Cospolich UCR10-2M-SN-MLR User manual
ShipboardModularUndercounterRefrigerator
TechnicalManual
Installation,Operation,andMaintenanceInstructions
Models:
Cospolich, Inc. - PO Box 1206, Destrehan, LA 70047, (800) 423-7761 — www.cospolich.com
February 2012
UCR10‐2M‐SN‐MLR
UCR10‐2M‐S‐MLR
2
TableofContents
List of Illustrations................................. 3
List of Tables......................................... 4
Chapter 1 General Information......................... 5-7
1.1 Introduction.......................................... 5
1.2 Scope................................................... 5
1.3 Equipment Description........................... 5
1.4 Equipment Supplied............................... 5
Table A Leading Particulars................................. 6
Illustration 1.A Main Unit Drawing........... 7
Chapter 2 Operation.......................................... 8
2.1 Introduction.......................................... 8
2.2 Controls and Indicators.......................... 8
Table B Controls and Indicators.......................... 8
Illustrations 2.A, 2B,…........................... 9
2.3 Start-up Procedure................................. 10
Table C Start-up Procedure................................. 11
Table D Shut Down Procedures…………................ 12
2.4 Shutdown Procedure Short Term........................ 12
Table E Shutdown Procedure Short Term........................ 12
2.5 Cleaning Instructions.............................. 12-13
2.6 Extended Period Inactivity...................... 13
Table F Shutdown for Extended Period................ 13
Chapter 3 Functional Description...................... 14
3.1 System Description................................ 14
3.2 System Operation.................................. 14
Chapter 4 Scheduled Maintenance.................... 15-17
4.1 Introduction.......................................... 15
4.2 Preventive Maintenance Index................ 15
4.3 Preparation for Maintenance................... 15
4.4 Maintenance Procedures......................... 15
A. Monthly Maintenance Requirements.. 15
B. Bi-Monthly Maintenance Requirements. 16-17
C. Annual Maintenance Requirements.. 17
D. 3-Year Maintenance Requirements.. 17
Table G Preventive Maintenance.......................... 18
Chapter 5 Troubleshooting................................ 19
Table H Mechanical & Electrical........................... 19
Chapter 6 Corrective Maintenance.................... 20
6.1 Introduction.......................................... 20
6.2 Repair Procedures.................................. 20
6.2.1 Compressor Fan Motor................... 20-22
6.2.2 Low Pressure Control…………………. 22
6.2.3 Thermal Expansion Valve (TXV)..... 23
6.2.4 Filter Dryer………........................... 23
6.2.5 Condenser Fan Motor.................... 23
6.2.6 Condenser Fan Blade.................... 23-24
6.2.7 Anti-Condensate Heater Wire........ 24
6.2.8 Door Latch................................... 24
6.2.9 Door Hinge.................................. 25
6.2.10 Door Gasket...............................
25
Chapter 7 Parts List............................................ 26-28
7.1 Introduction.......................................... 26
7.2 Source Codes........................................ 26
Table I Source Codes........................................ 26
Table J Parts List UCR10-2M-SN-MLR………………. 27-28
Illustrations 7.A—7.B Condensing Unit Assy 29
Illustrations 7.C—7.E Evaporator Coil Assy 30
Illustration 7.H Control Panel Detail 32
Illustrations 7.I—7.K Door & Accessories Detail 33
Illustration s7.L—7.M Main Unit Front/Rear I 34
Chapter 8 Installation........................................ 37
8.1 Unpacking............................................. 37
8.2 Installation............................................ 37
Chapter 9 Modular Installation.......................... 38-40
9.1 Introduction.......................................... 38
9.2 Installation. Skill Level............................ 38
9.3 Tools..................................................... 38
9.4 Primary Components................................. 38
9.5 Disassembly........................................... 38-40
Chapter 10 Electrical & Mechanical............................ 41-44
10.1 Introduction.................................................. 41
Illustrations 10.A—10.C.................................... 42-44
Chapter 11 Warranty.................................................. 45
Appendix 1 Revision History………………………………. 46
9.6 Final Check List 40
Illustrations 7.F—7.G Electronic Controller Assy 31
Illustrations 7.N—7.O Main Unit Front/Rear II 35
Illustration 7.P Interior Detail 36
3
ListofIllustrations
Figure Title Pg.
1.A General Arrangement Drawing — UCR10-2M-S(N)-MLR 7
2.A RCTL09, Control Panel Assembly Detail* 9
2.B Control Panel & Condensing Unit Assemblies 9
7.A Condensing Unit Assembly, RUT220-PM, Left Side View 29
7.B Condensing Unit Assembly, RUT220-PM, Right Side View 29
7.C Evaporator Coil Assembly, RWE010-PM, Lower View 30
7.D Evaporator Coil Assembly, RWE010-PM, Fan Motor/Cover Detail 30
7.E Evaporator Coil Assembly, RWE010-PM, Interior Detail 30
7.G RWTT40-PM, Electronic Controller Digital Display Detail** 31
7.H RCTL09, Control Panel Assembly Detail* 32
7.J Shelving & Shelf Clips Detail 33
7.K Leg Detail 33
7.L Main Unit with Electronic Controller-Front Detail View 34
7.M Main Unit with Electronic Controller-Rear Detail View 34
7.N Standard Main Unit-Front Detail View 35
7.O Standard Main Unit-Rear Detail View 35
7.P Interior Detail View 36
10.A Mechanical Piping Diagram 42
10.B Electrical Schematic-Standard Controls 43
7.F RWTT40-PM, Electronic Controller Detail** 31
7.I Door Detail 33
10.C Electrical Schematic-Electronic Controls 44
4
ListofTables
Table Title Page
A. Leading Particulars 6
B. Controls and Indicators 8
C. Start-Up Procedures 11
E. Shutdown Procedures for Extended Periods 13
F. Preventive Maintenance 18
G. Mechanical and Electrical Troubleshooting Guide 19
H. Source Codes 26
D. Shutdown Procedures 12
I. Parts List - UCR10-2M-S(N)-MLR 27-28
5
Chapter1—GeneralInformation
1.1 Introduction
This technical manual provides information on the installation, operation,
maintenance, and inspection of this unit manufactured by Cospolich Inc.,
Destrehan, Louisiana. A complete parts breakdown is provided in Chapter 7.
1.2
Scope of the Manual
This technical manual provides information for installation, operating,
preventative maintenance, and service instructions, including applicable
drawings and figures of the equipment.
1.3
Equipment Description
The unit consists of the following parts:
A.
Storage Compartment
- The storage compartment is clear storage
area. Included in this area are the adjustable shelves.
B. Door(s) –
Access to the storage compartment is through hinge
mounted door(s).
C.
Condensing Unit & Controls Compartment-
The condensing unit and
controls compartment is located on the lower left of the cabinet.
Access to this compartment is through an removable grill on the
front left of the cabinet.
D.
Evaporator Coil Assembly–
The evaporator coil assembly is located
in the storage compartment and is responsible for distributing the cold
air associated with the refrigeration system.
E.
Cabinet -
The cabinet is the enclosure in which all of the above items
are housed.
1.4
Equipment Supplied
The unit is shipped from the factory fully assembled, palletized and crated to
minimize the possibility of damage in shipping and storage.
6
TableA—LeadingParticulars
MANUFACTURER: Cospolich Inc.
Destrehan, Louisiana 70047
TYPE:
MODEL:
Marine Shipboard Modular Undercounter
Refrigerator Unit
PURPOSE: Storage of Refrigerated Food Items/Perishables
ELECTRICAL
REQUIREMENTS: Power Supply - 115 Volt AC, 60 Hz, 1 Phase
RLA: 6 Amps
REFRIGERANT: 404A
DRAIN: Not Required
DIMENSIONS: 49” WIDE X 25” ACTUAL CABINET DEPTH X 28” HIGH
UCR10-2M-SN-MLR
UCR10-2M-S-MLR
7
Illustration1.A—GeneralArrangementDrawing
8
Chapter2—Operation
2.1 Introduction
These models are heavy-duty pieces of food service equipment designed for
intermittent use. They incorporate electronic controls to regulate the cycling
and temperature of the refrigeration system.
2.2
Table B—Controls and Indicators
Note: Normal operating pressures in 90ºF ambient environments for refrigerator ap-
plications (37ºF Cabinet temperature) should be 68-84 lbs Suction Pressure and 250-
300 lbs Head Pressure.
Note: Normal operating pressures in 90ºF ambient environments for freezer applica-
tions (-5ºF Cabinet temperature) should be 15-20 lbs Suction Pressure and 250-300
lbs Head Pressure.
Name Type Function
Power Switch Toggle Switch Power Control, termi-
nates all electrical into
and past the supply cord
Electronic Controller** Push Button Electronic,
L.E.D. Display Cycles refrigeration sys-
tem (automatic)
Low Pressure Switch Contact Points Cycles the refrigeration
system (automatic)
Suction Valve Manual Plunger Valve Isolate suction at the
compressor
Discharge Valve Manual Plunger Valve Isolate Discharge line at
receiver
Solenoid Valve Automatic Plunger Shuts off refrigerant flow
9
Illustrations2A,2B—
ControlPanelAssembly&CondensingUnitAssembly
Illustration 2A-RCTL09
Control Panel Assembly
Illustration 2B-Control Panel &
Condensing Unit Assemblies
10
2.3 Start-Up Procedures
The refrigeration system is completely factory assembled, pre-charged, and
ready for operation. To energize the unit, it is only necessary to find the power
supply cord and connect it to a proper 115V power source. Once the supply
cord has been connected to a power source, the unit can be started by flipping
the power control switch to the “ON” position.
NOTE:
On modular units (MLR suffix in model number) the equipment will re-
quire dismantling.
11
TableC—Start‐UpProcedure
Operation Results
1. Activate system by connecting electrical service
cord to power supply. This brings power to the control. The com-
pressor should immediately come on line
along with the condenser fan and the evap-
orator fan(s)
2. Place power switch to “ON” position This brings power to the controls.
3. Locate liquid refrigerant indication glass mounted
on the receiver Once the system has been operating for two
minutes, the glass should appear clear and
full of liquid refrigerant.
4. Wait 15 minutes The temperature in the storage area should
begin to drop.
5. Wait 3 hours Once the operating temperature has been
reached, stocking of the cabinet are can
begin.
12
2.4 Shut Down Procedure for Short Term
To shut down, switch the power control to the off position.
WARNING: PRIOR TO CLEANING ANY OF THE UNIT, THE
SYSTEM SHOULD BE DEACTIVATED BY DISCONNECTING THE
POWER SUPPLY.
2.5 Cleaning Instructions
1. It is necessary that the power source be turned off..
2. Remove all shelves.
3. Wipe entire unit using a clean cloth or sponge with a mild detergent.
WARNING: DO NOT SPLASH OR POUR WATER ONTO THE EVAPORA-
TOR ASSEMBLY, CONTROL PANEL, CONDENSING UNIT AND/OR
WIRING.
CAUTION: POSSIBLE SHOCK HAZARD MAY RESULT AND UNIT MAY
BE DAMAGED SHOULD ELECTRICAL COMPONENTS BECOME WET.
4. A plastic scouring pad may be used in the storage area to remove any hard-
ened food particles.
5. When cleaning is finished, rinse the inside thoroughly with a solution
of vinegar and water to neutralize all detergent/cleaner residue.
TableD—Shut‐DownProcedureforShortTerm
Operation Results
1. De-energize the system by flipping the power
control switch “OFF”. Once the system is de-energized the cabinet
has no power.
13
Important: It is not recommended to use any strong or caustic
cleaners on the Undercounter Refrigerator. Do not allow ammonia to
stand in the interior of the unit. Make certain to rinse thoroughly to
remove all residue. Failing to do so may cause damage or corrosion
to the unit.
2.6 Preparation for an Extended Period of Inactivity
This unit is designed for periodic use. For extended shut down the electrical
should be disconnected and the interior cleaned.
TableE—Shut‐DownProcedureforExtendedPeriod
Operation Results
1. Fully close discharge valve at the receiver Compressor will pump liquid refrigerant
from system to receiver.
2. Fully close suction valve at the compressor This will isolate the refrigerant between the
two valves.
3. De-energize the system by flipping the power
control switch to the “OFF” position and discon-
necting the electrical supply cord.
De-energizes system. The condenser fan
and evaporator fan(s) will cease operation.
4. Clean and wipe dry the food storage compart-
ment This will reduce the odor buildup during
shut down period.
14
Chapter3—FunctionalDescription
3.1 System Description
The unit is a self-contained, automatically controlled, continuous duty perisha-
ble food storage system. It is designed with the intent and purpose of storing
perishable food items.
The operating temperature is automatically monitored by the electronic con-
trols that are factory set to maintain a predetermined adequate storage condi-
tion.
The equipment is comprised of the following two basic compartment
assemblies:
1. Condensing Unit Compartment—This area contains the condensing unit
along with the control panel assembly* or electronic control assem-
bly**.
2. Storage Compartment—The insulated food storage area is a tempera-
ture controlled refrigerated area. Included in this compartment is the
adjustable shelving and evaporator coil assembly.
3.2
System Operation
The design of the refrigerated cabinet focuses primarily on the safe storage of
food products requiring refrigeration. In engineering, considerable attention
was placed on not only its functionality, but also serviceability.
The refrigeration system is a closed loop system. Barring a leak in the system,
the addition of refrigerant will not be necessary. A periodic check of the refrig-
erant level, however, is recommended to insure that the system operates at the
optimum level at which is was designed.
The chilled food compartment is designed for the storage of perishable food
items that require a temperature range of 37 to 40ºF on refrigerators and –5 to
0ºF on freezers. It is a general rule that adequate spacing is allowed between
the stored items to allow for proper air circulation.
15
Chapter4—ScheduledMaintenance
4.1 Introduction
To insure the longest and most trouble free operation, a thorough periodic
maintenance schedule is required. The maintenance system should be aimed at
maximizing the efficient utilization of maintenance personnel, minimizing down
time, and providing the orderly acquisition of spare parts support.
The Cospolich Undercounter Refrigerator cabinet will generally be in operation
in a facility or onboard a vessel where scheduled maintenance is performed ac-
cording to Maintenance Index Plans. This unit requires regular maintenance.
This chapter is intended as an alternative to any standard maintenance pro-
gram that may pre-exist. The preventative maintenance schedule is based up-
on similar maintenance requirements for commercial refrigeration equipment.
4.2
Preventive Maintenance Action Index
If there is not a maintenance index plan, we have formulated our schedule for
periodic maintenance in Table G.
4.3
Preparation for Maintenance
Since many areas affected in the maintenance schedule are electrically
supplies, it may be necessary to de-energize the system when making these
inspections.
4.4
Maintenance
A. Monthly Maintenance
1. The unit should first be de-energized by switching the toggle switch to
the “OFF” position. The switch is found on the electronic control panel
assembly in the condensing unit compartment. Note: It is necessary
to first remove the louvered grill to the condensing unit compartment.
This is done by lifting it straight up, then pulling the bottom out and
down.
2. Using a vacuum or soft brush/broom, brush the condenser fins in a
vertical motion to remove dust or debris.
16
B. Bi-Monthly Maintenance
1. Check the drain line at both the inlet and outlet ends to make certain
that there are no obstructions (forced air evaporator models only). It
is not recommended to use any chemicals in clearing a clogged drain.
The preferred method is to use compressed air, with approximately 60
psi being sufficient to free most clogs or obstructions. To do so, simply
remove the drain line at the evaporator coil and attach an air line to it.
2. With the unit in a cooling cycle, use a flashlight and locate the refriger-
ant sight glass. If the compressor has been running for 3 or more
minutes, there should be no visible bubbles.
A. If bubbles are present:
Determine if there is a leak by using a halide or electronic
leak detector.
Repair any/all leak(s).
Warning:
The system should be de-energized when checking for leaks
B. To repair leaks:
1. Flared Fitting: Can often be repaired by simply tightening the
brass flare nut 1/4 of a turn. If tightening
does not repair the leak, it may be necessary
to re-flare the tubing.
2. Brazed Joint: It is necessary to pump down the system’s
refrigerant charge to remedy the problem.
To pump the refrigerant into the receiver, you
must first connect service gauges to the sys
tem at the suction valve on the compressor
and the liquid valve on the receiver. Purge the
gauges before opening the systems valves to
avoid contamination. Run the receiver (liquid
or high pressure) valve all the way in to stop
the refrigerant from exiting the receiver. Start
the unit and allow it to run until the suction or
low pressure gauge reads 5lbs., de-energize
the system. Once pumped down, the necess-
ary repairs can be made.
17
3. Using a mild non-abrasive detergent and soft cloth, wipe the in-
terior lining beginning with the top and working down. Also,
wipe the gasket and where it sits on the cabinet interior.
4. Remove the louvered air grill and unbolt the condensing unit,
then slide it out. The unit is capable of being completely re
moved due to the extra tubing coiled up behind/beside the unit.
With the unit de-energized, check the condenser fan motor and
make certain that it is secure and not loose. Inspect the fan
blade for cracks and make sure it is tight on the motor.
5. To inspect the evaporator motor, de-energize the unit. Remove
the drain line from the evaporator pan. Loosen the screws that
hold the shroud. Lower the shroud and disconnect the polarized
electrical connection. With the shroud out of the cabinet, pro-
ceed to inspect the motor mounting bolts and the fan for cracks
or excessive play. NOTE: In vertical style evaporators, lift/
remove the side cover to examine the evaporator fans, which
should be clearly visible and accessible.
6. Using a mild detergent and water, wipe the vinyl gasket. Make
certain to clean under the gasket to remove any mildew or resi
due that may have accumulated.
7. Using a mild, non-abrasive detergent and water, wipe the cabinet
exterior, paying careful attention to wipe the cabinet in the direc-
tion of the stainless steel grain texture.
C. Annual Maintenance
1. Slide the condensing unit out and check all refrigerant lines for leaks or
fatigue, making sure no copper lines are in direct contact with any
other metal surfaces. If contact exists, place an insulated material
between the two surfaces.
2. Inspect electrical connections to make certain that there is a good
contact and that wires are neither weakened or frayed.
3. Inspect the integrity of the cabinet.
4. Check all bolts and screws to make sure they are tight and secure.
18
TableF—PreventiveMaintenanceActionIndex
Frequency Description
1. Monthly A. Inspect condenser coil to make certain air flow is not obstructed and
that it is clear of dust and debris.
2. Bi-Monthly A. Inspect and clear drain line.
B. Check the liquid refrigerant sight glass for proper refrigerant charge
C. Clean interior and exterior of cabinet with mild detergent and wa-
ter, dry thoroughly
D. Check both condenser fan motor and evaporator motor(s) for prop-
er function and that they are mounted securely
E. Clean door gaskets and breaker strips with a damp cloth
3. Annually A. Slide out condensing unit, check all joints and fittings for signs of
wear, leaks, or fatigue
B. Inspect electrical connections to make certain that there is a good
contact and that wires are neither weakened or frayed.
C. Check the integrity of the cabinet
4. Three Year A. Replace all door gaskets
B. Inspect motor shafts for noise or wear
C. Inspect electrical controls and wiring
D. Inspect door latch (when applicable) and hinges.
D. Three Year Frequency Maintenance
1. Replace all door gaskets. To do so, first remove all products from the
refrigerated compartment. Using a Phillips screwdriver, remove the
door from the cabinet and lay it on a flat surface, gasket facing up. Lift
the flange off the gasket and remove all screws securing it to the door.
Remove the original gasket and replace with a new one. Reinstall all
screws and mount door back onto cabinet.
2. Inspect all motors and shafts for noise & wear, replace if necessary.
3. With the unit de-energized, remove the condensing unit from its com-
partment and inspect all wiring for signs of fatigue or wear.
4. Inspect the operation of the door latch assembly (when applicable).
Check for signs of wear, loose screws, or mechanical failure.
5. Inspect the operation of the door hinges. To do so, open the door at a
90º angle to the cabinet and lift on the outer edge of the door. If there
is upward movement of ½” or more, replace the hinges. On spring-
mount hinges, when the doors no longer close properly, replace the
hinges.
19
Chapter5—Troubleshooting
This chapter will assist in a systematic check of components in determining any
cause of equipment failure.
It will be necessary that the individual involved in the troubleshooting operation be
familiar with the function of the equipment as described in Chapter 3.
The following table lists the most common symptoms that may be experienced and
the recommended corrective action. The tables are separated into electrical mainte-
nance, mechanical maintenance, and operators’ actions.
Symptom Possible Failure Remedy
Unit does not operate A. Control failure
B. Incorrect voltage
C. Failed compressor
A. Adjust control or replace
B. Correct
C. Replace
Unit runs continuously A. Control failure
B. Bad connection at TXV
expansion valve
C. Restricted air flow
D. Bad condenser fan mo-
tor
E. TXV valve stuck open
F. Ineffective door seal
G. Restricted air flow in
storage compartment
A. Adjust control or replace
B. Check and secure sensor
bulb to suction line
C. Clear obstruction and clean
condenser
D. Check and replace
E. Replace
F. Adjust door latch and hinges
G. Redistribute food for even
air flow
TableG—MechanicalandElectricalTroubleshootingGuide
Low Head Pressure A. Defective Compressor
B. Low refrigerant
C. Ambient temp too low
A. Replace
B. Leak check & recharge
C. Raise room temperature
High Head Pressure A. Dirty compressor
B. System contains air
C. Refrigerant overcharge
D. Condenser fan bad
A. Clean compressor
B. Evacuate, change filter dry-
er, recharge
C. Reduce qty of refrigerant
D. Replace
Short Cycling A. Maladjusted control
A. Adjust control
20
Chapter6—CorrectiveMaintenance
6.1 Introduction
This chapter focuses on the instruction needed in the removal and replacement
of certain components. We will also address the repair of components not listed
under the schedule maintenance index covered in Chapter 4.
The components that we address are considered acceptable for repair using
standard procedures that we will detail. The level of skills required to perform
the service or repair will vary. Some may require specific training. It is up to the
individual and /or his supervisor to determine their capability to undertake the
particular task of service or repair. It is also important to know that any proce-
dure requiring the handling of electrical components and appliances. The ser-
vice or repair items are limited to those listed in Chapter 7.
6.2 Repair Procedure
**WARNING**
PRIOR TO PERFORMING ANY WORK ON THE SYSTEM, IT IS REQUIRED
THAT THE UNIT BE DE-ENERGIZED.
Note: To access the electrical components the louvered grill on the front of
the cabinet must be removed. To remove it, simply lift up and pull the bot-
tom of the grill outward.
6.2.1 Replacement of Compressor (Part #: RUT221)
1. Evacuate the refrigerant from the system using a recovery system in compli-
ance with all Federal regulations.
2. Disconnect power supply to the unit.
3. Remove the exterior louvered grill to access the condensing unit compart-
ment.
4. With the grill(s) removed, use a 3/8” wrench/socket to remove the mounting
bolts that secure the condensing unit to the cabinet base. Slide entire unit
out, paying attention to lift it over the angle mounting clips at the base.
5. Find electrical terminal box on side of compressor and remove cover. Discon-
nect the wires from the compressor. Remove the screws that attach termi-
nal box to the compressor. The compressor is now electrically detached.
This manual suits for next models
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Table of contents
