ˚ F 48°F Duration Min 30 Min 30 Min HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA PRODUCE (End) 31°F 34˚ F 34˚ F 32˚ F 24°F 21˚...
Page 119 6 Hrs — — — — — — 48˚ F 48˚ F 30 M i n HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 8 - 11 DAIRY / DELICATESSEN D5LE D5GE D5NHE D5HE D5NGE D6LE...
Page 120 O ff t i m e Temp Te r m ˚ F Duration Min Preliminary Data — Preliminary Data — Preliminary Data — Preliminary Data HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA DELICATESSEN FROZEN FOOD 30˚ F 23˚...
Page 121 48˚ F 48˚ F 60 M i n — — 18 M i n — — HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 8 - 13 ICE CREAM LWUG LWEG –22˚ F –20˚ F –20˚ F –30˚...
Page 122 Duration Min 24 Min 22 Min O ff t i m e Temp Te r m ˚ F — Duration Min — HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA FROZEN FOOD G5CH FMLG G6CH NRCV GWIT NC6H...
Page 123 90 Min 14 Min 14 Min 14 Min — — — — 70 Min 70 Min 90 Min HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 8 - 15 DELI CGDM MWI6 CSDM VGLR GWIT VGSR GWI6...
Page 124 14 Min O ff t i m e Temp Te r m ˚ F — Duration Min 56 Min 40 Min HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA DELI and CHEESE FHMG RDMH FHMH FHMGH FMGV FHMS...
Page 125 12 Min 12 Min — — — — 60 Min 60 Min 60 Min HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 8 - 17 PRODUCE B A K E RY PVWI CGBR Bulk Pack PHSM...
Page 126 Duration Min — O ff t i m e Temp Te r m ˚ F — Duration Min 100 Min 90 Min HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Additional Merchandisers Meat Cheese DSRP DSRP NVSA NVSB NVSC 36˚...
Page 127 16 Min 16-24 Min 16 Min — — — — 90 Min 60 Min HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 8 - 19 Produce Prep Areas Return 41˚ F Return 55˚ F — —...
Page 128: Branch Liquid Line Solenoid
After the last leak is repaired and tested, the system must stand unaltered for 12 hours with no pressure drop from 150 psig. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 9 - 1...
Page 129: Oil Levels
The vacuum pump must be in good condition filled with fresh oil to achieve desired results. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Procedure Pull a vacuum to 1500 microns. If the vacuum ⁄...
Page 130: Charging
C D A Valves replace fuse in panel board to place under control of defrost clock. Split Condenser—Operating under pressure controls. Check Oil levels for all compressors and Turba-shed. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 9 - 3...
Page 131: Final Checks
Turba-shed. Leak testing, evacuation and initial charg i n g are now completed. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996 Final Checks Once the system is up and running, it is the...
Page 132: Maintenance
Note: Oil level regulator sight glasses are designed to provide a hermetic seal when internally pressurized. Some leaking may occur when a deep vacuum is pulled. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A 9 - 5...
Page 133: Cleaning The Turba-Shed
Open housing, replace core and close up. Pressurize, leak test and bring back into line. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Revised August 1, 1996...
Page 134 INDEX SUBJECT Defrost Clock, Mechanical Paragon Precision 5-7, 9,11 Demand Cooling Dimensions Load Points Machine Room Receiver Super Plus™ Rack Satellite Electrical Schematics Remote Condenser Super Plus™ Equalizing Line Evacuation Expansion Loop Heat Reclaim High Pressure Control 8-17 Hoisting Remote Condenser Remote Satellite Super Plus™...
Page 135 SUBJECT CHAPTER PAGE Leak Testing Leveling Remote Condenser Super Plus™ Line Sizing Low Pressure Control Oil System Power Monitor Prep Room Special Piping Receiver Capacity Satellite Shipping Damage Remote Header Remote Satellite Super Plus™ Single Phase Protector Solder Subcooling Ambient...
Page 136 4. The condenser liquid return line is longer than 100 feet. 5. The system is equipped for low head pressure operation that seeks to obtain a maximum of subcooling. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A A - 1...
Page 137 Mount the condenser on beams supported by building columns or load-bearing walls. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Addendum – April 15, 1996 The mounting surface for the condenser...
Page 138 Addendum – April 15, 1997 P/N 340272A A - 3 Figure A-2. Rigging for Leg Assembly and Lifting HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 139 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Addendum – April 15, 1996 to the receiver. A s h u t o ff valve should be installed on the condenser side of the check valve.
Page 140 R-22 — 135 psig R-507 — 170 psig R404a — 165 psig Figure A-5. Split Condenser Wiring Diagram – Factory and Field Installed Kits HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA P/N 340272A A - 5...
Page 141 C a u t i o n : B e f o re entering any fan section, make sure power to the fan motors is dis - connected. HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA Addendum – April 15, 1996 3. Check that the proper winter condensing...
Page 142 Addendum – April 15, 1997 P/N 340272A A - 7 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 143 CONDENSER INSTALLATION Addendum – April 15, 1996 A - 8 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 144 Addendum – April 15, 1997 P/N 340272A A - 9 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 145 CONDENSER INSTALLATION Addendum – April 15, 1996 A - 10 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 146 Addendum – April 15, 1997 P/N 340272A A - 11 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...
Page 147 CONDENSER INSTALLATION Addendum – April 15, 1996 A - 12 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA...

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