Hussmann DC-1 Series User manual

Part Number:- IM-020 DATE: 27/06/19 REV: C
DC- 1 SERIES- COLD PLATE
INSTALLATION MANUAL: IM-020
Standard remote versions
The following models are covered by this Manual
DC13
66 Glendenning Road, Glendenning NSW 2761
PO Box 42 Doonside NSW 2767
t: [phone] f: [phone]

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 1 Hussmann
Contents
Pre-installation 2
Important Safety Instructions 2
Case services dimensions 3
Operating environment 4
Handling and transporting cases 4
Shipping damages and shortages 6
Installation 7
Positioning and levelling 7
Sealing case joins 10
Joining the cases 11
Attaching trims 13
Attaching kick plates 14
Connecting refrigerant lines 16
Refrigeration Schematic 18
Installing the waste drain 19
Connecting power supply 20
Installing sensor probes 21
Mounting fixtures 22
Commissioning 23
Cleaning case 23
Starting up 23
Start-up checks 23
Decommissioning 24
Disposal 24
Operation 24
Loading Merchandise 24
Cleaning and Maintenance 25
Daily Checks 25
Cleaning 25
Important Notes 25
Cleaning Procedure 25
Six Monthly Maintenance 26
Operation Servicing 27
Troubleshooting 28
Controller troubleshooting 29
Appendixes 30
Appendix 1 Wiring diagrams 30
Appendix 2 Produce Engineering Datasheets 30
Appendix 3 Setting table 30
Appendix 4 Attaching case ends 30
Appendix 5 Top glass horizontal adjustment 32
Appendix 6 Front glass camber adjustment 34
Appendix 7 Risk analysis 35
Appendix 8 Electronic Expansion Valve Specification 37
Appendix 9 Controller 37
Appendix 10 Warranty 38

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 2 Hussmann
Pre installation
Important Safety Instructions
Please read the user manual carefully and store for later reference. In this document you will see these symbols with
following meanings
NOTE
Information in this manual is to be followed
in conjunction with specifications, work
practices and regulations of the customer,
installing company and relevant industry.
CAUTION
Care must be taken to avoid damage to
drainage outlets and electrical equipment
mounted under or at the rear of cases.
CAUTION
This symbol indicates electrical safety must
be concerned
WARNING
•Leave enough space to install the system. The space requirement will be instructed in “Pre-installation” section.
•Before installing the system make sure the power source is accessible to the cases array.
•All the power source has to be properly earthed.
•If any potential fail or product disconformity is investigated, please consult a qualified service technician.
•Always disconnect the power of the cases before conducting any service or maintenance.
•Keep the case out of direct sunlight, fire hazardous environment, or high moisture or humidity area.
•Fail to install the system as instructed in this manual may void Hussmann Warranty.
REFRIGERANT WARNING
•Refrigerant is not factory charged.
•Default refrigerant is shown on the product rating plate and in engineering data sheets..
•Ensure that during the transportation and installation the refrigerant circuit is not damaged. The Hussmann contact
details are at the front of this manual.
The installation should follow AS 5149, AS NZS 3000 or other local safety requirements.

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 3 Hussmann
Case Services Dimensions
Fig (1) Service layout standard depth case

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 4 Hussmann
Operating Environment
All Hussmann Cases have been factory tested to AS1731, 25C at 60% RH. For best performance, store temperature
should be maintained at or below 24C at 50% RH, otherwise an “air ventilation kit” may be required to avoid under or rear
cabinet sweating.
To avoid condensation build-up, cases should be positioned to allow air to freely circulate around the underside and rear
of the case. Ideally, the floor will be levelled.
Cases must not be positioned in areas that may be subject to heat or air currents such as ventilation ducts, open doors or
windows, direct sunlight, electric fans or ovens, etc. Otherwise the cabinet may show poor temperature performance or the
operating life is affected.
NOTE
Refer to product MSDS for all hazardous substances used
during installation in relation to their application, PPE, first aid,
disposal and emergency management. Refer page 27 (Risk
Analysis)
For MSDS sheet contact your Hussmann Representative
Handling and Transporting cases
MANDATORY USE OF STRAP AND EDGE PROTECTORS FOR THE
TRANSPORTATION OF HUSSMANN REFRIGERATED CASE
Hussmann Refrigerated Display Cases are to be secured correctly during transport to ensure damage
free arrival at their destination. It is the responsibility of the Transport Company to ensure that the
correct method of loading and securing Refrigerated Display cases is used.
Refrigerated cases are to be strapped using the following method:-
•A heavy duty strap protector and the correct rated strapping are to be used to tie down cases.
•The cases are to be tied down as indicated on the exterior of the case wrapping. “STRAP HERE”
See figure 2a and figure 2b.
•Cases should not be transported without the use of the heavy duty strap protector otherwise
damage to the exterior case panels will occur.
•Hussmann Storage Warehouse Managers will refuse to load cases onto transport and trucks
will be turned away if the heavy duty protector and the correct rated strapping are not used.
To prevent any unnecessary damage and avoid delays to onsite case installation the correct materials
as detailed in this bulletin must be used.

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 5 Hussmann
Figure 2a Typical rear case view- “STRAP HERE” labels.
Figure 2b Strap and Heavy duty strap protector
Case dimensions can be found in the product engineering data sheets (PED).
(This manual is a guide only. Always refer to the latest case information available from Hussmann Customer Service)
Always ensure that the moving device is of a suitable type, and has sufficient lifting capacity for the case weight and
dimension. Always lift cases from the underside.
Refer to and follow the manual handling policies of your Company when moving cases.
CAUTION
Care must be taken to avoid damage to
drainage outlets and electrical equipment
mounted under or at the rear of cases.

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 6 Hussmann
Shipping Damage, Shortages and checklist
1. Where possible, it is recommended that packaging be removed from the case before they are moved into the store.
2. Inspect case for any shipping damage.
3. Any damage must be noted on the freight documentation supply by the transport company and contact a Hussmann
representative within 48 hours.
4. Take clear and accurate photos of damage parts with documentation and forward them to a Hussmann
representative.
5. Check and confirm all case part ie:- Trims, shelves, product fence, bumpers etc are supplied.
6. If case parts are short supplied please contact a Hussmann representative within 48 hours.
Note:-
Contact a Hussmann representative immediately
within 48 hours of damage case or missing parts
with photos and documentation.

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 7 Hussmann
Installation
NOTE
Information in this manual is to be followed in conjunction
with specifications, work practices and regulations of the
customer, installing company and relevant industry.
Positioning and Levelling
Each case has a unique identification number as follows:
##### - ## - ##
Job no. Line-up no. Case sequence no.
(within line-up)
Example: 106076.42.4 identifies this case in the 4th sequence of the line 42 for the job 106076.
As well as on the packaging, the case identification number appears as a serial number on the rating plate (most commonly
located on the ceiling panel left hand end of the case) refer to Fig (3) and is printed on a decal on the rear of the case ref
Fig (4). The case sequence number is also written on a ticket on the front panel.
Fig (3) Rating Plate
Fig (4) Decal rear of case with case sequence number

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 8 Hussmann
Cases must be positioned so that line-up numbers and case sequence numbers run in succession left to right standing in
front of the cabinet.
CAUTION
Ensure the lifting capacity of the trolley, etc. is
sufficient for the case. Refer to the product
engineering data tables and Risk Analysis (page 27).
To position the cases:
1. If the plinth surface is level, position the case designated as line up number 1 and case sequence number 1 in the
required position.
2. If the plinth surface is not level, determine where the highest point of the plinth is, and position the case allocated
to this position first.
3. Adjust the case height using the adjustable feet (if fitted) or metal shims (do NOT use timber) to ensure the case
is level to within +/- 1.5mm from front to back and side to side and chassis of case is NOT twisted. Maximum
25mm adjustment.
Fig (5) Levelling feet adjustment
NOTE
It is important that all cases are level for correct case joining and operation. If
cases are not properly levelled and positioned, door misalignment will be evident,
resulting in the job needing to be redone at complete cost to the installer.
Hussmann is not liable or responsible for the cost involved in fixing
problems arising directly from the installers’ failure to follow the
requirements outlined in this manual.
DO NOT SET CASE LEVELS OFF THE PATCH END fitted to a case.

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 9 Hussmann
Fig (6) Case Levelling
Fig (7) Case twisting
Make sure Chassis of
case is NOT TWISTED.

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 10 Hussmann
Sealing Case Join
(Applicable when two or more cases are joined together to set a line).
Before joining, all cases must be sealed to protect against water and air leakage.
To seal the joins
1. Apply a bead of sealant (approximately 10mm wide) ensure case seal correctly.
Fig (8) Case-end sealing positions
DO NOT leave any gaps to
ensure cases seal correctly
on edge of frame.

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 11 Hussmann
Joining the Cases
Ensure cases are sealed before joining them to other cases
For instructions on attaching case ends, refer to appendix 4: attaching case ends
CAUTION
Do not walk or sit on cases.
To join the cases
1. Draw up the required case tightly against the case already in position
CAUTION
Case joining bolts should only be used,
with care, at the final pulling-up stage.
2. Ensure that the case is level, from front to back and side to side, with the existing case.
3. Insert the joining bolts, found in the blister pack, into the end holes and tighten –see Fig (9): joining hole locations
(9) Joining holes location
Joining Holes

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 12 Hussmann
4. Seal all internal joints with silicon.
5. Apply either black or white silicon (depending on the interior colour of the case) all the way along the inside join
between the cases, (as supplied)
6. Applying slight pressure, run your finger along the length of the silicon.
7. Replace the square bungs in the air delivery panels and ceiling panels.
Fig (10) Sealing joins
Seal joint between cases with
appropriate coloured silicon between:
Air Delivery Panels
J/Trim used on the cold plate

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 13 Hussmann
Attaching Trims
1. Attached joining trims refer figure 11.
2. Ensure that the case is level from front to back and push them together.
3. Place trim to back of frame and align holes to suit.
4. Screw and join trim to back frame.
Fig (11) Case joint trim kit
NOTE: Attach the bumper using a rubber mallet ONLY

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 14 Hussmann
Attaching Kickplates
(This should be done after final Installation of Refrigeration and Drainage connections)
Attach kickplates and, if required, silicon seal to the floor once installation is complete and drains checked for water leaks.
Front Panel
1. Attached front panel and align with front skid rail refer figure 12.
2. Push front panel into bottom and top clips.
3. Check front panel is securely in position.
Fig (12) Attached front panel
Back Panel
1. Attached back panel and align with back skid rail refer figure 13.
2. Push back panel into bottom clip and over top clips.
3. Check back panel is securely in position.
Fig (13) Attached back panel

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 15 Hussmann
Side Kickplate
1. Attached side kickplate as per drawing refer figure 14.
2. Adjust slot in kickplate to suit. Make sure kickplate is above floor.
3. Screw kickplate in position.
4. Check kickplate is securely in position.
Fig (14) Attached side kickplate

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 16 Hussmann
Connecting Refrigerant Lines
Connection of refrigeration lines is to be undertaken by qualified persons only.
Refrigeration pipes are located under the cold plate and can be run from under the case. See Fig (1): service layout for
location of the refrigerant up-stand, and Fig (15) for the location of refrigeration lines.
Up to four cases can share one refrigeration up-stand, however, to ensure best performance, it is recommended that no
more than three cases share an up-stand. Site refrigeration engineer must ensure correct pipe route and size to comply
with refrigeration standard AS 5149 and refrigerant prepare drop coil return through the vertical risers.
The evaporator coils have been charged with dry nitrogen in the factory.
Fig (15) Refrigeration access holes
CAUTION
Do not run refrigeration lines from another compressor through
a case. Since pressure in the first system responds to the
coldest location, refrigeration lines from the first system running
through a second system may be chilled to the point that its
pressure control will respond to the pressure from the second
system. This is called cross controlling and should be avoided.
To connect refrigeration lines:
1. Ensure the evaporator coils are fully charged by checking the dry nitrogen holding charge against the pressure
written on the tag attached to the coil.
2. Run pipes underneath the cold plate as per store requirements.
3. Braze the pipes to the coil using dry nitrogen to prevent any foreign matter being left in the lines. Keep pressure
below 1700kPa (250 Psig).
REFRIGERATION
LINE ACCESS

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 17 Hussmann
CAUTION
Relocate or protect the expansion (TX) valve feeler
bulbs (or power lead if electronic valve) from heat.
Ensure the power lead is clear of heat and flame.
4. Insulate all external pipe work to Standard practice and Customer specifications.
5. Seal off all external access holes with polyurethane foam and then bituminous paint to prevent leakage and
condensation.
6. Connect to condensing unit or compressor.
7. Pressure test all welded and fastened connections to ensure they are free of leaks.
8. Dehydrate the refrigeration system using the triple evacuation method. Use a vacuum pump to 1000 microns for
the first two evacuations and 500 microns on the third, or to the customer’s specific requirements. Break
evacuations 1 and 2 with dry nitrogen, allowing the pressure to rise above atmospheric pressure each time.
9. Charge with refrigerant after final (3rd) evacuation.

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 18 Hussmann

PRODUCT INSTALLATION MANUAL DC13 COLD PLATE
_________________________________________________________________________________________________________________________
Page 19 Hussmann
Installing a Waste Drain
NOTES
Drains must be connected as per
stipulated local council requirements.
All joins must be solvent welded.
Each case must be connected to its own waste drain See Figure 1: service layout for of the drain up-stand. It is
recommended that 40mm DWV (PVC) piping be used.
To install a waste drain:
1. Fit an elbow and pipe to the existing pipe work.
2. Check that the drain is as per Fig (16a).
Fig (16a) Drain trap orientation
Fig (16b) Drain trap orientation
3. Use foot mounted brackets or mounting bracket to the case to support PVC drain assembly weight (Refer to Fig
16b).
4. Test for leakage by pouring water down the drain and ensure trap is primed before starting refrigeration.
CAUTION
Incorrectly installed drain traps will result in
adverse air leaking into the case.