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

Topics
Overview....................................................7-1
EPR Valve ..................................................7-1
Koolgas Valve ............................................7-2
Main Liquid Line Solenoid
Sporlan .................................................7-4
Alco......................................................7-5
Branch Liquid Line Solenoid Valves ........7-6
TEV............................................................7-7
Heat Reclaim Valve....................................7-9
Flooding Valve and Receiver Pressure
Regulating Valve................................7-10
Autosurge .................................................7-12
Mechanical Subcooling............................7-15
Demand Cooling ......................................7-17
Oil System................................................7-20
Tables
Troubleshooting EPR Valves......................7-2
Troubleshooting Koolgas Valves................7-3
Troubleshooting Branch liquid Line
Solenoid Valves....................................7-6
Troubleshooting TEV.................................7-8
Troubleshooting Flooding Valve..............7-10
Troubleshooting Receiver
Pressure Regulator..............................7-11
Figures
EPR Valve with Suction Stop Solenoid......7-1
Koolgas Valve Piping.................................7-2
2-Way Solenoid Valve................................7-3
3-Way Solenoid Valve................................7-3
Main Liquid Line Solenoid........................7-4
Alco Main Liquid Line Solenoid ..............7-5
Branch Liquid Line Solenoid....................7-6
Probe Locations For Setting TEV..............7-7
TEV............................................................7-7
3-Way Heat Reclaim Valve........................7-9
Condenser and Receiver Pressure
Regulation ..........................................7-10
A8 Flooding Valve ...................................7-10
A9 Receiver Pressure Regulator...............7-11
A9B Receiver Pressure Regulator............7-11
Autosurge and By-Pass Valves.................7-12
Autosurge Valve Connections..................7-13
Establishing Valve Operating Range........7-14
Shell and Tube Type Mechanical
Subcooler............................................7-15
Plate Type Mechanical Subcooling..........7-16
Demand Cooling Components.................7-17
Demand Cooling Piping...........................7-18
Oil System................................................7-20
Oil Pressure Differential Valve ................7-20
Sporlan Oil Level Regulator ....................7-21
AC & R Oil Level Regulator....................7-21
Revised August 1, 1996 P/N 340272A
CONTENTS

Topics
Overview....................................................8-1
Pressure Settings ........................................8-1
Plate Subcooling Controls..........................8-1
Shell and Tube Subcooling Controls..........8-1
Compound Rack, Additional Settings........8-1
EPR Settings...............................................8-2
Winter Condensing Pressure Controls .......8-2
Mechanical Low Pressure Controls............8-2
Alco...................................................8-2
Others...............................................8-4
Condenser Settings.....................................8-8
Merchandiser Settings................................8-9
Revised August 1, 1996 P/N 340272A
CONTENTS

Topics
Startup ........................................................9-1
Leak Testing.........................................9-1
Test Charge...........................................9-1
Oil Levels.............................................9-2
Evacuation............................................9-2
Charging...............................................9-3
Final Checks.........................................9-4
Maintenance ...............................................9-5
Compressor Replacement.....................9-5
Cleaning the Turba-shed™...................9-6
Replacing Drier and Filter Cores .........9-6
Revised August 1, 1996 P/N 340272A
CONTENTS

No. 7538
April 18, 1997
TO: Region Vice Presidents, Account Executives, District Managers,
Sales Managers, Sales Representatives, Branch Managers,
Hussmann Distributors, International
SUBJECT: Update for SuperPlus Fibertronic Manual, P/N 340272, Rev. A
The Super Plus Installation Manual has been updated as follows:
•Addendum – Condenser Installation
provides information on installing condensers with SuperPlus systems
(place behind index and in front of warranty page).
•Section 3 – Piping
changed Equalizing Line size to 7/8-inch (when required)
(discard page 3-3 and replace with page 3-3 dated April 15, 1997).
•Section 8 – Settings
updated Impact medium temperature settings and
added low temperature settings and new case settings
(discard pages 8-9 through 8-18 and replace with pages 8-9 through 8-20
dated March 1, 1997).

OVERVIEW
This section is limited to the information
needed to set the Super Plus™ Compressor
Rack. Power Supply requirements are found
under “Electrical”; piping, under “Piping”;
and charging, under “Startup and Mainte-
nance”. Auxiliary units are found in the
sections devoted to them or in the manuals
accompanying them.
SUPER PLUS™ COMPONENTS
Each Super Plus contains the following:
1. Two to eight Copeland, or two to seven
Carlyle semi-hermetic compressors with
a. High and Low Pressure Controls
b. Oil Pressure Safety Control
c. Primary Overload Protection
d. Compressor Cooling Fans on low
temperature application, or 3⁄4to 3 HP
rating on Copeland air cooled
compressors
2. Factory piping with
a. Suction, Discharge and LiquidHeaders
b. Turba-shed Oil Separator and return
system
c. Dual Receiver Tanks
d. Suction Filters on each compressor
e. Liquid Filter Drier and Sight-glass
f. Liquid Level Indicator
3. Factory-wired control panel with
a. Pre-wired Distribution Power Block
b. Individual component Circuit Breakers
and Contactors
c. Compressor Time Delays
d. Color-coded wiring system
e. Customized wiring diagram
4. Items supplied separately for field
installation
a. Liquid Drier Core
b. Vibration Isolation Pads (8)
c. Loose shipped items for accessories.
Revised August 1, 1996 P/N 340272A
1 - 1
Figure 1-1 – Super Plus™ System
INSTALLATION INSTRUCTIONS
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA

SHIPPING DAMAGE
All equipment should be thoroughly examined
for shipping damage before and while
unloading.
This equipment has been carefully inspected
at our factory and the carrier has assumed
responsibility for safe arrival. If damaged,
either apparent or concealed, claim must be
made to the carrier.
Apparent Loss or Damage
If there is an obvious loss or damage, it must
be noted on the freight bill or express receipt
and signed by the carrier's agent, otherwise,
carrier may refuse claim. The carrier will
supply the necessary claim forms.
Concealed Loss or Damage
When loss or damage is not apparent until
after equipment is uncrated, a claim for
concealed damage is made. Upon discovering
damage, make request in writing to carrier for
inspection within 15 days and retain all
packing. The carrier will supply inspection
report and required claim forms.
SUPER PLUS™ FRAME DIMENSIONS
Rack Assembly Length Height Depth
Nomenclature (in.) (in.) (in.)
01VK, 02VK, 04VY 77 78 35
03VK, 04VK, 05VY 90.5 78 35
05VK, 06VK, 06VY 113 78 35
07VK, 08VK, 07VY 135.5 78 35
08VY 158 78 35
Shell and Tube Mechanical Subcooler, or
Vertical receiver, adds 32 inches to length.
Piping stubs, and shipping crate may extend 6
inches beyond the frame.
Optional suction accumulators or water-cooled
condensers will add 15 inches to depth.
Note: For 08VY and other Extended Racks, consult
with Hussmann Engineering, Bridgeton, Mo.
SYSTEM WEIGHTS
Base Rack Weight
Rack Assembly
Nomenclature Base Weight (lbs)
01VK, 02VK, 04VY 1600
03VK, 04VK, 05VY 1700
05VK, 06VK, 06VY 1800
07VK, 08VK, 07VY 1900
08VY 2200
Shell and Tube Mechanical Subcooler adds
500 lbs to rack. Plate Subcooler adds 100 lbs.
Compressor Weights
Copeland Weight per
Compressor Body compressor (lbs)
M and N 300
2D and 3D 385
4D and 6D 575
3 AND 9 380
4 and 6 530
Carlyle Weight per
Compressor Style compressor (lbs)
06D 295
06E 500
Shipping Weight =
the Sum of Compressor Weights
+the Rack Base Weight.
RECEIVERREFRIGERANTCAPACITIES
Receiver Capacities are based on 80% liquid
fill at 110˚F. All receiver tanks have a
103⁄4inch diameter.
Rack Assembly Receiver R-404a /
Nomenclature Length R507 R-22
(in.) (lbs) (lbs)
01VK, 02VK, 04VY 77 328 394
03VK, 04VK, 05VY 90.5 387 465
05VK, 06VK, 06VY 113 487 584
07VK, 08VK, 07VY 135.5 585 702
08VY 158 684 821
INSTALLATION INSTRUCTIONS Revised August 1, 1996
1 - 2
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA

MACHINE ROOM REQUIREMENTS
•The equipment room floor must solidly
support the compressor unit as a live load.
Ground level installation seldom presents
problems, but a mezzanine installation must
be carefully engineered.
•Ventilation should be 100 cfm per
compressor unit horsepower. The air inlet
should be sized for a maximum of 600 fpm
velocity. The ventilation fans should cycle by
thermostatic control.
•All machine room ventilation equipment
must be field supplied. Check local codes for
variances.
•Proper ventilation provides airflow across the
compressors. Duct work may be necessary.
•Provide a floor drain for disposal of
condensate that may form on the compressor
unit or header defrost assembly.
•Equipment must be located in the machine
room to provide enough working space for
service personnel, and to meet electrical codes.
•Consult NEC National Fire Handbook
particularly “Installation of Switch Boards”
and “Working Space Requirements”. The
figure below demonstrates some suggested
distances. Refer to local codes for each
installation.
Super Plus Load Points (Center to Center)
Rack Assembly Load Point Dimensions
Nomenclature Length Width
(in.) (in.)
01VK, 02VK, 04VY 51 30
03VK, 04VK, 05VY 64.5 30
05VK, 06VK, 06VY 87 30
07VK, 08VK, 07VY 109.5 30
08VY 66 & 66 30
Note: The 08VY and other Extended Rack
have three cross feet and six load points, not the
usual two and four. For nonstandard racks such
as with mechanical subcooling consult
Hussmann Engineering, Bridgeton, Mo.
Revised August 1, 1996 P/N 340272A
1 - 3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA

Minimum Allowable Distances
From the Water Cooled Condenser Outlet to
the Super Plus Receiver Inlet, the minimum
allowable elevation is 1 foot.
With no Flooding Valve; from the mounting
surface of the air cooled Condenser to the
mounting surface of the Super Plus Rack, the
minimum allowable distance is 4.5 feet.
With a Flooding Valve; from the mounting
surface of the air cooled Condenser to the
center of the flooding valve, the minimum
allowable distance is 6 feet.
Maximum Allowable Distances
Remote Satellites should not be placed below
the level of the Super Plus Rack. The Satellite
may be positioned above the Rack. The
maximum allowable elevation is 6 feet from
the bottom of the Satellite to the bottom of the
Rack.
When piping from the Rack to a Remote
Satellite, the maximum allowable piping
equivalent is 50 feet.
When piping from the Rack to a Remote
Header, the maximum allowable piping
equivalent is 50 feet.
When piping from the Rack to a Condenser,
the maximum allowable piping equivalent is
100 feet.
When piping from the Rack to a Heat Reclaim
coil, the maximum allowable piping equivalent
is 50 feet.
INSTALLATION INSTRUCTIONS Revised August 1, 1996
1 - 4
UNIT PLACEMENT
When setting the Super Plus Rack plan in relation to the rest of the equipment to be installed.
Some minimum and maximum distances are listed. Note: Piping equivalent is not the same as
linear distance.
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA

LIFTING AND LEVELING
Using rigging with a spreader bar, the Super
Plus™ may be lifted into position. The
spreader bar is required to prevent damage to
the unit.
NOTE: This unit is slightly front heavy, due
to the Control Panel. Take necessary
precautions when lifting.
Vibration Isolation Pads are supplied with
each rack. The entire weight of the rack must
rest on these pads, with the rack cross leveled.
To adjust for slightly uneven floors, place
16 gauge 3x3-inch galvanized steel shims
between the vibration pads and the floor.
(Shims must be field supplied.)
Revised August 1, 1996 P/N 340272A
1 - 5
Figure 1-4 – Lifting and Leveling the Super Plus™
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA

Extended racks may have an additional
cross foot. These racks are supplied with
12 isolation pads and require cross leveling
for all six load points.
SETTING WITHOUT A CRANE
In many locations crane lifting may not be
practical. Where possible use equipment
dollies centered under each foot or Johnny
bars. Do not push or pull on any of the
pipes, valves, accessories, or Control Panel
when moving the Super Plus Rack.
For mezzanine installations, a fork lift
(operated within its height and weight
limits) may be used to raise the Rack into
place.
NOTE: This unit is slightly front heavy,
due to the Control Panel. Take necessary
precautions when moving and lifting.
INSTALLATION INSTRUCTIONS Revised August 1, 1996
1 - 6
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 • Printed in USA
Figure 1-6
Dolly Placement