Hussmann Super Plus User manual

Being Safe is Your Responsibility.
Wear proper eye protection whenever
working.
Wear proper hearing protection
whenever working in a machine room.
Stand to one side–never work directly in
front of:
•Any valve you are opening or closing
Manual refrigeration valves
Regulator valves on brazing
tanks and nitrogen tanks
•Electrical Circuit Breakers
•Refrigeration lines you are cutting or
opening
Always use a pressure regulator with a
nitrogen tank.
•Do not exceed 2 pounds of pressure and
vent lines when brazing.
•Do not exceed 350 pounds of pressure for
leak testing high side.
•Do not exceed 150 pounds of pressure for
leak testing low side.
Use only a striker to light torch.
Know whether a circuit is open at the
power supply or not. Remove all power
before opening control panels.
Always supply proper ventilation.
•Refrigerants and nitrogen can displace
oxygen causing suffocation.
•Refrigerants exposed to flame can
produce phosgene, a poisonous gas.
Be sure refrigeration lines are free of
pressure 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 if you
•Isolate liquid lines or compressor when
they can absorb heat over an extended
time period
•Overfill pumpdown refrigerant
containers
Never vent refrigerants into the
atmosphere.
Some equipment has more than one
power supply.
WARNING
SAFETY TIPS
Revised August 1, 1996

Congratulations!
With the purchase of Hussmann's Super Plus™ System, you are receiving
equipment designed to provide the finest refrigeration and temperature control
for modern supermarket display equipment and coolers.
Since the introduction of Hussmann Central Refrigeration Systems, thousands of
installations have confirmed our belief that, as with all fine equipment, good
installation and proper adjustment are the keys to customer satisfaction.
The information presented in this manual includes many details resulting from
our experience over many years. Its use will guide the contractor to a successful
installation. Time taken to read and to understand this information will pay off in
reducing lost time and duplication work.
Should there be questions concerning this information, do not hesitate to write
me. Your inquiry will be welcomed.
George Ballinger
Manager of Field Service
960801
Hussmann Corporation
12999 St. Charles Rock Road
Bridgeton, MO 63044-2483
[phone]

Installation and Service Manual
12999 St. Charles Rock Road •Bridgeton, MO 63044-2483 •[phone]
August, 1996
Printed in USA
Super Plus™
Fibertronic™

Topics
Overview....................................................1-1
Super Plus™ Components .........................1-1
Shipping Damage.......................................1-2
Super Plus™ Frame Dimensions ...............1-2
System Weights..........................................1-2
Receiver Refrigerant Capacities.................1-2
Machine Room Requirements....................1-3
Unit Placement...........................................1-4
Lifting and Leveling...................................1-5
Setting without a Crane..............................1-6
Figures
Super Plus™ System..................................1-1
Electrical Clearance Requirements ............1-3
Allowable Distances...................................1-4
Lifting and Leveling the Super Plus™.......1-5
Isolation Pad Location................................1-5
Dolly Placement.........................................1-6
Revised August 1, 1996 P/N 340272A
CONTENTS

Topics
Overview....................................................2-1
Super Plus™ Refrigeration System............2-2
Basic Refrigeration Cycle ..........................2-4
Heat Reclaim Cycle....................................2-6
Receiver Pressure and Vapor
Temperature Regulation.......................2-6
Koolgas Defrost Cycle...............................2-7
Oil System..................................................2-8
Subcooling..................................................2-9
Demand Cooling.......................................2-11
Figures
Super Plus™ Refrigeration System............2-2
Refrigeration Cycle....................................2-4
Turba-Shed.................................................2-4
Heat Reclaim Valve....................................2-4
Flooding Valve ...........................................2-4
Main Liquid Line Pressure
Differential Valve.................................2-5
Liquid Branch Solenoid Valve ...................2-5
TEV ........................................................2-5
EPR Valve..................................................2-5
Heat Reclaim Cycle....................................2-6
Receiver Pressure Regulation.....................2-6
A9 and A9B Valves....................................2-6
Koolgas Defrost Cycle ...............................2-7
Koolgas Defrost with Valve .......................2-7
Satellite Oil System....................................2-8
Autosurge for Ambient Subcooling ...........2-9
Mechanical Subcooling............................2-10
Demand Cooling.......................................2-11
Revised August 1, 1996 P/N 340272A
CONTENTS

Topics
Overview....................................................3-1
Refrigeration Line Runs.............................3-1
Rack to Condenser Piping..........................3-3
Rack to Remote Header..............................3-6
Rack to Remote Satellite............................3-6
Rack to Heat Reclaim.................................3-7
Offset and Expansion Loop Construction..3-7
Special Piping for Open Rooms.................3-8
Connecting Parallel 3-Way Valves.............3-8
Run Lengths and Equivalent Feet ..............3-8
Branch Line Piping.....................................3-9
Tables
"L" Values ..................................................3-7
Equivalent Feet...........................................3-8
Figures
Supporting Refrigeration Lines..................3-1
Insulating a Riser........................................3-2
Vibration Allowance ..................................3-2
P-Trap Construction ...................................3-2
Reduced Riser ............................................3-2
Rack to Condenser Piping..........................3-3
Rack to Condenser Piping,
3-Way Valve.........................................3-4
Rack to Condenser Piping,
2-Way Valves .......................................3-5
Offset Tee Construction..............................3-6
Remote Satellite Piping..............................3-6
Offset Construction ....................................3-7
Expansion Loop Construction....................3-8
Connecting to Parallel Suction Stubs.........3-8
Branch Piping.............................................3-9
Revised August 1, 1996 P/N 340272A
CONTENTS

Topics
Overview....................................................4-1
Field Wiring ...............................................4-1
Wiring Guidelines Based on
Various Components ............................4-2
Using Schematics.......................................4-3
Alarm Board...............................................4-3
Compressor Controls..................................4-4
Compressor Circuit Boards........................4-6
Compressor Board Related Circuit ..........4-12
Defrost Circuit Boards .............................4-22
Defrost Timer Motor................................4-28
Defrost Control Circuits...........................4-28
Other Controls..........................................4-32
Power Monitor..........................................4-33
Tables
Required Field Wire Size...........................4-2
Alarm Board Troubleshooting....................4-5
Compressor Board Troubleshooting
Mechanical...........................................4-9
EPC.....................................................4-11
Defrost Board Troubleshooting
Mechanical Time Clock .....................4-25
Fibertronic Time Clock......................4-27
Figures
Alarm Board Circuits.................................4-3
Alarm Board...............................................4-4
Compressor Board Faceplate .....................4-6
Compressor Circuit Board Connections.....4-7
Compressor Board – Mechanical
Low Pressure Control...........................4-8
Compressor Board – EPC Control..........4-10
K2 and Motor Contactor Circuits.............4-12
K1andCompressorAlarmCircuits................4-13
Parallel Switchback Controls...................4-14
Series Switchback Controls......................4-15
Switchback Controls ................................4-16
Koolgas and Interlock Relays ..................4-17
Compressor Protection.............................4-18
Carlyle Internally Compounded
Compressor Protection.......................4-19
Head Cooling Fan and
Demand Cooling ................................4-20
Circuits Parallel to the Compressor
Motor Contactor Coil.........................4-21
Branch Board Faceplate ...........................4-22
Defrost Board Inputs and Outputs............4-23
Defrost Board Mechanical Timer.............4-24
Defrost Board Electronic Timer...............4-26
Defrost Control Circuit.............................4-28
Suction Stop Koolgas Defrost..................4-29
Electric Defrost ........................................4-30
Off Cycle Defrost.....................................4-31
Refrigeration Thermostat w/ Header
Mounted Solenoid ..............................4-32
Wiring Defrost Termination
Thermostats........................................4-32
Power Monitor and Slave Contactor........4-33
Electrical Hookup.....................................4-33
Revised August 1, 1996 P/N 340272A
CONTENTS

Topics
Overview....................................................5-1
Remote Condensers....................................5-1
Remote Satellite .........................................5-6
Figures
Lifting the Condenser.................................5-2
Schematic – Ambient Temperature
Control..................................................5-4
Schematic – Pressure Control ....................5-5
Satellite Rigging and Lifting......................5-6
Revised August 1, 1996 P/N 340272A
CONTENTS

Topics
Overview....................................................6-1
Precision Defrost Timer .............................6-1
Paragon Defrost Timer...............................6-5
Figures
Inserting Tripper.........................................6-1
Proper Installation......................................6-1
Setting Precision Timer..............................6-2
Resetting Alarm Switch .............................6-3
Precision Defrost Timer .............................6-4
Paragon Program Module...........................6-5
Paragon Program Module,
Removal and Installation................6-6
Motor Module,
Removal and Installation................6-7
Paragon Defrost Timer...............................6-8
Revised August 1, 1996 P/N 340272A
CONTENTS