installation & installation and operations operation manual · 2016-10-10 · 2 installa pera...

Stratus Multi DeckInstallation and Operations

Manual

Installation & Operation Manual

KW-IOM-1003 October 2016 Part No. 31E11003

LEGACY Reach-In Display Cases with Modular Condensing Unit

KW-IOM-1003 | Version 01

Model:QDV5V(1)(3)4 - Medium TemperatureApplications:

Model:QIV5V(1)(3)4 - Low TemperatureApplications:

Table of ContentsPart I. Introduction, Installation, and Operation 2

1. Introduction 2

2. Description 2

2.1. Standard and Optional Features 2

2.2. Case Description 3

2.3. Major Components 3

3. Receipt, Installation and Operation 6

3.1. Site Selection and Preparation 6

3.2. Unpacking 6

3.3. Inspection 7

3.4. Installation of Cases 8

3.5. Installation of the Modular Condensing Unit 9

3.6. Refrigeration Charges 10

3.7. Expansion Valves and Adjusting the Superheat 11

3.8. Drip Pipe and Drain Strainer 11

4. Operation 13

4.1. Loading 13

4.2. Normal Operation with the Modular Condensing Unit 13

4.3. Cleaning 14

5. Paragon Case Controller 16

5.1. Controller Front Panel Display 16

5.2. Programming, Settings, Error Codes, and the Parameters for the ERC-2 Case Controller

17

6. Technical Data 18

6.1. Case Data for the QDV5V(1)(3)4 and QIV5V(1)(3)4 Cases 18

6.2. Case Dimensions 20

6.3. Technical Data for the ERC-2 Refrigeration Case Controller 21

7. Electrical 22

7.1. Electrical Field Connections 22

7.2. Power Sources 22

7.3. Wiring Diagrams 23

8. Parts Lists 29

9. Warranty 30

Appendices 32

Appendix A. ERC-2 Case Controller Information 32

Appendix B. Installation of the SHURflo Condensate Pump

36

Appendix C. Refrigeration Connections 38

Part II. Specification Sheets 43

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Installation and Operation Manual

Part I. Introduction, Installation, and OperationThis manual is in two parts: Part I includes the introduction, installation, and operation of the unit, and Part II contains the unit’s specifications as displayed in the specification sheets issued separately. The user can get both at the Heatcraft Web page at www.heatcraft.com/literature/.aspx.

1. Introduction

Kysor/Warren (KW) is a leading manufacturer of commercial refrigerated display cases and refrigeration systems for supermarkets throughout North America. KW offers an array of merchandising and refrigeration solutions for our customers.

These cases should be installed and operated according to the instructions contained in this manual. They are designed for display of products in an air-conditioned store where temperature and humidity are maintained at a maximum of 75º dry bulb temperatures and 55% relative humidity.

2. Description

The QDV5V(1)(3)4 and QIV5V(1)(3)4 cabinets (Table 2-1) are designed to merchandise frozen food, ice cream, and medium temperature products. The basic design of these cabinets include:

• Glass door reach-ins• 2, 3, 4, or 5 foot doors• Five shelves in standard depth• Optional modular condensing unit

Model Description

QDV5V(1)(3)4Upright/Glass Door, Medium Temp Merchandiser (Off-Cycle Defrost) Vertical Lighting/Eliminator Door

QIV5V(1)(3)4Upright/Glass Door Ice Cream Merchandiser (Electric Defrost)

Vertical Lighting/Eliminator Door

2.1. Standard and Optional Features

Standard features for both models include:• 1” increments for shelf positioning.• 20 Standard and 90 premium color options.• High efficiency EC motors.• Hinged fan plenum.• Anthony eliminator doors• Top/rear piping (pipe Line sized to the case specification)• Top wiring• Suction to liquid line heat exchanger• Low temperature cases have electric defrost (208V/60Hz/1Ph)• Medium temperature cases have off-cycle defrost

Optional features for both include:• Heavy-duty or one-piece shelving• Wire and plexi shelf dividers• Plexi & glass end options• Multiple Door makes, styles and hinging

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• Top mounted modular condensing units• Electronic expansion valves• Alternate refrigerants (Glycol, CO2-liquid overfeed and CO2-Dx)• Top refrigerant & electrical piping

Another option is a buck and boost transformer. It is discussed later in this manual.

2.2. Case Description

Figure 2.1 is an example of a QDV5V(1)(3)4 series unit – the exterior of the QIV5 series is very similar. The callouts identify the major exterior features.

2.3. Major Components

The major components discussed below are:• ERC-2 refrigeration case controller• Condensate pump• Modular condensing unit

Figure 2.1 Example of a QDV5V(1)(3)4 Series Unit

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ERC-2 Refrigeration Case Controller

For more information on programming procedures, parameters, error codes, and so forth, see section 6

Condensate Pump

The condensate pump is a compact, submersible pump with a built-in, hermetically sealed, pressure activated switch. It has the following features:

• Electrical rating of 120V/60Hz/1Ph, 0.9A• Capacity: 45GPH @ 10’ of head• Quiet operation• Pump operates automatically when water level

reaches approximately 1.2” & turns off at .75”• Pump is field installed into a 3-gallon drain pan• Pump is UL Listed

Note: See Appendix B, for instruction on its installation.

Modular Condensing Unit

The selected Condensing Unit has the following features:• Electrical rating of 208-230V/60Hz/1Ph• Refrigerant R404A• Manual Reset High Pressure Safety Cut-Out• Receiver and Suction Valve• All Refrigeration Lines Sweat Connections• Each Condensing Unit designed to operate one Case• Condensing units are UL Listed

Condensate Evaporator Pan Heater

The ERC-2 electronic refrigeration control is a microprocessor-based electronic controller designed to control both the temperature and the defrost functions of a commercial unit. It can be powered by 120, 208, or 240 VAC (50 or 60 Hz). The control contains four relay outputs:

• Compressor• Defrost• Evaporator fan• Alarm

The ERC-2 includes a digital display module providing readouts of the temperature, time, and built-in diagnostics.

The condensate evaporator pan heater has the following features:• Electrical rating of 120V/60Hz/1Ph, 8.3A, 1000 W• Condensate dissipation rate: 8.5 Gallons per day• Three-gallon evaporator pan• Evaporator pan heater is UL listed

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Buck & Boost Transformer – Optional Equipment

When the Buck & Boost transformer option is chosen, the transformer is factory wired to provide 208V output with 195V input. The transformer connections can be rewired in the field to provide alternative buck and boost percentages. Wiring instructions are provided on the transformer cover. The Transformer is UL listed.

Refrigerant

The QDV5V(1)(3)4 medium temperature and QIV5V(14)(34) low temperature cases use R404A refrigerant.Table 2.2 lists the refrigerant charge by unit and door size.

A 1.5 KVA Buck & Boost Transformer is an option. The primary and secondary of Buck & Boost transformer can be interconnected for use as an autotransformer to slightly step up or down voltages. When used as an autotransformer to slightly adjust voltage, the Buck & Boost Transformer can carry loads in excess of its nameplate rating.

Model 2 Foot Door 3 Foot Door 4 Foot Door 5 Foot DoorQDV5V(1)(3)4 3.72 Lbs. 4.50 Lbs. 5.80 Lbs. 7.20 Lbs.

QIV5V(1)(3)4 7.75 Lbs. 5.5 Lbs. 8.25 Lbs. 11.2 Lbs.

Table 2-2. Refrigerant Charge

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3. Receipt, Installation and Operation

Section 3 discusses:• Site Selection and Preparation• Unpacking• Inspection• Installation of cases• Installation of trim, caps, and shelves• Drip pipe and drain strainer• Expansion valves and superheat adjustments

NOTE: Read all instructions carefully before beginning installation

3.1. Site Selection and Preparation

Proper site selection ensures:• The equipment is where it is supposed to be• Equipment is near adequate electrical outlets and drainage • Optimal operation

The following are some criteria for selecting the site for the case.

# Site Selection and Preparation1 Site is in accordance with approved floor plan.

2 When installing the first of multiple cases, there is sufficient space for the rest of the units.

3 Verify installation area is at least:• 15 feet from any outside entrances or heating and cooling outlets• A 2-foot separation between hot and cold cases

4 Ensure floor loading will support the case and the case contents.

5 Ensure proper AC power is available. Refer to case AC input requirements located in the electrical connections section of this manual.

6 Ensure location will allow connection to drain lines and the drain line, when installed, will meet the recommendations as set forth in the refrigeration piping and dehydration section of this manual.

7 To prevent condensation on the end panels of cases, allow sufficient space (6 inches) between the case and wall, or provide some other means to ensure adequate air circulation.

8 Clean area where case is to be installed.

9 Ensure expansion valve in case is the proper valve for the type of refrigerant used at the installation site.

3.2. Unpacking

The following instructions are provided for unpacking, moving, loading, and lifting the case prior to installation.

# Unpacking Checklist1 Material is unpacked as near to the site of the case as possible. This avoids losing or misplacing parts.

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# Unpacking Checklist2 Inspect material against packing list. Report missing or broken parts – see guidance on inspecting material.

3 Remove all shipping tape from lamps and ensure that all lamp ends are snapped in place.

4 Ensure the evaporator cover is installed correctly with the deck pans installed.

5 Organize the components to ease assembly.

6 Move the case into position, install, adjust superheat, and perform the operational checkout procedures following the instructions within this manual.

WARNING!Some components are heavy and may cause injury or be damaged if dropped.

Cautions: Be careful not to damage the factory-installed end while moving the case.Use the case lift points on the case to move it to the proper location.

3.3. Inspection

Inspect the system components and accessories for damage or shortages before and during unpacking. If there is any damage, notify the carrier immediately.

At a minimum, the following should be checked on receipt. Use the owner’s checklist if available as well as the parts list. Be sure that you receive all accessories because they may be packaged separately.

# Inspection Checklist on Receipt of Material1 Check the packing list against the contents. Annotate any discrepancies.

2 All parts are present.

3 Pressure in the system is within specified limits.

4 Verify electrical specifications match on-site power configuration.

5 Field installed material meets manufacturer's specifications

6 Field Installed material meets specified pressure ratings.

If parts are damaged, missing or unserviceable, ensure:

# Action for Missing and Damaged Parts1 The delivery receipt is annotated that the equipment was received damaged, had missing parts, or was not

serviceable.

2 If damage is not noticeable on receipt, contact the carrier immediately when the damage is discovered.

NOTES:It is the responsibility of the consignee to file all claims for damage with the transportation company.

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All claims for shortages must be submitted within 10 days after receipt of shipment.

3.4. Installation of Cases

The installation of the first unit should take the most time. It will define the positions of the other cases in a line-up as well as the overall efficiency of all the units.

NOTE: All cases are factory numbered with line up and position numbers. Make sure that cases are installed in order (line up sticker found on the fan plenum or door and on the back panel of the case)The steps to install the first case include:

# Installing Cases1 Site is properly prepared

2 Use the case lift points on the case to move it to the proper location

3 If multiple cases are to be installed, find the highest area of the floor to place the first case.

4 Allow a minimum of 6 inches between the rear of the case and the store walls and/or other cases.

This space reduces the possibility of condensation problems. It may also be necessary to provide forced air ventilation.

5 All cases are located on a firmly based floor and leveled within ± 1/16 in.

6 All cases are located on a firmly based floor and leveled within ± 1/16 in.6.1 Use shims provided to support and level the entire case length.

6.2 All rails of the case must be properly shimmed and in contact with the floor.

6.3 Cases with shims on the ends must also have shims in the middle and no more than 4 ft. apart.

6.4 All legs of the case must be properly adjusted and in contact with the floor.

7 If multiple cases are to be installed, refer to the floor plan and install the first case in the lineup by snapping a chalk line where the front and rear of the cases are to be located.

8 Continue the chalk line if multiple cases are to be installed.

9 Connect input AC power. Reference electrical installation procedure later in this manual.

10 Connect refrigerant lines. Reference procedure later in this manual.

11 Set condensing unit on top of case at location supplied (see 3.5 below). Also:• Pipe into case using the sight glass and liquid line filter drier supplied.• Follow normal procedures for brazing; pressure testing, and evacuation of the system.• Once system has been evacuated:

° Charge system ° Program controller ° Check for proper operation

12 Remove shipping tape on fluorescent lamps and remove all other shipping material

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NOTES: Refer to the operational start up procedures later in this manual.Cases must be leveled from front to back end-to-end and supported continuously as needed with shims.

3.5. Installation of the Modular Condensing Unit

This section covers the following:The mounting base and enclosureThe assembly of the modular condensing case

The Mounting Base and Enclosure

The evaporator pan, control box, and Buck & Boost transformer are factory mounted on a base plate attached to the top of the case. The condensing unit, enclosures panels, sight glass, & liquid line filter drier are shipped loose and is field installed. (Refer to pictures below)

The Assembly of the Modular Condensing Case

The front enclosure panel has a knock out provided for the controller display. This panel must face the front of the case. See Figures 3-1 and 3-2.

# Installing Cases1 All components are installed as shown in Table 3-1.

2 Assembly of the condensing unit2.1 The condensing unit must be slid from the back of the case, facing the condenser coil to the left side of the case

viewed from the back.

2.2 Condensing unit is aligned to the corner brace (13) at the right back corner of the base.

2.3 Condensing unit is screwed to the base plate at the pre-punched hole locations.

3 Spacing3.1 A minimum of: 12 inches between the condenser coil and the side panel

3.2 A minimum of 5 inches between the back of the condensing unit and the rear panel

4 All electric wiring is routed through flexi metallic conduit.

Figure 3.1 Top View of Modular Condensing Case

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Description of the callouts in Figure 3-2. are contained in Table 3-1, below.

Callout Descriptions for Figure 3-1# Description # Description1 Front Panel 11 Terminal Blocks 120

2 Rear Panel 12 Case Controller

3 Side Panels (2) 13 Corner Brace

4 Remote Display 14 Condensing Unit

5 Evaporator Pan Heater 15 Base Plate

6 Boost Bucks Transformer 16 Air Deflector, Front

7 Electric Raceway 17 Air Deflector, Rear

8 Electric Box 18 3/8 Inch Flexi Conduit

9 Electric Box Cover 19 ¾ Inch Flexi Conduit

10 Terminal Blocks 230 20 Controller Interface Cable

3.6. Refrigeration Charges

QDV5V(1)(3)4/QI5V(1)(3)4 cases comes with the charges of R404A refrigerant as shown in Table 3-2.

Refrigerant ChargeModel and Door Size In Condenser In Case Total Charge

QDV5V(1)(3)4-02 2.20 lbs. 1.55 lbs. 3.75 lbs.

QDV5V(1)(3)4-03 3.00 lbs. 1.50 lbs. 4.50 lbs.

QDV5V(1)(3)4-04 3.00 lbs. 2.80 lbs. 5.80 lbs.

Figure 3.2 Isometric View of the Modular Condensing Case

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QDV5V(1)(3)4-05 3.00 lbs. 4.20 lbs. 7.20 lbs.

QIV5V(1)(3)4-02 4.40 lbs. 0.35 lbs. 4.75 lbs.

QIV5V(1)(3)4-03 5.10 lbs. 0.40 lbs. 5.50 lbs.

QIV5V(1)(3)4-04 6.90 lbs. 1.35 lbs. 8.25 lbs.

QIV5V(1)(3)4-05 7.50 lbs. 3.70 lbs. 11.20 lbs.

3.7. Expansion Valves and Adjusting the Superheat

The expansion valve furnished with the case has been sized for maximum coil efficiency. To adjust the superheat, perform the following steps below.

Caution: During service, precautions should be taken to prevent loss of refrigerant to the atmosphere. Always install the expansion valve stem cap after making valve adjustments.

# Adjusting Superheat1 Place a thermocouple near the expansion valve bulb. Read the suction line pressure as near to the coil as possible.

(If at the condensing case, estimate suction line loss at 2 PSIG).

2 Convert coil suction pressure to temperature. The difference between coil temperature and the thermocouple temperature is superheat. (Use average superheat when expansion valve is hunting).

3 Do not set superheat until cases have pulled down to operating temperature and:• Never open or close the valve over ¼ turn between adjustments• Allow 10 minutes or more between adjustments.

4 Superheat should be set to 6-8°F.

5 After the initial setting, the superheat should be rechecked when product is stocked and at designed temperature.

Figure 3.2 is an example of calculating superheat.

3.8. Drip Pipe and Drain Strainer

Cases are equipped with 1 ½” M-NPT waste outlet connection that terminates in the center of the refrigerator below the insulated bottom. The water seal trap is shipped loose for field installation.

The drip pipe/waste outlet allows liquid to leave the display. Improperly installed drip pipes can seriously affect the operation of the unit and result in increased maintenance cost. The following are some general guidelines for the

Figure 3.2 Example of Calculating Superheat

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proper installation of a drip pipe:

# Installation of the Drip Pipe1 Never use a double water seal.

2 Never use a pipe smaller than the size pipe or water seal supplied with the equipment.

3 Always provide as much fall as possible in drip pipe. The fall should be at least 1 inch per 4 feet of drip pipe.

4 Avoid long runs in a drip pipe.

5 Provide a drip space between drip pipe and floor drain or sewer connection

6 Do not allow the drip pipe to come in contact with uninsulated suction lines. This will cause the condensation from the refrigerator to freeze.

Figure 3.3 Shows the location of the waste outlet where the drip pipe is connected.

Drain strainers help prevent blockage by keeping debris from entering the PVC drain. To install:• Insert into drain until drain strainer stops. • The strainer will not be flush and will exceed the hub by 1 inch (see Figure 3-4).• Do not flatten drain strainer

NOTE: Not all cases have drain strainers.

Figure 3-3 Location of the Case Waste Outlet

Figure 3.4 Drain Strainer

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4. Operation

Merchandise should not be placed in the fixture until all controls have been adjusted and the case is at the proper steady state operating temperature. The merchandiser should not be stocked with product above the load limit line located on the top of the inside back panel. If these load lines are exceeded, cooling performance will be adversely affected and will result in warm product temperatures as well as increased operating costs.

Each merchandiser contains an electronic controller (see below for more detail) used to control discharge air temperature and defrosting. The discharge air sensor is located in the rear discharge air duct. The settings for low temperature and medium temperature are preset in the electronic controller and no adjustment is required after connecting power to the merchandiser.

CAUTIONS: • Air discharge and return flues must remain open and free of debris or obstruction at all times to provide proper

refrigeration and air curtain performance.• Do not allow any product, signs, debris, etc., to block return air grills.• Do not use any non-approved shelving, display racks, or any accessory that could hamper air curtain

performance.

NOTE: Electric defrost is standard on these models and the fans run continuously.

4.1. Loading

Merchandise should not be placed in the case until all controls have been adjusted and the case is at the proper temperature. Air discharge and return flues must remain open and free of debris or obstruction at all times to provide proper refrigeration and air current performance. Do not allow any product, signs, debris, etc. to block these grilles. Do not use any non-approved shelving, display racks or any accessory that could hamper air current performance.

Follow these recommendations for optimal performance when loading the unit.

# Loading the Refrigeration Unit1 Load only the merchandise the refrigeration unit is designed for.

2 Do not place merchandise in the unit until all controls are adjusted and it is at the proper temperature.

3 Do not stack merchandise beyond the load line located on the top of the back baffle and each end of the refrigerator. This will degrade performance and increase operating costs.

CAUTION: At no time should the case be stocked beyond the load line or over the front edge of adjustable shelves

WARNING!Do not walk on top of the cases! This could result in damage to the case and serious personal injury could

occur. These cases are not designed to support excessive external weight. Do not use top of cases for storage.

4.2. Normal Operation with the Modular Condensing Unit

Off-Cycle Defrost is standard on medium temperature models. The fans run continuously and defrost termination is by termination Klixon.

Electric Defrost Models are standard for low temperature cases. Electric heaters are utilized to melt the frost and ice on the coil. The heaters are located in the air stream underneath the coil.

The defrost cycle is time initiated and temperature terminated. Case fans shut off during defrost. During refrigeration

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the fans start after the evaporator coil temperature reaches 10°F and run continuously thereafter. As a safety precaution, a safety cutoff Klixon is wired in series with the defrost heater to turn the heater off at temperatures above 65°F.

Condensing Unit: An electronic controller is used to control case temperatures. The sensing bulb is mounted in the discharge air stream.

4.3. Cleaning

As a general rule, always use mild soap and water to wipe the case down. Special precautions must be taken when cleaning some components of the case.

Exterior surfaces should be cleaned with warm water and mild soap to protect and maintain the finish. Do not use cleaners containing abrasive materials or ammonia, that will scratch or dull the finish. The waste outlet should be flushed with water following each cleaning.

Interior surfaces may be cleaned with most mild soap formulas, ammonia based cleaners, and sanitizing solutions with no harm to the surface.

To ensure minimum maintenance cost, the merchandiser should be emptied and thoroughly cleaned every three months. The exterior should be cleaned weekly. The waste outlet should also be checked and cleaned weekly.

WARNINGS!Always disconnect power during the cleaning process. Cleaning the case with electrical power applied is a

shock hazard that may cause serious injury or death.

Do not use hot water on cold glass surfaces. This could cause the glass to shatter and could result in personal injury. Glass fronts and ends should be warm before applying hot water.

Do not flush modular condensing unit cases with a water hose. The condensate drain pan will over flow resulting in water on the floor.

CAUTIONS: • Do not use solvent, oil or acidic-based cleaners on any interior surfaces as the surface may become

damaged.• Do not use abrasive cleaners and scouring pads, as these will mar the finish.• Never introduce water into the case faster than the waste outlet can release it.• Do not use steam or high pressure systems to clean the case, as seals may be broken which will cause the

case to leak.

NOTE: Do not stack anything that may block airflow in front of louvers on the case. Self-contained cases draw air from back to front and blocking this airflow will cause the case to overheat and shut down.

Shelves

Do not use a hose or submerge shelves in water. When cleaning lighted shelves, wipe down with a wet sponge or cloth so that water does not enter the light rails.

Mirrors

Mirrors are sheets of clear glass that have a thin reflective coating applied to one side. These coatings are susceptible to deterioration if certain cleaning solutions and even water are allowed to come in contact with them. Every precaution should be made to keep liquids away from the coated side of the mirrors. If liquids are allowed to flow along the face side of the mirror to its edge, the liquid can seep between the coating and the glass, causing serious damage.

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To help prolong the life of the mirrors:• Use only mild cleaning solutions (Windex, Solox, or a weak solution of vinegar and water.)• Do NOT spray liquids on mirrors. Dampen the cleaning cloth, and then use the cloth to wipe the mirror.• Wipe water from the mirrors immediately to prevent difficult to remove water spots and also to prevent the

water from reaching the mirrors edge.• Never use dirty cloths, scrapers or any other abrasive materials for cleaning.

Cleaning the Condensing Units

Follow the previous general cleaning of the interior and exterior parts. However, do not use a water hose to clean evaporator or tub of the case.

Once a month, use:• A vacuum cleaner to remove any lint or other debris that may have collected on the entering air side of the

condenser coil.• Compressed air blown through the condensing coil, in the opposite direction of normal air flow, to clear any

debris or dust.

Cleaning the Honeycomb Assembly

The honeycomb should be cleaned every 6-8 months, depending on store conditions. The honeycomb may be cleaned with a vacuum cleaner or removed to be washed with soap and water. The honeycomb must be completely dry before returning it to the case. See Figure 4.1.

NOTE: Remember the position and angle of the honeycomb when removing from the case. Honeycomb must be replaced at the same angle.

Figure 4.1 Removing the Honeycomb for Cleaning

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5. Paragon Case Controller

The ERC-2 electronic refrigeration control is a microprocessor-based electronic controller designed to control both the temperature and the defrost functions of a commercial unit. It can be powered by 120, 208, or 240 VAC (50 or 60 Hz). The control contains four relay outputs:

• Compressor• Defrost• Evaporator fan• Alarm

The ERC-2 includes a digital display module providing readouts of the temperature, time, and built-in diagnostics. The display can be mounted with or away from the unit. The digital display also contains a keypad for simple programming. It uses a clock for defrost control.

The ERC-2 is NSF certified and can be applied to many commercial refrigeration applications where accurate control of refrigerated space and defrost cycles are required. Some of its capabilities include:

• Temperature Control: The controller: ° Turns on the compressor when the discharge air temperature increases above the cut-in set point. ° Shuts off the compressor when the case reaches the desired discharge air temperature.

• Compressor Control: The controller is adjusted by the operator for the following: ° Minimum off time ° Minimum run time ° Start-up time delay

When powered up, the ERC-2 initially displays the last configured selection (time or temperature) or 12:00 AM. The ERC-2 maintains the correct time of day even if there is a power outage because it is powered by a capacitor - needs no batteries. The time is maintained for up to 100 hours, depending on the capacitor charge.

The ERC-2 has two levels of programming:

• The first level allows the user to set two parameters: ° CLoC: time of day ° Set: setpoint temperature

• The second level permits access to the other parameters (see Appendix A for the list of parameters)

5.1. Controller Front Panel Display

Figure 5.1 shows the ERC-2 electronic refrigeration control. To program the case controller, remove the cover so the LED display is visible (Figure 5.2). Three buttons program the controller: SET, UP, and DOWN.

A manual defrost is initiated by pressing and holding the MAN DEF button for 3 seconds.

Figure 5.1 ERC-2 Electronic Control Figure 5.2 ERC-2 LED Display

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5.2. Programming, Settings, Error Codes, and the Parameters for the ERC-2 Case Controller

See Appendix A.

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6. Technical Data

This section discusses the technical data for:• Cases• Case dimensions• Technical data for the ERC-2 refrigeration case controller

6.1. Case Data for the QDV5V(1)(3)4 and QIV5V(1)(3)4 Cases

Table 6.1 displays the technical case data for the QIV5V(1)(3)4 case with the modular condensing unit.

115V Circuit Data 2 Door 3 Door 4 Door 5 DoorPower Supply (Volts/Phase/Amps) 115/1/60

Anti-Sweat Amps (ELM Door) 2.43 3.32 4.40 5.44

Evap Fan Motor Amps (PSC opt) 0.44 0.66 0.88 1.10

Evap Fan Motor Amps (EMC opt) 0.40 0.60 0.80 1.00

Light Amps (T8) 1.39 1.80 2.32 2.79

LED Light Amps (Gelcore opt) 0.70 1.05 1.40 1.73

Drain Pan Heater 0.39 0.65 0.91 1.17

Condensate Pump Amps 0.94 0.94 0.94 0.94

Condensate Evaporator Amps 8.00 8.00 8.00 8.00

Minimum Circuit Amp 13.83 15.61 17.69 19.68

Maximum Overcurrent Protection 20.00 20.00 20.00 20.00

208V Circuit Data 2 Door 3 Door 4 Door 5 DoorPower Supply (Volts/Phase/Amps) 208/1/60

Compressor RLA 9.60 11.40 11.4 16.7

Compressor LRA 59.20 59.20 59.2 87.0

Condenser Fan Motor Amps 0.85 2.60 1.70 5.20

Defrost Heaters Amps 6.09 9.13 12.17 15.22



Horse Power 1 2 2 ¼ 3

Defrost ControlsDefrost Per Day Fail Safe Termination

Electric 1 45 min 65°F

BTU Per Door

PSC Fan 820

ECM Fan 780

Note: For sizing conventional/individual condensing units. Maintained temperature -5°F.

Discharge Air Velocity Discharge Air Temp

300 FPM -5/-12 °F

Table 6.1 QIV5V(1)(3)4 Low Temperature case with the Modular Condensing Unit

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Table 6.2 displays the technical case data for the QDV5V(1)(3)4 with the modular condensing unit.

115V Circuit Data 2 Door 3 Door 4 Door 5 DoorPower Supply 115/1/60

Anti-Sweat Amps (ELM Door) 0.81 1.17 1.57 1.91

Evap Fan Motor Amps (PSC opt) 0.44 0.66 0.88 1.10

Evap Fan Motor Amps (EMC opt) 0.40 0.60 0.80 1.00

Light Amps (T8) 1.67 2.22 2.78 3.34

LED Light Amps (Gelcore opt) 0.70 1.05 1.40 1.73

Condensate Pump Amps 0.94 0.94 0.94 0.94

Condensate Evaporator Amps 8.00 8.00 8.00 8.00



208V Circuit Data 2 Door 3 Door 4 Door 5 DoorPower Supply 208/1/60

Compressor RLA 4.20 5.70 5.70 5.70

Compressor LRA 16.80 24.10 24.10 24.10

Condenser Fan Motor Amps 0.70 0.70 0.70 0.70



Horse Power 1/3 1/2 1/2 1/2

Defrost ControlsDefrost Per Day Fail Safe Termination

Off Cycle 3 30 min 40°F

BTU Per Door

PSC Fan 820

ECM Fan 780

NOTE: For sizing conventional/individual condensing units. Maintained temperature +38°F.

Discharge Air Velocity Discharge Air Temp

300 FPM +32 °F

Table 6.2 QDV5V(1)(3)4 Medium Temperature Case with the Modular Condensing Unit

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6.2. Case Dimensions

Figures 6.3 and 6.4 show the cross sectional and bottom view of the cases.

Figure 6.3 Cross-Sectional View of the QDV5V(1)(3)4/QIV5V(1)(3)4 Cases

Figure 6.4 Bottom View of the QDV5V(1)(3)4/QIV5V(1)(3)4 Cases

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6.3. Technical Data for the ERC-2 Refrigeration Case Controller

The following are the technical specifications for the ERC-2 control unit:

Statistic SpecificationInput Power 120/208-240VAC 50/60Hz (+10, -15%)

Power Consumption 5VA @ 120-240VAC

Zone and Evaporator Coil Temperature Sensors NTC thermistor. Range -40 to 199°F

Ambient Operating Conditions -40 to 122°F; 0 to 95% RH (non-condensing)

Display Module Dimensions 2.75” W x 1.10” H x 1.38” D

Case Dimensions 4.40” W x 7.28” H x 3.80” D

Shipping Weight 3.0 lbs.

Agency Approvals • c-UR-us Recognized Component – Models ERC-2-1xxxxxx• c-UL-us Listed Product – Models ERC-2-2xxxxxx • NSF International Certified

Output Relay Ratings

Output Relay RatingsCompressor: SPST NO 120 VAC 208 VAC 240 VACHorsepower rating (hp) 1 1.5 2

FLA/LRA 16/96 12/72 12/72

Pilot Duty 470 470 470

Defrost: SPST NC 120 VAC 208 VAC 240 VACResistive Amps 16 16 16

Horsepower Rating (hp) 1/2 3/4 1

Pilot Duty 470 470 470

Evaporator Fan: SPST NC 120 VAC 208 VAC 240 VACResistive Amps 16 16 16

Horsepower Rating (hp) 1/2 3/4 1

FLA/LRA 10/59 8/48 8/48

Pilot Duty (VA) 470 470 470

Alarm: SPST NO 120 VAC 208 VAC 240 VACResistive Amps 5 5 5

Pilot duty (VA) 240 240 240

Resistance Versus TemperatureTemperature Resistance Temperature Resistance

°F 0°C Ohms °F °C Ohms-40 -40 1010000 32 0 97950

-31 -35 728100 41 5 76170

-22 -30 531000 50 10 59700

-13 -25 391200 59 15 47130

-4 -20 291200 68 20 37470

5 -15 218900 77 25 30000

14 -10 166000 86 30 24170

23 -5 127000

22


7. Electrical

This sections covers:• Electrical field connections• Power Sources• Wiring Diagrams

7.1. Electrical Field Connections

There are three field connections consisting of the condensing unit and two power supplies (see the arrows on the Wiring Diagram in this section). All remaining connections are made at the factory (Table 6-1).

Table 6.1 Electrical Factory Connections

7.2. Power Sources

There are two power sources: • A 208V/60Hz/1Ph power supply for the condensing unit and the defrost heater; this power supply will be

connected through the Buck & Boost Transformer. • A 115V/60Hz power supply for the case. There is an electrical box on the top of the case to wire all the

electrical components.

23


7.3. Wiring Diagrams

Wiring diagrams for the QDV5V(1)(3)4 and QIV5V(1)(3)4 include:• QDV5V(1)(3)4 Medium Temperature Case Wiring Diagram• QIV5V(1)(3)4 Low Temperature Case Wiring Diagram• Isometric view of condensate pump and heater• 120 Volt Pump/Heater Relay• Fan relay assembly and wiring

24


QDV5V(1)(3)4 Medium Temperature Case Wiring Diagram

25


QQIV5V(1)(3)4 Low Temperature Case Wiring Diagram

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Isometric view of condensate pump and heater

27


120 Volt Pump/Heater Relay

28


Fan Relay Assembly and Wiring

29


8. Parts Lists

Table 8.1 shows the parts list for the QDV5V(1)(3)4/QIV5V(1)(3)4 2/3/4/5 foot door cases.

Description Part No.Quantity

2 Ft Door 3 Ft Door 4 Ft Door 5 Ft DoorFan Motor EMC 09A10131 2 3 4 5

Fan Blade 25Deg 8” Diameter 09B10061 2 3 4 5

Honeycomb -White 13A15028 2 3 4 5

Honeycomb -Black 13A15058 2 3 4 5

Fan Bracket STD 54V11869 2 3 4 5

Fan Bracket PSC and EMC 54V11870 2 3 4 5

Deck Pan 54N18427 2 3 4 5

External Drain Trap 96H26979 1 1 1 1

Defrost Control, Electric 08A11048 1 1 1 1

Electric Defrost Safety 08A11050 1 1 1 1

Case Control – Paragon ERC-2 08A10118 1 1 1 1

Condensate Pan Heater 1,000W 120V 28H12042 1 1 1 1

NOTE: Standard parts are listed. Individual cases may have options different than listed and the serial number for these cases is required when ordering parts.

Table 8.2 shows the parts list for the SHURflo Condensate Pump

Table 8.1 Parts List QDV5V(1)(3)4/QIV5V(1(3)4 2/3/4/5 Foot Door Cases

Description Part NumberElectrical Outlet Box Assembly 82A17072

SHURflo Pump 48A10004

FITTING STRT 3/8NPT X 3/8 BARB 07F10022

FITTING ELBOW 3/8NPTX3/8 BARB 07F10023

Drain Pan Clip 18G10072

Pump Strainer (Drain pan Installation) 56B20110

3/8” Copper Tube Guider 63C23080

3/8” PVC Tubing 13A11133

Table 8.2 Parts List for the SHURflo Condensate Pump

30


9. Warranty

Parts Warranty Policy The following procedures are in accordance with Kysor/Warren’s standard one-year warranty, which covers any part to be free of defects under normal use and service for one year from the date of installation. Not to exceed one year and thirty days from the date of original shipment form the factory.

New Equipment Parts Shortages and Defects Any parts shortages or damage must be reported to Kysor//Warren no more than 10 working days from the date of delivery. After this time has expired Kysor/Warren will assume the parts were lost during installation and all parts required will be charged cost plus shipping to replace.

Parts Ordering Procedure All parts must be ordered through the Kysor/Warren parts department with the following information:

• Store Name and Number• Location• Case or Case Model and Serial Number• Firm or Contractor Placing Order• Shipping Address• Parts Description• Reason for Defect

If the order is for a replacement part still in warranty a Purchase Order Number will be required from the contractor placing the order. We will then issue a Return Material Authorization Tag (RMA) that will be sent to the firm or contractor who has ordered the part.

Return Authorization Procedure Warranty parts must be returned postage prepaid to Kysor/Warren within 30 days from replacement part ship date and must be accompanied by a RMA in order to ensure the proper credit. The RMA should also be written on the outside of the box. Any parts not returned within 30 days will be invoiced to the firm or contractor who has placed the order.

IN THE CONSTANT EFFORT TO IMPROVE OUR PRODUCTS, WE RESERVE THE RIGHT TO CHANGE AT ANYTIME SPECIFICATIONS, DESIGN, OR PRICES WITHOUT INCURRING OBLIGATION. One-Year Warranty KYSOR/WARREN warrants to the original purchaser this new equipment and all parts thereof, to be free from defects in material and workmanship under normal use and service. If any part or parts of the equipment should prove defective during the period of one year from installation date (not to exceed one year and thirty days from the date of original shipment from the factory), KYSOR/WARREN hereby guarantees to replace or repair, without charge (F.O.B. Columbus, Georgia), such part or parts as proven defective, and which KYSOR/WARREN’S examination disclosed to its satisfaction to be thus defective, with a new or functionally operative part. The liability of KYSOR/WARREN under this warranty shall be limited to claims made by the original purchaser to KYSOR/WARREN or its local distributor within the warranty period.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS, AND ALL OTHER OBLIGATIONS OR LIABILITIES OF KYSOR/WARREN.

I. GLAZING: Glass is not guaranteed against breakage. If this refrigerator is equipped with a glazing assembly

31


carrying the manufacturer’s brand name (Thermopane, Twindow, etc.), the manufacturer’s glazing warranty in effect at the time of this shipment is extended to that assembly. It is void outside the continental United States.

II. BULBS: Light bulbs and fluorescent lamp tubes are not covered by any warranty for length of life or for any type of breakage.

III. THIS WARRANTY SHALL NOT APPLY:

1. To the condensing unit used with refrigerated equipment unless it was sold and shipped by KYSOR/WARREN.2. When this equipment or any part thereof is damaged by fire, flood, act of God, or when the original model and

serial number plate has been altered, defaced, or removed.3. When this equipment or any part thereof is subject to accident, alteration, abuse, misuse, tampering, operation on

low or improper voltages, or is put to a use other than recommended by KYSOR/WARREN.4. When this equipment or any part thereof is damaged, or when operation is impaired, due to failure to follow

installation manual (improper installation is the responsibility of the installer).5. Outside the continental United States, Canada and Mexico.6. To labor cost for replacement of parts, or for freight or shipping expenses.7. To freight or shipping charges or to customs duties to any country.8. If the Warranty holder fails to comply with all the provisions, terms and conditions of this Warranty.

Parts replaced under this Warranty are warranted only through the remainder of the original Warranty. KYSOR/WARREN may, at its option and in its discretion, elect to honor this Warranty and to disregard the original purchaser’s non-compliance with any of the provisions, terms and conditions of the Warranty. THIS WARRANTY DOES NOT COVER CONSEQUENTIAL DAMAGES.

KYSOR/WARREN shall not be liable under any circumstances for any consequential damages, including loss of profits, additional labor costs, loss of refrigerant or food products, or injury to person or property caused by defective material or parts or for any delay in the performance of this Warranty due to causes beyond its control. The foregoing shall constitute the sole and exclusive remedy of any purchase and the sole and exclusive liability of KYSOR/WARREN in connection with this product.

32


AppendicesThere are four appendices:

• Appendix A: Programming the ERC-2 and its parameters• Appendix B: Installation of the SHURflo Condensate Pump• Appendix C: Refrigeration connections

Appendix A. ERC-2 Case Controller Information

A-1. Programming the ERC-2 Case Controller

Programming the controller includes:• Changing first level parameters• Accessing and changing second level parameters

Changing First Level Parameters

Follow the steps below to change the first level parameters: time of day and the temperature setpoint.

Changing the Time and Set-Point Temperature1 Press and hold set for 5 seconds. The display will show CLoC

2 Press SET again to change time-of day

3 Press UP or DOWN until the correct time-of-day is displayed

4 Press SET to accept the new time

5 Press DOWN to go to the next parameter – Setpoint temperature – SEt (cut out)

6 Press SET to change the setpoint temperature

7 Press UP or DOWN to go to the desired setpoint. The range is -40 to 60°F or - 40 to 16°C

8 Press SET to accept the change

9 Press DOWN to exit the first level of programming.

Notes:

During programming, if no button is pushed during 30 seconds, the control will go back to the normal operating mode. This is valid for both programming levels.

When changing the time, press and hold the MAN DEF button for 3 seconds to change the AM/PM mode

or

or

33


Changing Second Level Parameters

Follow the steps below to change second level parameters.

Changing the Time and Set-Point Temperature1 Press and hold SET and DOWN for 10 seconds. The display will show

dSPL

2 Press SET to change the parameter

3 Press UP or DOWN to change the options, time or temperature for the current parameter

4 Press SET to accept the new value

5 Press DOWN to go to the next parameter. Then go back to Step 2. After the last parameter is displayed (ALHi), the display will go back to the normal operating condition

NOTE: To scroll down the parameters without changing them, press the DOWN button.

A-2. Recommended Control Settings

The following are recommended settings and parameters for the ERC-2 refrigeration controller. The medium and low temperature cases have different settings.

QDV5V(1)(3)4 Medium Temperature Case# Parameter Setting1 tDay Adjust the time of Day – see section 6.2 above

2 rSP Set the discharge air temperature (cut-out) at 32°F – see section 6.2 above

3 rSP Select as display status

4 dFtP Select ELEC for Electric Defrost/Off Cycle Defrost

5 EFAN Fan Status During Defrost = NO (Select Default). Fan will not be controlled through the Case Controller.

6 dFIN Type of defrost Interval = tdAy

7 nodF Number of defrosts per day = 1 per day

8 dEF1 Set the desired defrost time = 1

9 dEFd Defrost duration = 30 minutes

10 dEF Defrost termination temperature = 40°F

11 diF Set point Differential = 4°F

QDV5V(1)(3)4 Medium Temperature Case# Parameter Setting1 tDay Adjust the time of Day – see section 6.2 above

2 rSP Set the discharge air temperature (cut-out) at 12°F – see section 6.2 above

3 rSP Select as display status

4 dFtP Select ELEC for Electric Defrost/Off Cycle Defrost

and

or

34


5 EFAN Fan Status During Defrost = NO (Select Default). Fan will not be controlled through the Case Controller, but will be controlled by the Current Sensing Relay & Fan Delay Thermostat

6 dFIN Type of defrost Interval = tdAy

7 nodF Number of defrosts per day = 3 per day

8 dEF1 Set the desired defrost time = 1

9 dEFd Defrost duration = 45 minutes

10 dEF Defrost termination temperature = 65°F

11 diF Set point Differential = 4°F

A-3. Error Codes

Table 6.2 displays the error codes and their reset procedures for the ERC-2 controller.Display Control Status Resetting

Er 1 ERC Fault – software or hardware failure Cut the power to the unit and correct the problem to reset the display.

Er 2 ERC Communication Fault – indicates that there is a problem with the display module cable

Cut the power to the unit and correct the problem to reset the display.

Er 3 Zone Sensor Fault – indicates an open or shorted temperature sensor

1. Press the UP or DOWN button on the display to reset the error message. 2. Replace the sensor If the display still shows the message.

Er 4 Evaporator Sensor Fault – indicates an open or shorted evaporator sensor

1. Press the UP or DOWN button on the display to reset the error message. 2. Replace the sensor If the display still shows the message.

Er 5 ERC Fault – software or hardware failure Cut the power to the unit and correct the problem to reset the display.

Er 6 Low Temperature Alarm – indicates that the temperature has dropped below the low alarm setpoint

Will automatically reset once the temperature is back within the two setpoints.

Er 7 High Temperature Alarm – indicates that the temperature has gone above the high alarm setpoint

Will automatically reset once the temperature is back within the two setpoints.

A-4. Parameters for the ERC-2 Case Controller

Parameter Display Symbol

Description Range/Options Delfield Settings

Display Status

dSPL Information shown on the display during operating conditions

tDAy – time-of-day rSP - Zone temperature (refrigerated space) CyCL – cycle between time and zone temperatureEpr - evaporator coil temperature

CyCL

Clock Format CLHr Format of the time (12 or 24 hours mode)

12Hr – AM/PM format24Hr – 24 hour format

12Hr

Temperature Format

°dSP Temperature degrees °F – degrees Fahrenheit°C – degrees Celsius

°F

Defrost Type dFtP Type of defrost used in the application

ELEC – electric heater defrost/off cycle HgAS – hot gas

ELEC

Table 6-2. Error Codes

35


Fan Status During Defrost

EFAN Enable or not the evaporator fan during defrost

no – fan is turned off during defrostyES – fan remains on during defrost

no

CFAN Enable or not the condenser fan during defrost

no – fan is turned off during defrostyES – fan remains on during defrost

no

Defrost Interval

dFin Type of defrost interval TdAy – time-of-day setpointCPrn – compressor run timetdEF – temperature initiated defrost

TdAy

Minimum Compressor Off Time

CoFF Minimum time that the compressor will remain turned off

Range: from 0 to 15 min 0

Minimum Compressor On Time

Con Minimum time that the compressor will remain turned on


Alarm Delay ALrd Time delay before the alarm goes off after the temperature fall off the two alarm setpoints


Compressor Run Time

CPrn Time the compressor will run between defrosts

Number of Defrosts

nodF Number of defrosts per day

From 0 to 8 (0 means 1defrost every 28 hours)

4

Defrost Start Time

dEF1-8 Start time of each defrost

Defrost Duration

DEFd Defrost duration time (back-up for defrost termination temperature)

Range: from 0 min to 4 hours Frzr: 45Refr: 30

Fan Delay FAnd Delay time for the fan after defrost (back-up for fan cut-in temperature)


Pump Down Pudn Pump down duration Range: from 0 to 59 min 0Drip Time driP Drip time duration Range: from 0 to 59 min 0Setpoint Differential

diF° Cut-in temperature differential Note: cut-in is cut-out plus differential

Range: from 1 to 25 6

Defrost Termination Temperature

dEF° Temperature in the evaporator that will terminate the defrost cycle

Range: from 0 to 75°F or -18 to 25°C Frzr: 55°F Refr: 45°F

Fan Cut-In Temperature

FAn° Temperature in the evaporator that will turn the fan on after defrost

Range: from -40 to 60°F or -40 to 23°C 30°F

Low Temperature Alarm

ALLo Low temperature setpoint that will make the alarm do off and the error message appear on the display

Range: from -40 to 60°F or -40 to 23°C -40°F

High Temper-ature Alarm

ALHi High temperature setpoint that will make the alarm do off and the error message appear on the display

Range: from -40 to 60°F or -40 to 23°C 83°F

Table 6-1. ERC-2 Parameters

36


NOTE: To change from degrees C to F or vice-versa, the user must reprogram all the parameters that are related to the temperature. The unit does not convert parameters automatically from degrees F to C or vice-versa.

Appendix B. Installation of the SHURflo Condensate Pump

The SHURflo condensate pump replaces the old condensate pump. It is factory-installed for newer units but has to be retro-fitted for units in the field.

The following are instructions to properly install the SHURflo pump in the field.

SHURflo Field Retrofit Instructions1 Before starting the retrofit operation disconnect power to the case.

2 Remove cover from the electrical control box.

3 Clip the electrical outlet box conduit into the knock out hole on the electrical control box.

4 Connect the white wire to the neutral leg of the 230V terminal board in the electrical control box.

5 Connect the black wire to the L1 leg of the 230V terminal board in the electrical control box.

6 Connect the red wire to the defrost termi-nal on the paragon controller (Terminal P11)

7 Mount the electrical outlet box next to the condensate pan.

8

Mount the SHURflo pump behind the electrical outlet box next to the condensate pan.

9 Plug the SHURflo pump into the electrical outlet.

10 Connect the 3/8” hose from the drain pan under the case to the inlet side of the pump.

Connect the 3/8” hose connected to the condensate pan to the outlet side of the pump.

Notice the flow arrow on the pump.

37


11

Use the white hose clip provided to secure the 3/8” hose to the top of the case.

12 Pull drain pan out from under the front of the case.

13 Remove old pump.

14 Use provided clips to mount the copper tubing to the back side of the drain pan.

15 Connect the 3/8” hose to the u-bend on the copper tubing.

16

Place pump strainer in the drain pan with the copper tubing inside the notch on the pump strainer as shown.

17 Slide drain pan back under the case making sure it is under the drain.

18 Put the cover back on the electrical control box.

19 Restore power to the case.

20 Add water to the drain pan

21 Using the paragon display place the case into manual defrost mode to ensure the pump is working properly.

22 Pump should run when case is in defrost mode.

38


Appendix C. Refrigeration Connections

Appendix C has two parts:• Instructions on connecting couplings• Examples of connections

C-1. Instructions on Connecting Couplings

The couplings on the ends of the pre-charged line sets are self-sealing when installed properly. Follow these instructions carefully.

NOTE: An EPA Certified Type II or higher technician must perform these steps.

# Coupling Connection Instructions1 Remove the protector caps and plugs. Wipe the seats and threaded surfaces with a clean cloth to remove any

foreign matter.

2 Thoroughly lubricate the threads, o-rings, diaphragms and all internal coupling surfaces with polyolester (POE) refrigerant oil.

Caution: Lubricating is very important. Couplings will leak without lubrication.

3 Position the condenser with the fittings facing the female fittings on the case.

4 Connect the couplings

4.1 Begin to tighten the couplings together by hand. Continue to turn the swivel nuts by hand until it is certain that the threads are properly engaged.

Model Suction Line Liquid Line

QDV5V(1)(3)4-02 1/2” 3/8”

QDV5V(1)(3)4-03 1/2” 3/8”

QDV5V(1)(3)4-04 5/8” 3/8”

QDV5V(1)(3)4-05 5/8” 3/8”

QIV5V(1)(3)4-02 1/2” 3/8”

QIV5V(1)(3)4-03 5/8” 3/8”

QIV5V(1)(3)4-04 5/8” 3/8”

QIV5V(1)(3)4-05 5/8” 3/8”

Coupling

Fitting Size Location of Connecting Points

39


4.2 Using two wrenches, one to rotate the swivel nut and one to hold the tubing in place, tighten each coupling.

Caution: It is CRITICAL that ONLY the NUT on the pre-charged tube be turned, or the diaphragms will be torn by the piercing knives and become loose in the refrigeration system causing severe operational problems.

NOTE: As the coupling is tightened, the diaphragms in the quick connect couplings will begin to be pierced. As that happens, there will be increased resistance to tightening the swivel nut.

4.3 Continue tightening the swivel nut until it bottoms out or a very definite increase in resistance is felt (no threads should be showing). Do NOT over tighten.

5 Use a marker or pen to mark a line on the coupling nut and unit panel. Then tighten the coupling nut an additional one-quarter turn. The line will show the amount that the nut turns.

6 After all connections have been made, check the couplings for leaks.

C-2. Examples of Connections

The following are examples of:• Ends of couplings prior to connection• Incorrect connection of a coupling with two threads showing• Incorrect connection of a coupling with one thread showing• Incorrect connection of a coupling with threads flush but not completely sealed• Correct connection•

No sealing takes place until the final stage, when the outer edge of the center post in the swivel nut is forced against the bottom of the male fitting, creating a mechanical seal.

Ends of Couplings prior to Connection

The swivel nut end contains one diaphragm in the center post. The male fitting contains the knife blades and its own diaphragm.

Tighten the Swivel Nut

Rotate Swivel Nut ¼ Turn More

40


NOTE: 3/8 male ends have one knife blade.

Incorrect Connection of a Coupling with Two Threads Showing

The table below shows what appears to be a completed assembly with only two threads showing, but the diaphragms have just begun to be pierced. This causes severe operational issues as well as refrigerant leaks.

NOTE: Couplings that are screwed together but have threads showing are not only leaking refrigerant, they are restricting the flow of refrigerant through the small slits in the membranes or diaphragms.

Incorrect Connection of a Coupling with One Thread Showing

The figures below show an even more complete assembly, with only one thread showing. However, this assembly is still not complete. If not tightened further, there will be refrigeration restrictions and leaks.

One Thread Showing

Knives Just ShowingBarely Pierced

Two Threads Showing

41


NOTE: Couplings that are screwed together but have threads showing are not only leaking refrigerant, they are restricting the flow of refrigerant through the small slits in the membranes or diaphragms.

Incorrect Connection of a Coupling with Threads Flush but Incompletely Sealed

Below shows the two parts almost together; the threads are flush. At this point the mainproblem will be refrigerant leaks.

Correct Connection

The example below shows a properly assembled coupling.

Knives VisiblePierced but will Leak

Threads Flush

Knives ExposedPartly Pierced

42


Correctly Tightened

Fully Open Fully Open

43


Part II. Specification SheetsPart II contains the unit’s specifications as displayed in the specification sheets issued separately. The user can get both at the Heatcraft Web page at www.heatcraft.com/literature/.aspx.

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