topics figures - hussmann · 0095 101 0105 93 0115 101 0125 101 0185 97 0145 106 0155 172 0165 172...

Topics Figures

P/N 311859Eiii

971107 HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

TABLE OF CONTENTS

1. Installation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Shipping Damage . . . . . . . . . . . . . . . . . . . .1-1Rigging and Hoisting . . . . . . . . . . . . . . . . .1-1Isolation Pads . . . . . . . . . . . . . . . . . . . . . . .1-2Product Code . . . . . . . . . . . . . . . . . . . . . . .1-3Base Dimensions . . . . . . . . . . . . . . . . . . . .1-4Unit Weights . . . . . . . . . . . . . . . . . . . . . . . .1-5Quad-Ventional Weights . . . . . . . . . . . . . . .1-7Quad-Ventional Dimensions . . . . . . . . . . . .1-7Machine Room Requirements . . . . . . . . . .1-8Unit Placement . . . . . . . . . . . . . . . . . . . . . .1-9Shipping Block Removal . . . . . . . . . . . . . .1-9

Rigging and Lifting . . . . . . . . . . . . . . . . . .1-1Rigging and Lifting Quad-Ventional . . . . .1-2Machine Room Requirements . . . . . . . . . .1-8Removing Shipping Block . . . . . . . . . . . . .1-9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Refrigeration Cycle . . . . . . . . . . . . . . . . . . 2-1Heat Reclaim

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Description . . . . . . . . . . . . . . . . . . . . . . 2-4Location and Mounting . . . . . . . . . . . . 2-4

Low Ambient ControlsAdjustable Flooding Valve

and Check Valve . . . . . . . . . . . . . . . . 2-5Fixed Flooding Valve . . . . . . . . . . . . . . 2-6

Liquid Line Solenoid Valve . . . . . . . . . . . . 2-6TEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7EPR Valve . . . . . . . . . . . . . . . . . . . . . . . . . 2-8CPR Valve . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Demand Cooling . . . . . . . . . . . . . . . . . . . . 2-9Copeland Scroll Compressors . . . . . . . . . .2-11Reverse Cycle Defrost . . . . . . . . . . . . . . . 2-12Temperature Control . . . . . . . . . . . . . . . . 2-15

Refrigeration Cycle . . . . . . . . . . . . . . . . . . 2-1Heat Reclaim Valve . . . . . . . . . . . . . . . . . . 2-2Adjustable Flooding Valve and

Check Valve . . . . . . . . . . . . . . . . . . . . . . . 2-2Fixed Flooding Valve . . . . . . . . . . . . . . . . . 2-2Liquid Line Solenoid . . . . . . . . . . . . . . . . . 2-2TEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2EPR Valves . . . . . . . . . . . . . . . . . . . . . . . . 2-3Heat Reclaim Valve . . . . . . . . . . . . . . . . . . 2-3Heat Reclaim Expansion Ratios . . . . . . . . 2-4Heat Reclaim

Smoothing Air Velocities . . . . . . . . . . . . . 2-5Heat Reclaim withAir Conditioning Coil . . . . . . . . . . . . . . . 2-5

Adjustable Flooding Valve andDifferential Check Valve . . . . . . . . . . . . . 2-5

Fixed Flooding Valve . . . . . . . . . . . . . . . . . 2-6Liquid Line Solenoid Valve . . . . . . . . . . . . 2-7TEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Probe Locations for Setting TEV . . . . . . . 2-8Direct Acting EPR Valve . . . . . . . . . . . . . . 2-8Pilot Operated EPR Valve . . . . . . . . . . . . . 2-8Direct Acting CPR Valve . . . . . . . . . . . . . . 2-9Pilot Port CPR Valve . . . . . . . . . . . . . . . . . 2-9

2. Refrigeration

Topics Figures

P/N 311859Eiv

HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.) 971107

3. Piping

TABLE OF CONTENTS (Continued)

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Refrigeration Line Runs . . . . . . . . . . . . . . 3-1Merchandiser Piping . . . . . . . . . . . . . . . . . 3-4Special Piping for Open Rooms . . . . . . . . 3-5Run Lengths and Equivalent Feet . . . . . . . 3-5Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Supporting Refrigeration Lines . . . . . . . . . 3-1Insulating a Riser . . . . . . . . . . . . . . . . . . . . 3-2Vibration Allowance . . . . . . . . . . . . . . . . . 3-2P-Trap Construction . . . . . . . . . . . . . . . . . . 3-2Reduced Riser . . . . . . . . . . . . . . . . . . . . . . 3-2HIRU to Condenser Piping . . . . . . . . . . . . 3-3Line Piping Inside Merchandisers . . . . . . . 3-4

Equivalent Feet for Angle Valve andElbow 90° . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . 4-1Wiring Guidelines Based on

Various Components . . . . . . . . . . . . . . . . 4-1Electrical Diagrams in this Section . . . . . . 4-2Defrost Timers . . . . . . . . . . . . . . . . . . . . . . 4-2Heat Reclaim Circuits . . . . . . . . . . . . . . . . 4-4Fan Cycling Circuits . . . . . . . . . . . . . . . . . 4-5440V Compressors . . . . . . . . . . . . . . . . . . 4-6Electric Defrost . . . . . . . . . . . . . . . . . . . . . 4-6Copeland Scroll Compressors . . . . . . . . .4-12Additional Timer Circuits with

Reverse Cycle Defrost . . . . . . . . . . . . . 4-13

8145 Timer . . . . . . . . . . . . . . . . . . . . . . . . . 4-28245 Timer . . . . . . . . . . . . . . . . . . . . . . . . . 4-3A633 Timer . . . . . . . . . . . . . . . . . . . . . . . . 4-3CD104MB Timer . . . . . . . . . . . . . . . . . . . . 4-4Heat Reclaim Circuits . . . . . . . . . . . . . . . . 4-4Heat Reclaim Circuit with

Reverse Cycle Defrost . . . . . . . . . . . . . . . 4-5Single Fan Circuits . . . . . . . . . . . . . . . . . . 4-5Fan Bank Circuits . . . . . . . . . . . . . . . . . . . 4-5Cycling Fan Bank Circuits . . . . . . . . . . . . 4-5Variable Speed Fan Control . . . . . . . . . . . 4-5Cycling Fan Bank Circuits withReverse Cycle Defrost . . . . . . . . . . . . . . 4-6

4. Electrical

2. Refrigeration (continued)

Demand Cooling Components . . . . . . . . . 2-10Demand Cooling Wiring . . . . . . . . . . . . . 2-11Demand Cooling Alarm Connections . . . 2-11Liquid Injection Schematic . . . . . . . . . . . .2-11Pilot Valve Operation . . . . . . . . . . . . . . . . 2-12Reversing Valve Connections . . . . . . . . . 2-13Heat Reclaim with Reverse Cycle Defrost 2-13Reverse Cycle Defrost –

Refrigeration and Defrost Modes . . . . . 2-14

Topics Figures

P/N 311859Ev


Warranty

5. Control Settings

TABLE OF CONTENTS (Continued)

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Control Settings . . . . . . . . . . . . . . . . . . . . 5-4Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

4. Electrical (continued)

Variable Speed Fan Control withReverse Cycle Defrost . . . . . . . . . . . . . . 4-6

440V Compressor with230/208V Control Panel . . . . . . . . . . . . . 4-7

Defrost Sub Breaker Wiring . . . . . . . . . . . 4-78145 Indoor Clock Schematic . . . . . . . . . . 4-88245 Indoor Clock Schematic . . . . . . . . . 4-9A633 Outdoor Clock Schematic . . . . . . . 4-10CD104MB Clock Over 110 Min . . . . . . 4-11Liquid Injection Wiring . . . . . . . . . . . . . .4-12Wiring for Discharge Thermostat

and Trax-Oil . . . . . . . . . . . . . . . . . . . . . .4-12Timer Circuits with

Reverse Cycle Defrost . . . . . . . . . . . . . 4-12

P/N 311859Evi


Being Safe is Your Responsibility.

Wear proper eye protection wheneverworking.

Wear proper hearing protection wheneverworking in a machine room.

Stand to one side—never work directly infront of:

• Any valve you are opening or closingManual refrigeration valvesRegulator valves on brazing tanks and nitrogen tanks

• Electrical Circuit Breakers

• Refrigeration lines you are cutting oropening

Always use a pressure regulator with anitrogen tank.

• Do not exceed 2 pounds of pressure andvent lines when brazing.

• Do not exceed 350 pounds of pressure forleak testing high side.

• Do not exceed 150 pounds of pressure forleak testing low side.

Use only a striker to light torch.

Know whether a circuit is open at the powersupply or not. Remove all power beforeopening control panels.

Always supply proper ventilation.•Refrigerants and nitrogen can displaceoxygen causing suffocation.

• Refrigerants exposed to flame can producephosgene, a poisonous gas.

Be sure refrigeration lines are free ofpressure before cutting. Check:

• Both sides of a two way valve

• All lines to a 3-way or 4-way valve

Dangerous hydraulic explosions may result ifyou

• Isolate liquid lines or compressor when they can absorb heat over an extended time period

• Overfill pumpdown refrigerant containers

Never vent refrigerants into theatmosphere.

SAFETY TIPS

O V E RV I E W

This section is limited to the information needed toset the HICA, HOCA, HIRU and Quad-Ve n t i o n a lunits. Power Supply requirements are found underElectrical; piping, under Piping; and charg i n g ,under S t a rtup and Maintenance. Auxiliary units arefound in the sections devoted to them or in themanuals accompanying them.

SHIPPING DAMAGE

All equipment should be thoroughly examined forshipping damage before and while unloading.

This equipment has been carefully inspected at ourfactory and the carrier has assumed responsibilityfor safe arrival. If damaged, either apparent or concealed, claim must be made to the carrier.

A p p a rent Loss or D a m a g eIf there is an obvious loss or damage, it must benoted on the freight bill or express receipt andsigned by the carrier's agent; otherwise, carrier mayrefuse claim. The carrier will supply the necessaryclaim forms.

Concealed Loss or D a m a g eWhen loss or damage is not apparent until afterequipment is uncrated, a claim for concealed damage is made. Upon discovering damage, makerequest in writing to carrier for inspection within1 5 days and retain all packing. The carrier will supply inspection report and required claim forms.

RIGGING AND HOISTING

Under no circumstances should the manifolds, piping return bends or control panel be used for lift-ing or moving the unit. Use lifting eyes provided onthe two tier units. On single tier units, secure liftinghooks to the under side of the base. The installer isresponsible to see that equipment used to move theunits is operated within its limits.

P/N 311859E1 - 1


INSTALLATION INSTRUCTIONS

On the Quad-Ventional, rigging should lift theframe just below the compressors. A hook andsafety strap should be used since the controlpanel makes the unit top heavy toward the back.

When using a fork lift, extra care should be takento prevent the unit from tipping backward.

ISOLATION PADS

The Quad-Ventional is shipped with 6 IsolationPads. If a shim is used to adjust for a slightlyuneven floor, it must go under the Isolation Pad.Shims are field supplied and should be the samesize as the Pads. The Pads are used runninglengthwise with the base.

P/N 311859E1 - 2


P/N 311859E1 - 3


PRODUCT CODE

H X X X – X X X X – X X X – X XReceiver Assembly

Condenser Assembly A = 01FHA = 20FH B = 02FH

Electrical Requirements B = 21FH C = 03FHD = 230/1/60 C = 22FH D = 04FHK = 208-230/3/60 D = 23FH E = 05FHM = 460/3/60 E = 24FH F = 06FHU = 380/3/50 F = 25FH G = 07FHS = 200/3/50 G = 26FH H = 08FH

H = 27FH I = 09FHTemperature Application I = 28FH J = 11FH

L = Low J = 29FH K = 12FHS = Medium/High K = 30FH L = 10FHH = High L = 31FH

M = 32FHRefrigerant N = 33FH

V = R-22 O = 34FHP = R404a/507 P = 35FHJ = R134a Q = 36FH

R = 37FHS = 38FHT = 39FHU = 40FH

Compressor Assembly V = 41FHLast Digit indicates Type W = 43FH

2 = Copelaweld X = 44FH4 = Copeland Discus Y = 50FH5 = Copeland Reeds Z = 51FH7 = CarlyleA = Copeland Scroll, R-22 Low and Med TempB = Copeland Scroll, R-22 High TempC = Copeland Scroll, R-404a/507 Low TempD = Copeland Scroll, R-404a/507 and R-134a Medium Temp

General DescriptionHICA = Hussmetic Indoor Air Cooled Condensing UnitHOCA = Hussmetic Outdoor Air Cooled Condensing UnitHIRU = Hussmetic Indoor Compressor with Remote Condenser

BASE DIMENSIONS

Single Compressor ApplicationN o m i n a l L e n g t h Depth Height

h p (in.) (in.) (in.)

HICA 01 - 04 39 291⁄2 40 Max

05 - 10 47 37 50 Max

*12 - 25 47 37 91 Max

HOCA 01 - 04 39 34 40 Max

05 - 10 47 44 50 Max

*12 - 30 94 44 50 Max

HIRU 01 - 04 39 291⁄2 37 Max

05 - 25 47 37 45 Max

*H I C A units with condenser assemblies larg e rthan 31FH utilize two parallel condensers. Theseare stacked on a Two-Tier frame. H O C A units of 15 nominal hp and above withcondenser assemblies larger than 31FH require adouble-wide housing to hold the single coil double-length condenser.

Two-Tier ApplicationLength and Depth equal single compressor appli-cation for the bottom tier. Since the mountingsurface for the top tier is always 53 in. high thetotal unit height is determined by the top tierheight + 53 in.

HICA Top Tier Compressor Total HeightNominal HP (in.)

01 7311⁄2 79

02 - 04 8105 - 06 8571⁄2 - 12 91

The height of Two-Tier HIRU units depends onthe height of the top control panel. The totalheight maximum is 87 in.

P/N 311859E1 - 4


UNIT WEIGHTS

With Modular Conventional Units the customercan build units specific to particular needs.Compressors, condensers (including frame), and

receivers may be selected in a variety of combi-nations. To determine approximate weights addthe component weights together.

P/N 311859E1 - 5


CompressorWeights

ScrollCOPELAND

Assembly Weight4 Numbers of

Product Code (lbs)030A 65035A 68040A 85050A 94

060A 95075A 225100A 225030B 65

035B 68040B 85050B 94060B 95

075B 225090B 225100B 225130B 240

030C 65035C 68040C 85050C 94

060C 95075C 225100C 225030D 65

035D 68040D 85050D 94060D 95

075D 225100D 225

HermeticCOPELAWELD


Product Code (lbs)

0152 700202 720252 790312 80

0352 910402 910502 950752 180

0902 180

Semi-HermeticCOPELAND


Product Code (lbs)0045 930055 930065 820075 101

0085 930095 1010105 930115 101

0125 1010185 970145 1060155 172

0165 1720205 1780215 175

Semi-HermeticCOPELAND (cont'd)


Product Code (lbs)

0225 1780245 1800304 2650305 230

0315 2310326 2310335 1970355 197

0356 2620475 2420404 2650484 265

0494 2650504 2650524 2650604 265

0654 2850704 2850724 3550734 355

0934 3701024 3701064 3701204 380

1314 3801464 3801514 4121964 415

2025 4212204 420

Semi-HermeticCOPELAND (cont'd)


Product Code (lbs)

2504 4352704 4982824 440

3014 5353025 535

Semi-HermeticCARLYLE


Product Code (lbs)0227 1450317 1500337 2130457 213

0477 2130527 2130537 2280677 243

0687 2880767 2951027 3031107 303

P/N 311859E1 - 6


Condenser Weights

Assembly Weight Number of HOCA Outdoor Housing*Next to Last Letter of Product Code (lbs) 1⁄2 hp Fans Length x Depth x Ht (in.) Weight (lbs)

A (20FH) 235 1 39 x 34 x 35 52B (21FH) 225 1 39 x 34 x 35 52C (22FH) 265 1 39 x 34 x 40 58

D (23FH) 280 1 39 x 34 x 40 58E (24FH) 300 1 39 x 34 x 40 58F (25FH) 320 2 47 x 44 x 44 81

G (26FH) 340 2 47 X 44 x 44 81H (27FH) 365 2 47 x 44 x 50 92I (28FH) 375 2 47 x 44 x 50 92

J (29FH) 390 3 47 x 44 x 50 92K (30FH) 400 3 47 x 44 x 50 92L (31FH) 410 3 47 x 44 x 50 92

M (32FH) 720 4N (33FH) 735 4O (34FH) 750 4

P (35FH) 770 6Q (36FH) 785 6R (37FH) 800 6

S (38FH) 720 4 94 x 44 x 50 161T (39FH) 735 4 94 x 44 x 50 161U (40FH) 770 6 94 x 44 x 50 161

V (41FH) 785 6 94 x 44 x 50 161W (43FH) 800 6 94 x 44 x 50 161X (44FH) 825 8 94 x 44 x 63 161

HIRU Application Base OnlyY (50FH) 175 0Z (51FH) 210 0

*Add Outdoor Housing weight toHOCA units when figuring total weightsHeight includes the base.

Conventional Receiver Weights

Assembly Dimensions Weight 80% ChargeLast Letter of Product Code (in.) (lbs) R-22 (lbs) R-404a (lbs)

A (01FH) 6 x 29 29 24 21B (02FH) 8 5⁄8 x 29 40 48 42C (03FH) 8 5⁄8 x 38 60 64 56

D (04FH) 8 5⁄8 x 45 72 77 66E (05FH) 9 3⁄4 x 29 50 60 51F (06FH) 9 3⁄4 x 38 70 80 69

G (07FH) 9 3⁄4 x 45 76 96 82I (09FH) 10 3⁄4 x 45 117 117 102K (12FH) 8 5⁄8 x 92 143 160 139

L (11FH) 8 5⁄8 x 84 136 146 1xxx

QUAD-VENTIONAL WEIGHTS

To figure the weight of a Quad-Ventional unit,add the compressor weights and the receiverweights to the rack base weight of 1,000 pounds.

The compressors are the same as for convention-al units (except for mounting), but the receiversare different. Use the table below for Quad-Ventional receiver weights.

QUAD-VENTIONAL DIMENSIONS

The unit is 84 in. long by 76 in. high by 31 in.deep. Depth measurement includes space for thepiping and accessories on the back of the unit.The height includes 1 in. for isolation pads.

P/N 311859E1 - 7


Quad-Ventional Receiver Weights

Assembly Dimensions Weight 80% ChargeLast Letter of Product Code (in.) (lbs) R-22 (lbs) R-404a (lbs)

53VQ 8 5⁄8 x 29 40 48 40.754VQ 8 5⁄8 x 38 60 64 54.255VQ 9 3⁄4 x 38 70 80 67.656VQ 10 3⁄4 x 38 97 98 82.557VQ 11 3⁄4 x 38 124 118 99.0

MACHINE ROOM REQUIREMENTS

•The equipment room floor must solidly supportthe compressor unit as a live load. Ground levelinstallation seldom presents problems, but amezzanine installation must be carefully engineered.

•HIRU and Quad-Ventional ventilation should be100 cfm per compressor unit horsepower. The airinlet should be sized for a maximum of 600 fpmvelocity (0.5 ft2 of air intake per compressor unithorsepower). HICA ventilation should be 750 to1000 cfm with 2 to 2.5 ft2 of air intake per com-pressor unit horsepower. The ventilation fansshould cycle by thermostatic control.

• All machine room ventilation equipment mustbe field supplied. Check local codes for variances.

• Proper ventilation provides airflow across thecompressors. Duct work may be necessary.

• Provide a floor drain for disposal of condensatethat may form on the compressor unit.

• Equipment must be located in the machine roomto provide enough working space for service personnel, and to meet electrical codes.

• Consult NEC National Fire Handbook particu-larly “Installation of Switch Boards” and“Working Space Requirements”. The figuresdemonstrate some suggested distances. Refer tolocal codes for each installation.

P/N 311859E1 - 8


ExhaustFan

Baffle

Exhaust Fan

Baffle

Louvers

Louvers

Baffle

Figure 1-3 Machine Room Requirements

4 ftmin

11 ftmin

2 ftmin

2 ftmin

9 ftmin

4 ftmin

4 ftmin

2 ft min

3 ftmin

2 ft min

3 ft max

UNIT PLACEMENT

When setting the units, plan in relation to the restof the equipment to be installed and existingstructures. Some minimum and maximum dis-tances are listed. Note: Piping equivalent is notthe same as linear distance.

Minimum Allowable Distances

Between a HOCA and any vertical structure(except open chain link fence) the minimumallowable distance is 4 feet.

Between one HOCA exhaust and another HOCAintake the minimum allowable distance is12 feet.

Between the sides of two HOCA units the mini-mum allowable distance is 5 feet.

On HICA and HIRU units the minimum distancebetween the Control Panel and a wall is 3 feet.

On HICA and HIRU units the minimum distancebetween the Control Panel and a another livepanel is 4 feet.

On HICA units the minimum distance betweenthe Condenser Air Intake and a louvered wall is2 feet.

Maximum Allowable Distances

When piping a suction riser the maximum verti-cal distance between P-traps is 20 feet.

When piping from HIRU to a Condenser, themaximum allowable piping equivalent is100 feet.

SHIPPING BLOCK REMOVAL

Units are shipped with blocks under each com-pressor foot to prevent transit damage. Loosenthe mounting spring nuts at least one full turnand remove the blocks.

Adjust the torque on the mounting spring nuts sothat the compressor feet are 1 inch above theunit’s base.

P/N 311859E1 - 9


OVERVIEW

This section details the refrigeration process bytracking the refrigerant flow through the systemcomponents. Heat Reclaim, Demand Coolingand Reverse Cycle Defrost are covered here.See Piping for piping guidelines.

In this instruction the following constants aremaintained to assist the reader.

In the diagrams refrigerant flow direction is gen-erally clockwise.

Electrical solenoid valves carry the same initialabbreviations as in the electrical schematics.

Each specific refrigerant state and pre s s u remaintains the same fill pattern throughout theinstruction.

Vapor - hot high pressure...............

Vapor - warm high pressure...........

Liquid - warm high pressure .........

Vapor - cool low pressure ..............

REFRIGERATION CYCLE

Beginning with the Compressor, vapor refriger-ant is compressed into the Discharge Line.

P/N 311859E2 - 1


REFRIGERATION PROCESS

A 3 - Wa y Heat Reclaim Va l v e (HS) directsthe refrigerant to either the condenser or aHeat Reclaim Coil. When the HS solenoid isd e - e n e rgized, the valve directs the refrigerantto the condenser.

The C o n d e n s e r d i s c h a rges the unwanted heatfrom the system.

Low Ambient Contro l s include Fan Cycling(See Electrical Section), field supplied andinstalled louver controls (See manufacturer'smanual) and Flooding Valves. These valves maybe fixed or adjustable. The adjustable floodingvalve works in parallel with a 20 pound diff e r-ential check valve.

The fixed flooding valve maintains head pressurein response to a charge in its dome.

The R e c e i v e r acts as a vapor trap and suppliesthe Liquid Line with quality liquid refrigerant.

A Liquid Line Drier removes moisture and contaminants from the refrigerant.

The Sight Glass allows service personnel toview refrigerant flow inside the liquid line.

The Liquid Line Solenoid Valve closes offrefrigerant supply to the evaporator.

The T E V, located in the merchandiser, metersliquid refrigerant through its orifice to the lowpressure side of the system where it evaporates,absorbing heat from the coil.

P/N 311859E2 - 2


A SORI or EPR Valve ( E P R ) may be used tocontrol the evaporator temperature by preventingthe evaporator pressure from dropping below aset point.

The A c c u m u l a t o r catches liquid refrigerant inthe suction line and provides a means for it toboiloff before it reaches the compressor.

A Suction Filter is placed upstream of the compressor to remove system contaminants fromthe refrigerant vapor.

At critical locations along the refrigerant path,service valves or ball valves allow isolation ofcomponents.

HEAT RECLAIM VALVE

A 3 - Wa y Heat Reclaim Valve directs the refrigerantto either the Condenser or a Heat Reclaim Coil.When the solenoid is de-energized the valve directsthe refrigerant to the condenser.

The pilot valve, a check valve, is directional. W h e nthe solenoid is de-energized, the high pressure inletis stopped and the passage between suction andvalve chamber is open. When the solenoid is e n e rgized, the suction outlet is stopped and the passage between high pressure and the valve chamber is open.

"B" version of the valve has a bleed port throughthe drive piston to the suction manifold. T h ebleed port provides a vent for fluids trapped inthe Heat Reclaim circuits during normal opera-tion.

When installed with Reverse Cycle Defrost, theHeat Reclaim Valve is installed upstream of theReversing Valve and the return enters the line tothe condenser downstream of the ReversingVa l v e .

P/N 311859E2 - 3


HEAT RECLAIM DESCRIPTION

Hussmann Heat Reclaim uses the heat normallydischarged to the atmosphere from the condenserto provide heat to the store.

Heat reclaim is available on 3 hp and larg e rHussmetic condensing units, either indoor aircooled, water cooled, or remote condensers.Heat Reclaim is not applicable to outdooru n i t s . It is also not normally applied to coolersor preparation areas because of their limited heatreturn.

Normally, the heat reclaim system will supply al a rge percent of the total heat required for asupermarket. But, because of the many variablesinvolved, supplemental booster heat is advisedand should be installed.

The principle behind heat reclaim is that the hotd i s c h a rge gas that normally passes through thecondenser is routed first through the heat reclaimcoil and then to the condenser. This has a built-insafety feature so that a failure occurring in thestore air handling system will not affect therefrigeration equipment.

The complete heat reclaim system includes thefollowing:

A. Heat Reclaim Valve Kit for each HICA,H I C W or HIRU unit from which heat will bereclaimed.

B. Multi-circuited Heat Reclaim Coil foreach store.

C. Control System, usually either an environ-mental control panel or a two state heating ther-mostat.

Installing Heat Reclaim systems requires:A. Location and mounting of the heat reclaim

coil.B. Piping between heat reclaim coil and con-

densing units with heat reclaim valve kit.C. Electrical interconnection of the heat

reclaim control to the heat reclaim valves.

LOCATION AND MOUNTING

The heat reclaim coil is installed in the duct sys-tem of the air handler and is integrated with thestore heating and air conditioning systems. T h ecoil is installed downstream of the air condition-ing coil and upstream of any booster heatersinvolved with the duct work.

Whenever possible, air should enter the coil onthe refrigerant outlet side of the coil. If neces-s a r y, for more desireable location of headerstubs, the coil can be rotated such that the air-f low will be reversed (into the gas inlet) .H o w e v e r, the liquid outlet(s) must always belower than the gas inlet(s). The heat reclaim coilmust be located so the refrigerant piping neitherto nor from the heat reclaim coil exceeds 100 lin-eal feet each, and should not be more than 3 feetbelow the compressor unit.

Allow sufficient space between the coil and thebooster heater so radiant heat from the boosterheater will not affect the coil. Duct transitionmust be constructed to allow even air distribu-tion through the heating coil. The distance for atransition should be sufficient for an expansionratio of 4:1 on the inlet side and a contractionratio of at least 3:1 on the outlet side.

When heat reclaim coils are mounted in abruptexpansions downstream from the air discharges,it is very difficult to achieve even velocitiesacross the face of the coil because air distribuitonis poor. If it becomes necessary to place duct

P/N 311859E2 - 4


coils in this arrangement, then a 50% free airperforated plate is recommended to improve performance. This method will give good air dis-tribution across the duct coil without significanteffect on airflow rate or static pressure. The platemust be posisitoned at a distance from the fanoutlet of 1.5 times the diameter of the fan. Anyother location will not give acceptable performance.

Here, the heat reclaim coil is mounted down-stream from the air conditioning coil in an airhandler.

LOW AMBIENT CONTROLS

Adjustable Flooding Valve with Diff e re n t i a lCheck Valve

The Adjustable flooding valve maintains headpressure in low ambient conditions by reducingthe available condensing area. When restrictingliquid refrigerant flow from the Condenser, theAdjustable flooding valve prevents the liquidrefrigerant from leaving the Condenser as fast asit is forming, so the Condenser floods with itsown condensate.

During high ambient conditions, the inlet pressure on the seat disc exceeds the force of theadjusting spring and the valve stays open.

During low ambient conditions the head pressuredrops. As the inlet pressure on the seat disc falls,the force of the adjusting spring pushes the seatdisc toward a closed position. As the valve closesit throttles the refrigerant flow out of the condenser.

Since the Adjustable flooding valve responds tolow head pressure by throttling the liquid returnline to the receiver, the receiver pressure tends todrop even further. To maintain receiver pressurethe adjustable flooding valve is applied with aparallel differential check valve requiring about20 pressure pounds to open. If the receiver pres-sure drops below the condenser pressure by 20pounds, the check valve opens directing compressor discharge vapor into the receiver tomaintain sufficient high side pressure for T E Voperation.

P/N 311859E2 - 5


Fixed Flooding Valve

The Fixed Flooding Valve maintains head pressure in low ambient conditions by reducingthe available condensing area. When restricting liquid refrigerant flow from the Condenser, theFixed Flooding Valve prevents the liquid refrig-erant from leaving the Condenser as fast as it isforming, so the Condenser floods with its owncondensate.

During high ambient conditions the inlet pressure from the Bypass exceeds the force onthe diaphragm from the pressure in the dome.The passage from the condenser inlet to thereceiver outlet stays open.

During low ambient conditions the head pressuredrops. As the bypass inlet pressure falls, theforce on the diaphragm from the pressure in thedome pushes the seat disc toward a closed position. As the valve closes it throttles therefrigerant flow out of the condenser and opensthe bypass. The opened bypass directs compres-sor discharge vapor into the receiver to maintainsufficient high side pressure for TEV operation.

Notes:• The Fixed Flooding Valve is not recommendedfor use with fan cycling controls.• In some installations check valves may berequired to prevent migration of refrigerant dur-ing off-cycle periods.

LIQUID LINE SOLENOID VA LV E

The Liquid Line Solenoid Valve closes off refrig-erant supply to the evaporator.

When the Solenoid is de-energized, the Va l v ePort ➀ is held closed. Higher Pressure ➁upstream fills the Valve Chamber ➂ through theEqualizing Port ➃ , keeping the Valve closed.

In refrigeration the Valve Port ➀ opens, empty-ing Valve Chamber ➂ faster than the EqualizingPort ➃ can fill it. Higher Pressure ➁ upstreamforces the Valve open.

N o t e : If a liquid line solenoid valve is used withReverse Cycle Defrost it must be a bi-flow type.Otherwise, a check valve must be piped aroundthe solenoid to allow reverse flow during defrost.

P/N 311859E2 - 6


TEV

The Thermal Expansion Valve regulates refriger-ant flow into the evaporator by responding to thetemperature of superheated vapor at the outlet ofthe evaporator.

Note: With Reverse Cycle Defrost, the evapora-tor piping and expansion valve assembly are thesame as in Koolgas merchandisers.

Before attempting to set a TEV be sure the mer-chandiser is within 10˚F of its normal operatingrange. Attach temperature probes at both theT E V bulb location (under the clamps), andbetween the TEV and the evaporator Inlet.

P/N 311859E2 - 7


While the valve is hunting the temperature d i fference between the two probes should notexceed 3-5˚F. The differential may fall to zero.To reduce differential, turn the adjusting stemcounter clockwise and wait at least 15 minutesbefore checking results.

Valve RecommendedBody Adjustment

G 1⁄2 turnBF 1⁄4 turn

EPR VALVE

Evaporator Pressure Regulator Valves respond toupstream pressure and are used to maintain aminimum evaporator temperature. The final testfor setting an EPR should always be evaporatordischarge air temperature. Basically all EPR andORI valves open on upstream suction pressurerise.

In the direct acting EPR the outlet pressureapplies equal force to both the Valve Disc ➁and the Spring Diaphragm ➀. Since outlet pres-sure on the diaphragm opens the valve, and onthe disc closes the valve, outlet pressure is negat-ed as a factor in the valve operation. The tworemaining forces on the valve disc are the SpringTension ➂ pushing it closed, and the UpstreamPressure ➃ pressing it open.

Pilot operated EPR Valves (used on some HOCAunits) require an external high pressure supply topower the main piston chamber. This high pres-sure supply must maintain a positive diff e r e n-tial of at least 50 psig above the down streamside of the valve. Lower pressure diff e r e n t i a l smay cause valve malfunction.

Achieve the desired suction pressure by balanc-ing Adjustment Spring ➀ against UpstreamSuction Pressure ➁ and Fixed Pressure CounterSpring ➂. As upstream pressure rises it closesthe high pressure inlet to the Main Va l v eChamber ➃. The downstream bleed off reducesthe Main Chamber pressure to the point thatPiston Spring ➄ and Upstream Pressure ➅ openthe main valve.

P/N 311859E2 - 8


CPR VALVE

There are basically two designs of CrankcasePressure Regulators used. On smaller units adirect acting type is sufficient. For larger units apilot operated valve is used because of the vol-ume of refrigerant flow.

In the Direct Acting CPR the inlet pressureapplies equal force to both the Valve Disc ➁

and the Spring Diaphragm ➀ . Since i n l e tpressure on the diaphragm closes the valve, andon the disc opens the valve, inlet pressure isnegated as a factor in the valve operation. Thetwo remaining forces on the valve disc are theSpring Tension ➂ pushing it open, and the

Downstream Pressure ➃ pressing it closed.

When the downstream pressure exceeds theadjusting spring force, the valve closes.

In the Pilot Operated CPR Valve theDownstream Pressure ➀ fills the Chamber ➁just below the the Adjusting Spring Diaphragm➂ . When the Downstream Pressure falls belowthe force of the Adjusting Spring, the Pilot Port➃ opens allowing upstream pressure into theValve Chamber. As the Valve Chamber fills thevalve opens. When the Downstream Pressureexceeds the Spring Force the Pilot Port is closed.

The Valve Chamber empties through Bleed Portsand the Closing Spring pulls the main valveclosed.

When the downstream pressure exceeds theadjusting spring force, the valve closes.

DEMAND COOLING

The Demand Cooling System is designed toinject saturated refrigerant into the suction cavitywhen the compressor internal head temperatureexceeds 292˚F. Injection continues until the temperature is reduced to 282˚F. If the tempera-ture remains above 310˚F for one minute thecontrol shuts down the compressor. After correcting the cause of shutdown, manual reset isrequired.

Demand Cooling is available only on LowTemperature Discus compressors using R22refrigerant.

P/N 311859E2 - 9


The System PartsTemperature SensorControl ModuleInjection Valve

The Temperature Sensor employees a NegativeTemperature Coefficient (NTC) Thermistor toprovide signals to the Control Module. The NTCresistance drops on temperature rise.

Temperature Approximate Ω˚F Reading77 90,000282 2,400292 2,100310 1,700

Probe test readings between 100,000Ω and1,600Ω usually indicate an operating probe.

Component TestingRemove power to the system. Unplug theTemperature Sensor from the Module. T h eSensor should ohm out between 1,600Ω and100,000Ω.

Leave the Sensor unplugged and restart the sys-tem. There should be no voltage between termi-nals "S" and "L2" on the Module. The inlet andoutlet sides of the Injection Valve should feel thesame temperature. After one minute the alarmrelay should trip. Remove power to the system.Press the manual reset on the Module.

Using a small piece of wire jump the Sensor cir-cuit at the female plug in the Module. Restartthe system. There should be v o l t a g e b e t w e e nterminals "S" and "L2" on the Module. The out-let side of the Injection Valve should feel colderthan the inlet side. After one minute the alarmrelay should trip. Remove power to the system.Press the manual reset on the Module.

Remove the jumper wire and plug in theTemperature Sensor.

Restart the System.

Alarm CircuitThe Alarm Circuit has three terminals in theControl Module.

"L" —Common"M" —Normally Closed"A" —Normally Open

"L" and "M" are wired into the compressor con-trol circuit so an alarm condition removes thecompressor from the line and power to theModule. A manual reset is required to call atten-tion the alarm condition.

P/N 311859E2 - 10


Alarm RelayThe Alarm Relay is activated after a one minutedelay under the following three conditions:

• When compressor discharge temperatureexceeds 310˚F.• A shorted circuit or very lowThermistorResistance.• An open circuit or very highThermistorResistance.

Operational Notes:Demand Cooling does N O T replace head cool-ing fans which are still required on low tempera-ture applications.

Temperature Sensor cable must not touch any hotsurfaces or the cable will be damaged.

SPECIAL NOTES REGARDINGCOPELAND SCROLL COMPRESSORS

Liquid InjectionCopeland’s Midpoint Liquid Injection is standardon all low temperature (ZF) scroll compressormodels. A precision sized capillary tube mountedon the compressor is fed from the unit liquid lineafter the drier. The refrigerant flow to the capil-lary tube is controlled by a solenoid valve whichcloses when the compressor is not running. Onthe 3- to 6-HP models, a current sensing relay isincluded to close the solenoid if the compressorshuts off on internal protection.

P/N 311859E2 - 11


Figure 2-24 Liquid Injection Schematic

Oil Level MonitoringThe oil level in scroll compressors is monitoredby the Sporlan Trax-Oil device. On other appli-cations the Trax-Oil is used to regulate the flowof oil back to the compressor, but onConventional Units the Trax-Oil is used as acompressor protective device only. The Trax-Oilhas a sightglass with a float to indicate the actualoil level in the compressor. When the oil leveldrops below 1/2 sightglass for more than1 2 0 seconds, the Trax-Oil unit will open thecompressor control circuit.

Crankcase HeaterA crankcase heater is required on all outdoorscroll compressor units.

Discharge Line ThermostatA d i s c h a rge line thermostat is standard on allCopeland scroll compressors 6 HP and smaller.

AccumulatorDue to the smaller footprint of the scroll com-pressors, factory installed accumulators will nowbe available as an option on these units.

Phase MonitorA phase monitor is standard on the scroll com-pressor units. It is a requirement that the scrolloperate with the correct direction of rotation, soa monitor is needed to maintain correct phaseorientation.

REVERSE CYCLE DEFROST

Reverse Cycle Defrost may be applied to HICAunits. The 4-Way Reversing Valve provides a twoline gas defrost by switching the functions of theevaporator and the condenser during defrost. T h epilot valve on the Reversing valve is a direct act-ing reversing valve. The valve is installed so thatsolenoid failure leaves the unit in refrigerationm o d e .

N o t e s :• If a liquid line solenoid valve is used with ReverseCycle Defrost it must be a bi-flow type.• If a fan cycling control is used on the condenser,a bypass relay keeps the fans running duringd e f r o s t .• With Heat Reclaim the Valve is installedupstream of the Reversing Valve and the returnenters the line to the condenser downstream of theReversing Valve. Heat Reclaim is locked out dur-ing defrost.• 71⁄2 through 15 hp units use two parallelb i -flow driers. 20 hp and above use a standard drierand check valve together in parallel with a secondcheck valve for reverse flow.

P/N 311859E2 - 12


Figure 2-25 Pilot Valve Operation

P/N 311859E2 - 13


Figure 2-26 Reversing Valve Connections Figure 2-27 Heat Reclaim withReverse Cycle Defrost

P/N 311859E2 - 14


Figure 2-28 Reverse Cycle Defrost—Refrigeration and Defrost Modes

P/N 311859E2 - 15


TEMPERATURE CONTROL

Varied applications, temperature ranges, piping runs, machine selection and placement, along with thecustomer needs, all affect the selection of temperature control devices. Five methods of controllingtemperature are listed below along with advantages and disadvantages of each method.

METHOD ADVANTAGES DISADVANTAGES

Thermostat + Quick compressor response – No positive refrigerant shutoff—possible liquid migrationcontrolling to suction line (not recommended for long off cycles)CompressorMotor + Less short cycling than with pressure control – Requires stat to control panel wiringContactor

+ Thermostat is part of compressor control circuit – Thermostat voltage is the same as the control panel voltage

Thermostat + Reduces liquid migration to suction line – Slower compressor responsecontrolling by pumping down at cycle endLiquid LineSolenoid on + Same solenoid acts for defrost pumpdown – Requires stat to control panel wiringCompressorUnit + Convenient for installation and service – Compressor may short cycle(Compressorrun controlled + Thermostat is part of control panel circuit – Thermostat voltage is the same as the control panel voltageby pressure)

– Oil foaming during pumpdown

Thermostat + Reduces liquid migration to suction line – Slower compressor responsecontrolling by pumping down at cycle endLiquid LineSolenoid at + Same solenoid acts for defrost pumpdown – Compressor may short cycleEvaporator(Compressor + Requires no stat to control panel wiring – Oil foaming during pumpdownrun controlledby pressure) + Quick evaporator response

+ On walk-ins the circuit may be used witha door switch

*EPR Valve + Provide the most consistent humidity – Decrease compressor efficiencywith and temperature controlThermostat

– May increase compressor short cycling during low loadconditions without unloader

Low + Simple control panel – Suction line must be run so ambient conditions do not affectPressure evaporator performanceControlonly + Suitable for non-critical Medium Temperature – Unsuitable for products requiring a narrow temperature range

applications to maintain shelf life

– Unsuitable for HOCA or HIRU in low ambient application

– May increase compressor short cycling during low loadconditions without unloader

– During low load and low ambient conditions refrigeration may continue below desired cutout temperature

*EPR Valves are required as primary temperature control with a thermostat as secondary control for all service deli and meat merchandisers.

OVERVIEW

This section deals with the information neces-sary for installing the refrigeration lines forConventional Units. The Conventional Units arepiped as completely as practical at the factory.Field piping requires only interconnection of themajor components and the refrigerators.

Use only clean, dehydrated, sealed refrigerationgrade copper tubing. Use dry nitrogen in thetubing during brazing to prevent the formationof copper oxide. All joints should be made withsilver alloy brazing material, and use 35% silversolder for dissimilar metals.

REFRIGERATION LINE RUNS

Liquid lines and suction lines must be free toexpand and contract independently of each other.Do not clamp or solder them together. Run supports must allow tubing to expand and contractfreely. Plan proper pitching, expansion allowance,and P-traps at the base of all suction risers. Uselong radius elbows to reduce line resistance andbreakage. Avoid completely the use of 45˚ elbows.Install service valves at several locations for easeof maintenance and reduction of service costs.These valves must be UL approved for 450 psigminimum working pressure.

P/N 311859E3 - 1


Always use a Pressure Regulator on thenitrogen tanks.

WARNING

COMPONENT PIPING

Support Detail

Floor Run Ceiling Run

Figure 3-1 Supporting Refrigeration Lines

Through Walls or FloorsRefrigeration lines run through walls or floorsmust be properly insulated. Avoid running linesthrough the refrigeration cases. When this is done,the lines must be adequately insulated—Armaflexor equivalent.

From Machinery to Solid ObjectWhen mounting lines from machinery to a solidobject, allow line freedom for vibration to prevent metal fatigue.

P-Trap ConstructionA P - Trap must be installed at the bottom of allsuction risers to return oil to the compressors.

Reduced RiserWhen a reduced riser is necessary, place thereduction coupling downstream of the P-Trap.

Factory Supplied StubsStub sizes provided do not automatically correspond to the line sizes necessary. It is theinstaller's responsibility to supply reduction couplings.

Protecting Valves and ClampsWhen brazing near factory installed clamps orvalves be sure to protect them with a wet rag toavoid overheating.

P/N 311859E3 - 2


Connecting Remote Condenser• Discharge Line will be routed directly to the condenser inlet stub with a purge valve at the highestpoint.• Liquid Return Line will be pitched downstream,and provide trapless drainage to the receiver.

Purge Valve LocationThe purge valve will be installed at the highestpoint of an inverted P-trap, with at least a 3-inchrise. (Use with approved recovery vessel.)

P/N 311859E3 - 3


Vent the Receiver Safety Relief Deviceproperly.

WARNING

Heat ReclaimValve

Bleed Lineto Suction

Receiver

Liquid Return Line

Fixed Flooding Valve

Fixed Flooding Valve Piping

All Pipingand Valvesin this boxare fieldsuppliedandinstalled.

Header Endof Condenser

Heat Reclaim Valve

3" MinRise

FromHeat

Reclaim

Bleed Lineto Suction

To HeatReclaim

12" Min

Pitch 1/4" per Foot

ReceiverLiquid ReturnLine

AdjustableFlodingValve

DifferentialCheckValve

Heating Coil

Figure 3-6 HIRU to Condenser Piping

Purge Valve Service Valve

Ball Valve

Check Valve

Discharge Lines

Liquid Return Lines

MERCHANDISER PIPING

Suction Line• Pitch in direction of flow.• May be reduced by one size at one-third of caserun load and again after the second third. Do notreduce below evaporator connection size.• Suction returns from evaporators enter at thetop of the branch line.

Liquid LineOfftime and Electric Defrost• May be reduced by one size after one-half thecase load run. Do not reduce below evaporatorconnection size.• Take-offs to evaporators exit the bottom of theliquid line. Provide an expansion loop for eachevaporator take-off. (Minimum 3 inch diameter.)

Reverse Cycle Defrost• Merchandisers on Reverse Cycle Defrost arepiped and equipped like Koolgas cases.• Maximum of 6 evaporators per Unit.• Increase the liquid line size inside the case bytwo sizes.

Line Size In Case Size1⁄2 7⁄85⁄8 11⁄87⁄8 13⁄811⁄8 15⁄813⁄8 21⁄8

• Take-offs to evaporators exit the bottom of theliquid line. Provide an expansion loop for eachevaporator take-off. (Minimum 3 inch diameter. )

P/N 311859E3 - 4


Field Connection of Heat ReclaimEach circuit of the heat reclaim coil is tagged tocorrespond with a specific condensing unit andmust be connected only to that unit.

The supply and return lines are to be installed asshown in Figure 3-6.

SPECIAL PIPING FOR OPEN ROOMS

An open preparation room allows heat infiltra-tion from the rest of the store at a rate which mayjeopardize total refrigeration performance. Toprotect the refrigeration system, open preparationroom evaporators must be piped with aCrankcase Pressure Regulating Valve (CPR).

The CPR is field installed in the suction line(s)from the evaporator(s). The installer is responsi-ble for proper adjustment of the Valve.

RUN LENGTHS AND EQUIVALENT FEET

When figuring run lengths, angle valves andelbow 90˚ are figured as additional straight pipe.The following chart gives equivalent lengths forthese components.

Table 3-1 Equivalent Feet forAngle Valve and Elbow 90˚*

*ASHRAE 1994 Refrigeration Handbook

INSULATION

For merchandisers and unit coolers with G A SDEFROST:The suction and liquid lines should NOT contacteach other and should be insulated separately fora minimum of 30 ft from the merchandiser.

For merchandisers and unit coolers withOTHER than gas DEFROST:The suction and liquid lines should be clampedor taped together and insulated for a minimum of30 ft from the merchandiser.

FOR ALL merchandisers and unit coolers: Additional insulation for the balance of the liquidand suction lines is recommended wherever con-densation drippage is objectionable or the linesare exposed to ambient conditions.

P/N 311859E3 - 5


Tubing Size Angle Valve Long Radius

Elbow 90˚1⁄2 6 1.05⁄8 7 1.27⁄8 9 1.4

11⁄8 12 1.7

13⁄8 15 2.3

15⁄8 18 2.6

21⁄8 24 3.3

25⁄8 29 4.1

31⁄8 35 5.0

35⁄8 41 5.9

41⁄8 47 6.7

OVERVIEW

The scope of this section is limited to main fieldwiring connections, and to the control panel.

The standard Custom Conventional Unit isavailable wired for 208-230/3/60 or 460/3/60compressors. In either case, the control circuit is2 0 8 - 2 3 0 V.

Q u a d - Ventionals with 208V compressors have asingle point connection. With 460V c o m p r e s-sors, two single point connections are used, onefor the compressors and one for the control anddefrost circuits.

Refer to the serial plate located on the controlpanel to determine wire size (MCA) and over-current protection (MOPD).

FIELD WIRING

Unit components are wired as completely as possible at the factory with all work completedin accordance with the National Electrical Code(NEC). All deviations required by governingelectric codes will be the responsibility of theinstaller.

The lugs on the circuit breaker package in thecontrol panel are sized for copper wire only, with7 5O C T H W insulation. All wiring must be incompliance with governing electrical codes.

For 208-230/3/60 Compressor Units:To each Unit provide

one 208-230/3/60 branch circuit

For 460/3/60 Compressor Units:To each Unit provide

one 460/3/60 branch circuitone 208-230/3/60 branch circuit

WIRING GUIDELINES BASED ON VARIOUS COMPONENTS

Check the store legend for components requiringelectrical circuits to either the compressor unit orthe defrost control panel.

These include:-Defrost Termination Thermostat-Thermostat controlling a Motor Contactor

All thermostat and temperature sensor wiresshould be sized for pilot duty at 120VA 120VAC.Run a 2-wire circuit for each system using eithercontrol listed above.

Unit Cooler Fan WiringProvide a 120/1/60 fused power supply for eachc o o l e r. (Check the store legend to see if 208-230/1/60 is required at this location.) 208V forpower can be picked up from the time-clock oran optional breaker/contactor kit.

Evaporator Mounted Liquid Line SolenoidPower for a liquid line solenoid in the case canbe picked up from the fan circuit. (Check fanmotor and solenoid voltages first.)

Cooler Door Switch WiringCheck the store legend for door switch kits(M115 or M116). The switch must be mounted tothe cooler door frame, and must be wired to control the field installed liquid line solenoid andthe fan circuit. For Reverse Cycle Defrost appli-cations, Kit M116 includes a check valve tobypass the liquid line solenoid valve.

Sizing Wire and Overcurrent ProtectorsCheck the serial plate for Minimum CircuitAmpacity (MCA) and Maximum OvercurrentProtective Devices (MOPD). Follow NECguidelines.

P/N 311859E4 - 1


ELECTRICAL

Defrost ControlsThe basic defrost circuits are shown on thewiring diagrams in this section. These circuitsmay be repeated and/or intermixed in one store.

Other ControlsWhen other controls are used, refer to the manu-al included with that control.

ABOUT THESE ELECTRICAL DIAGRAMS

All diagrams show the electrical sys tem D E -e n e rgized and in refrigeration mode.Diagrams emphasize individual circuit continuityand logic. They aid troubleshooting and testingby identifying point-to-point connections. Colorcoding wires allows easy transfer to the controlpanel. The diagrams normally move from left toright so the user can "read" the series of compo-nents and their terminals which make up a circuit.

Generally, in a control circuit the loads are limit-ed to coils, lights, and bells. By identifying onecontrol circuit load and "reading" the schematicto the load, the sequence of operation becomesobvious. Troubleshooting that circuit then breaksinto test point terminals. Take only one circuit ata time.

Important Note:The diagrams in this section show circuit logic.They are not intended for troubleshooting ordesign work. For Unit Cooler fan power, electricdefrost sub circuit balance, and other locationspecific circuits refer to the schematics on control panels or contact Hussmann Engineering.

DEFROST TIMERS

G e n e r a l l y, one of four time clocks will be usedon a Conventional Unit for defrost control. Eachis used because it fills the needs of a particularapplication.

8145 Indoor Clock

APPLICATIONS

Temperature Range- MediumLow

Types of Defrost- ElectricReverse AirOff-TimeReverse Cycle

Types of Termination- TimeTemperature

SEQUENCE OF OPERATION

On call for defrost contacts 1 - 3 close and 2 - 4open. On call for termination contacts 1 - 3open and 2 - 4 close.

P/N 311859E4 - 2


TIM

E

T U

RN

KN

OB

110100

90

8070

60

5040

30

2

1020

TU

RN

KN

OB

12

34

5

78

9

1011

12

3

45

6 7 8

910

11

6

NIG

HTN

OO

N MID

G

1N

4X

2

3

8145

X

N

2

4

1

3

T

Figure 4-1 8145 Timer

8245 Indoor Clock

APPLICATIONS


Types of Defrost- ElectricReverse AirOff-Time

Types of Termination- Pressure


On call for defrost contacts 1 - 3 close and 2 - 4open. On call for termination contacts 1 - 3open and 2 - 4 close.

A633 Outdoor Clock

APPLICATIONS


Types of Defrost- ElectricReverse AirOff-Time

Types of Termination- TimeTemperature


On call for defrost contacts 3 - 1 open.Four minutes later contacts 2 - 4 open and 3 - Nc l o s e .On call for termination contacts 3 - N open and3 - 1 close, contacts 2 - 4 close.

P/N 311859E4 - 3


TIME

TU

RN

KN

OB

110

100

90

8070

60

5040

30

2

1020

T U

RN

KN

OB

12

34

5

7 89

10111

2

34 5

678

910

11N

IGH

T NO

ONM

ID

1 N

4X

2

3TM

8245

Pressure SettingAdjustable Screw

Increase

Pressure Range36 to 110 psi

Cut-in Pressure

X

N 2

4

1

3

T

Figure 4-2 8245 Timer

TIM

E

T U

RN

KN

OB

110100

90

8070

60

5040

30

2

1020

TU

RN

KN

OB

12

34

5

78

9

1011

12

3

45

6 7 8

910

11

6

NIG

HTN

OO

N MID

G

1 N 4T

X23

A-633

X N

2

41

3T T

SRSB

Pumpdown SolenoidPumpdown Switch

Figure 4-3 A633 Timer

CD104MB Indoor Clock, for Defrost Duration over 110 minutes.

APPLICATIONS

Temperature Range- MediumTypes of Defrost- Off-TimeTypes of Termination- Time

On call for refrigeration contacts 1 - 2 and 4 - 3 close.

HEAT RECLAIM CIRCUITS

Heat Reclaim Solenoids often have a power supply separate from the HICA, HOCA o rHIRU. Heat Reclaim requires a PumpdownSolenoid which is energized while the compres-sor is running.

When Reverse Cycle Defrost is used, the HICAwill have a lockout relay to keep Heat Reclaimfrom operating during defrost. The LockoutRelay Coil is energized during defrost, openingthe Heat Reclaim Circuit.

P/N 311859E4 - 4


FAN CYCLINGCIRCUITS

Condenser fans come on with thec o m p r e s s o r. In addition a pressuretype fan cycling control may beused.

A single fan is spliced into theOrange and Brown wires in thecompressor terminal box. If a fancycling control is added, it is placedin series with the fan.

On Fan Banks a fan contactor con-trols the 3 phase power to the fans.The Fan Contactor Coil is wiredparallel to the Compressor MotorContactor Coil.

Fan Cycling Control is spliced intothe Orange wire in the CompressorTerminal Box. If the #1 Fan iscycled with the compressor it isspliced into the Orange and Brownwires in the Compressor Te r m i n a lBox. Fans #2 thru #6 remain wiredas shown.

With Variable Speed Fan Control,while the compressor is running thefan RPM is reduced as the con-denser pressure drops below a setpoint.

P/N 311859E4 - 5


Since Reverse Cycle Defrost usesthe ambient heat around the con-denser to defrost the merchandisere v a p o r a t o r, the condenser fansneed to be running during defrost.Reverse Cycle Defrost includes aBypass Relay parallel to thecycling control. This N o r m a l l yClosed Relay is e n e rgized dur-ing Refrigeration mode. InDefrost the de-energized relaycompletes a circuit around thecycling control.

Should the Bypass Relay fail, thefans will cycle with the compres-sor.

P/N 311859E4 - 6


440V COMPRESSORS

When 440V compressors areused a second power supplyof 208/230V 3Ph must bewired to the control panel forfans and control circuits.

ELECTRIC DEFROST

Sub Breaker Wiring to themerchandisers must be doneto provide good phase bal-ance from the DefrostC o n t a c t o r. Individual mer-chandiser amp loads must betaken in to account.

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Special Provisions forCopeland Scroll Compressors:

Liquid InjectionCopeland’s Midpoint Liquid Injection is standardon all low temperature (ZF) scroll compressormodels. A precision sized capillary tube mountedon the compressor is fed from the unit liquidline after the drier. The refrigerant flow to thecapillary tube is controlled by a solenoid valvewhich closes when the compressor is not run-ning. On the 3 – 6 HP models, a current sensingrelay is included to close the solenoid if the com-pressor shuts off on internal protection.

Discharge Line ThermostatA d i s c h a rge line thermostat is standard on allCopeland scroll compressors 6 HP and smaller.The thermostat will prevent discharge line tem-perature from exceeding 250°F and it is to belocated on the discharge line 6 inches from thed i s c h a rge service valve. Refer to diagrambelow for wiring detail.

Oil Level MonitoringThe oil level in scroll compressors is monitoredby the Sporlan Trax-Oil device. On ConventionalUnits the Trax-Oil is used as a compressor protective device only. The Trax-Oil has a sightglass with a float to indicate the actual oil levelin the compressor. When the oil level dropsbelow 1⁄2 sight glass for more than 120 seconds,the Trax-Oil unit will open the compressor control circuit.

Phase MonitorA phase monitor is standard on the scroll ( 3-phase ) compressor units. It is a requirement thatthe scroll operate with the correct direction ofrotation, so a monitor is needed to ensure correctphase orientation. The phase monitor will openthe control circuit if the phases are not alignedproperly as well as for low voltage, loss ofphase, and voltage unbalance. If the phasesequence is incorrect switch two of the incomingpower legs to the unit. As a further check thepumping direction of the compressor should beverified. (See Start-Up, Section 5.)

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Figure 4-16 Wiring for Discharge Thermostat, Trax-Oil, and Liquid Injection

Figure 4-15 Current Sensing Relay Wiring

A D D I T I O N A L TIMER CIRCUITSWITH REVERSE CYCLE DEFROST

If a Drip Cycle is desired at the end ofDefrost, a Time Delay Relay is added.The Relay Coil is wired between "4" and"N" on the defrost timer and has anadjustable delay on circuit make. T h enormally open contacts are wired from"2" on the timer to "TR." If the relayfails, the system will not refrigerate.

When used, a Fan Cycling Bypass RelayCoil is wired between "4" and "N" on thedefrost timer. The normally closed con-tacts are wired parallel to the fan cyclingcontrol. If the relay fails the fans willcycle with the compressor.

A Heat Reclaim Lockout Relay is requiredwith Heat Reclaim. Its Coil is wiredbetween "3" and "N" on the defrost timer.The normally closed contacts are wired inseries with the Heat Reclaim Solenoid. Ifthis relay fails Heat Reclaim may remainon during the defrost cycle.

The Reverse Cycle Defrost Solenoid isWired between "3" and "N" on the defrostt i m e r. Because of system capacityrequirements a Ranco valve with a 24VSolenoid is used on larger systems. A2 0 8 / 2 3 0 V by 24V Class 2 transformer iswired between "3" and "N" on the defrosttimer. The Transformer powers the ValveSolenoid during defrost.

If the Solenoid or Transformer fail thesystem will be left in refrigeration mode.

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Figure 4-17 Timer Circuits with Reverse Cycle Defrost

HEAT RECLAIM TWO STAGE THERMOSTAT

The thermostat should be located in an areawhere air discharge grilles create an average airmix of normal store air. This will prevent it frombeing affected by abnormal air conditions suchas heat from appliances and lights; cold air fromrefrigerated fixtures, doors and windows; and airfrom heating and cooling air discharge outlets.

The heat reclaim valve solenoid coil requires a120V power supply. Wire additional heat reclaimvalves in parallel. All wiring should be in accor-dance with NEC and governing electrical codes.

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Figure 4-18 Heat Reclaim Schematic5

STARTUP

Leak TestingVisually inspect all lines and joints for properpiping practices.

ISOLATE

Compressors—Front-seat Service Valves onSuction and Discharge.

Pressure Transducers—Close Angle Valves.

OPEN

Valves—to condenser, heat reclaim, receiver.

Liquid Line Solenoid Valve—Solenoid should beenergized.

DISCONNECT

Defrost Time Clock—Disconnect power to theclock.

VERIFY

Refrigerant requirements for System, Compres-sors, and TEV's in merchandisers and coolers.

Electrical supply and component requirements.

Test ChargeUse properly regulated dry nitrogen and refriger-ant mixture to pressurize the system with vaporonly. Bring the system pressure up to 150 psig.Use an electronic leak detector to inspect all con-nections. If a leak is found, isolate, repair, andretest. Be sure system is at 150 psig and allvalves closed to isolate the leak are opened.After the last leak is repaired and retested, thesystem must stand unaltered for at least 12 hourswith no pressure drop from 150 psig.

Oil LevelsCheck oil levels for the compressor:

Compressor sight glass 1⁄8 to 1⁄2 full

If oil level is low, add recommended oil only:

Copeland CarlyleR22 Suniso 3GS Suniso 3GS

R404A/ Mobile EAL ICI EmkarateR507 ARCTIC 22 CC RL68H

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Know whether a circuit is open at the power supply or not. Remove all power before openingcontrol panels. Note: Some equipment has more than one power supply.

Always use a pressure regulator with a nitrogen tank. Do not exceed 2 pounds of pressure andvent lines when brazing. Do not exceed 350 pounds of pressure for leak testing high side. Do notexceed 150 pounds of pressure for leak testing low side.

Always follow current EPA regulations and guidelines.

Warning

STARTUP, CONTROL SETTINGS, AND SERVICE

Always recapture test charge inapproved recovery vessel

for recycling.

Warning

E v a c u a t i o nNitrogen and moisture will remain in the systemunless proper evacuation procedures are followed. Nitrogen left in the system may causehead pressure problems. Moisture causes T E V i c eblockage, wax build up, acid oil, and sludge for-m a t i o n .

Do not simply purge the system—this procedureis expensive, harmful to the environment, andmay leave moisture and nitrogen behind.

Do not run the compressor to evacuate—thisprocedure introduces moisture into the compres-sor's crankcase oil and does not produce ade-quate vacuum to remove moisture from the restof the system at normal temperatures.

SE T U P

Using all copper lines and packless valves, con-nect an eight CFM or larger vacuum pump to a7⁄8-inch header and from the header to the accessport on both the suction and discharge of theCompressor. Connect one micron vacuum gaugeat the pump and one at the furthest point in thesystem from the compressor. Plan procedures sobreaking the vacuum with refrigerant will notintroduce contaminates into the system. The vac-uum pump must be in good condition filled withfresh oil to achieve desired results.

PROCEDURE

Pull a vacuum to 1500 microns. If the vacuumfails to hold, determine the cause and correct.Begin again with the first of the three requiredevacuations.

Break the vacuum with R22 vapor to a pressureof about 2 psig. Do not exceed the microngauge transducer's maximum pressure limit.Liquid refrigerant may cause damage to compo-nents through thermal shock or a pressure surg eto the transducer of the micron gauge.

Repeat first two steps.

Install the suction and liquid drier cores.

Pull a vacuum to 500 microns. Close vacuumheader valves and allow system to stand for aminimum of 12 hours. If the 500 micron vacuumholds, charging may begin. If not, the cause mustbe determined and corrected. Repeated the entireevacuation procedure from the first step.

PRE-CHARGE CHECK LIST

While the system is being evacuated preparationfor charging can begin. During any of the pulldowns check:

MerchandisersElectrical requirements and power supplyElectrical connections tight and cleanProper fan operationThermostat setting.

Walk-in coolers and freezersElectrical requirements and power supplyElectrical connections tight and cleanProper fan operationThermostat setting.

CondensersElectrical requirements and power supplyElectrical connections tight and cleanProper fan operationThermostat or pressure settingsDamper operation, if equipped.

Heat Reclaim and other systemsElectrical requirements and power supplyElectrical connections tight and cleanComponent operation.

Note: Remember to reinstate control to unitcomponents jumpered to make tests.

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Never trap liquid refrigerantbetween closed valves.A hydraulic explosion

may result.

Warning

Set all mechanical pressure controls. Compres-sors should still be isolated from the rest of thesystem.

During the last evacuation look up and make a listof the required control settings for the system. Acopy of the equipment legend will be needed todetermine the system's design operating points.High and low pressure, heat reclaim lockout, wintercontrol settings, and other controls on the systemshould be noted.

ChargingUse standard procedures for charging whilewatching for possible problems. Check:

Suction and discharge pressureOil LevelVoltage differential and balanceAmpere draw and balance.

Shut down the unit at first indication of unusualoperation, locate and correct cause.

Leak testing, evacuation and initial charging arenow completed.

Note: With non-azeotropic refrigerants, it is bestto charge the entire contents of the cylinder toprevent fractionalization of the refrigerant whencharging vapor.

Winter ChargeWhen charging HOCA units equipped with winterHead Pressure Control (HPC) Valving, additionalrefrigerant is required for winter operation. Theadditional quantity by weight which should beadded is determined by Nominal Condenser Sizeand ambient temperature entering the condenserduring charging procedure.

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Winter Charge (pounds) for HOCA Units with HPC ValvingNOMINAL AMBIENT TEMPERATURE ENTERING CONDENSER

CONDENSER SIZE >80˚F 60˚F 40˚F 20˚F 0˚F0.5 to 1.0 5 4 2 1 0

1.5 6 6 3 1 02 10 7 4 2 0

3 20 15 10 5 04 to 6 35 25 16 8 0

7.5 to 10 50 37 24 12 0

10 to 12 70 50 32 16 015 to 20 100 74 48 24 022 to 30 120 94 56 34 0

Compressor Motor RotationTo check compressor rotation, use the followingprocedure:

1. Install gauges on suction and discharge side of compressor. A momentary compressorrun should cause a drop in suction header and a rise in discharge header pressure.

2. With main disconnect OFF, switch OFF allbreakers in the control panel.

3. Turn ON main disconnect.

4. Look for the light on the single phase pro-t e c t o r. If it is not lit, turn O F F the main disconnect. Have the field connections to themain breaker of the unit corrected so thephase protector indicates phase alignment.(The light is lit.)

5. Turn ON main disconnect.

6. Momentarily turn O N the compressor breaker and verify correct pumping direction.If the compressor is rotating backwards,change two Legs on the load side of the compressor contactor.

Note: DO NOT run compressors for more than 10 seconds during test.

Final ChecksOnce the system is up and running, it is theresponsibility of the installer to see that all thefine adjustments are made so the CustomConventional delivers maximum temperatureperformance and efficiency for the customer.These include:

Defrost scheduling and timingCondenser controlsWinter controlsEPR settingsTEV superheat adjustmentCPR settingsHigh and low pressure controlsThermostat settingsAdjustments to electronic controls.

Thoroughly inspect all field piping while theequipment is running and add supports whereline vibration occurs. Be sure additional supportsdo not conflict with pipe expansion and contrac-tion.

When merchandisers are completely stocked,check the operation of the system again.

At 48 hours of operation, replace the liquid drierand suction filter cores.

At 90 days recheck the entire system, includingall field wiring.

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CONTROL SETTINGS

Compressor Oil Failure Safety requires manualreset.

Compressor Cut-in Cut-out Time Delay(psig) (psig) (seconds)

Copeland 7-11 12-18 90-150Carlyle 4-6 9-12 45-75

High Pressure SafetyHigh pressure safety for both R22 and R404a is395 psig cut-out. Differential is fixed.

R134a safety is set at 240 psig cut-out.

Low Ambient ControlsThe customer may specify lower pressure settings than those recommended; however,refrigeration performance may be aff e c t e d .Minimum receiver pressure is 140 psig.

Refrigerant Flooding ReceiverValve Pressure

(Liquid) (Vapor)(psig) (psig)

R404a 205 185R22 175 155

EPR Settings

Evap EPR Pressure Setting (psig)Temp Refrigerant Application(OF) R404a R22–25 13 7–22 15 9–20 16 10–15 20 146 39 299 43 3212 46 3515 49 3818 53 4121 57 4425 62 4930 70 55

N O T E : The final test for proper EPR settingmust be discharge air temperature.

Condenser Fan Cycling

Refrigerant Setting (psig)R404a 220

R22 185R134a 115

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LOW PRESSURE CONTROL

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R404a Low Temp

Compressor

CIpsig

81011

131416

171920

24

COpsig

467

91012

131516

20

DesignSuctionTemp

˚F

-33-30-28

-25-23-21

-20-16-15

-10

R134a Med Temp

Compressor

CIpsig

101213

141516

182122

263035

COpsig

689

101112

141718

222631

DesignSuctionTemp

˚F

71012

141516

202325

303540

R404a Med Temp

Compressor

Caution:Never run the compressors in a vacuum.

DesignSuctionTemp

˚F

71012

141516

202325

CIpsig

404446

484950

566062

COpsig

364042

444546

525658

R22 Low Temp

Compressor

CIpsig

456

789

101213

17

DesignSuctionTemp

˚F

-33-30-28

-25-23-21

-20-16-15

-10

R22 Med Temp

CompressorDesignSuctionTemp

˚F

71012

141516

202325

30354045

CIpsig

262931

333435

394245

51576472

COpsig

202325

272829

333639

45515866

COpsig

012

345

679

13

SERVICE

This Pro c e d u re is not designed to coversystem changeover to a different refrigerant.

Compressor ReplacementSince each machine room tends to be unique,plan carefully as to how you will move the com-pressors without harming personnel, equipmentor the building. Before beginning removal of oldcompressor make replacement unit ready toinstall:

VERIFY

Replacement compressorElectrical requirementsRefrigerant applicationCapacityPiping hookup location and designSuction and discharge gasketsMounting requirements.

Have compressor in an easily accessible position, uncrated and unbolted from shippingpallet.

DISCONNECT ELECTRICAL SUPPLY

Turn off motor and control panel power suppliesto the Unit.

Turn off control circuit and open all compressorcircuit breakers.

Tag and remove electrical wires and conduitfrom the compressor.

ISOLATE COMPRESSOR

Front-seat Suction and Discharge Service Valves.

Bleed compressor pressure through both d i s c h a rge and suction access ports into anapproved recovery vessel.

Remove externally mounted components whichwill be re-used on the replacement compressor.

Plug holes to compressor manufacturer's specifications.

Disconnect suction and discharge service valves.

Remove mounting bolts.

When moving the compressor, use a come-along,hoist or hydraulic lift to carry the weight.

Do not use the piping or panel to support a hoistor come-along.

Do not use ceiling trusses to support a hoist orcome-along.

A properly constructed ceiling rail may be usedto support a hoist or come-along.

On semi-hermetic compressors, an eye bolt may beinstalled in the rear top of the compressor head tomake hookup and lifting easier.

When the old compressor has been removed,clean the suction and discharge service valvegasket surfaces to shiny metal. Clean the gasketsurfaces on the new compressor to shiny metal.Be careful not to groove or round the surfaces.Gasket surfaces must be clean to prevent leaking.

Install the new compressor in reverse order ofremoval. Be sure compressor is charged withproper oil for the application. If the compressoris less oil, charge it with the proper oil for theapplication. Do not open the new compressor tothe system until after it has been leak tested andtriple evacuated.

Replacing Drier and Filter CoresShut down the system. Isolate the core to bereplaced and bleed off pressure into an approvedrecovery vessel. Open housing, replace core andclose up. Pressurize, leak test and bring back intoline.

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