J&E Hall JCC2 User manual

JCC2
CELLAR AND PRODUCT COOLERS
ISSUE: 01.02.2016
CELLAR COOLER RANGE
TECHNICAL MANUAL

Issue: 01.02.2016 Page 2
Contents
Nomenclature 3
Standard Product Configuration 3
Specifications
Capacity data 4
System data 4
Unit dimensions & weights 5
Electrical data & requirements 5
Health & Safety
General information 6
Installation
Unit location 7
Installation clearances 8
Field piping 9
Pressure testing 10
Evacuation & charging 11
Drainage 12
Electrical 13
Commissioning 14
Service & Maintenance 15
F-Gas Information 16
Drawings
Indoor unit dimensions (25E & 40E) 17
Indoor unit dimensions (50E & 60E) 18
Outdoor unit dimensions 19
Electrical wiring diagrams (indoor & outdoor) 20
Technical Information
Dixell electronic controller 21
Controller parameters 22
Fan speed controller 23
Certification
Declaration of Conformity 24

Issue: 01.02.2016 Page 3
Nomenclature
Electronic controller
Approximate Nominal Capacity in Kilowatts
25: 2.5Kw
JCC2: J & E Hall Cellar Cooler (Version 2)
Standard product configuration
 Brewery specification 6 fins per inch evaporator coil
 Galvanised mild steel casing with polyester powder coating
 Electronic controller
 Refrigerant R410A
 Low pressure safety switch
 Rotary type compressor
 Acoustic insulation on outdoor unit and compressor
 3/4” BSP drain fitting on indoor unit
 Can operate down to +4°C and up to +16°C
 Suitable for cooling beers, wines, flowers, fruit & vegetables etc.
 Suitable for pipe runs up to 25 metres
JCC2 25 E

Issue: 01.02.2016 Page 4
Specifications
Capacity data
Model
4°C 6°C 8°C 10°C 12°C 12.7°C 14°C 16°C
JCC2 25E 2.70 2.74 2.78 2.82 2.86 2.87 2.90 2.94
JCC2 40E 3.78 3.90 4.02 4.14 4.27 4.31 4.40 4.53
JCC2 50E 4.19 4.32 4.45 4.59 4.73 4.78 4.87 5.02
JCC2 60E 5.29 5.41 5.53 5.65 5.77 5.82 5.90 6.03
Cooling capacities in kW at 32°C ambient temperature
* Room temperature of +4°C is only available with pipe lengths of less than 15 metres
System data
Liquid Suction Length Rise m³/h m dB(A)
JCC2 25E 2560 8 48
J5LC15C 1631 n/a 29
JCC2 40E 2270 8 48
J5LC20C 2208 n/a 29
JCC2 50E 2680 8 47
J5LC25C 2480 n/a 32
JCC2 60E 2560 8 47
J5LC28C 2463 n/a 34
4) Indoor unit air throw distance is 8 metres based on final air velocity of 0.4m/s.
Notes:
1) Db(A) Noise levels are sound pressure levels @ 10m free field
2) Cooling capacities are nominal duties @ 12.7°C db / 10°C wb & 32°C ambient
3) The pipe length must include the rise - the rise is not additional to the length
5.82 3/8" 5/8" 25m 8m
4.78 1/4" 5/8" 25m 8m
4.31 1/4" 1/2" 25m 8m
Noise
Levels
2.87 1/4" 1/2" 25m 5m
Indoor
Airthrow
Unit Model
Cooling
Capacity
Kw
System Pipe Sizes Maximum Pipe Run Unit
Airflows
Important
For applications where the system pipe run exceeds 15m up to the maximum of 25m, the following guidelines must be followed:
 A condenser fan speed controller (not supplied as standard) should be fitted. See page 23 for details.
 The maximum indoor room temperature is restricted to +6°C.

Issue: 01.02.2016 Page 5
Specifications
Unit dimensions & weights
Weights
Width Depth Height Width Depth Kg
JCC2 25E 865 372* 489 745 n/a 31
J5LC15C 700 250 540 441 278 34
JCC2 40E 865 372* 489 745 n/a 34
J5LC20C 855 328 654 603 362 57
JCC2 50E 902 370* 545 824 n/a 36
J5LC25C 855 328 756 603 362 60
JCC2 60E 902 370* 545 824 n/a 38
J5LC28C 855 328 756 603 362 65
Notes:
2) Unit width does not include pipe services - add approximately 70mm
Unit Dimensions (mm)
Model Fixing Centres (mm)
1) * Does not include fan motor depth - add 90mm
Electrical data & requirements
LRA RRC Watts RRC Watts RRC V/Ph/Hz Amps
JCC2 25E n/a n/a n/a n/a 160 0.73
J5LC15C 24 5.2 35 0.31 n/a n/a
JCC2 40E n/a n/a n/a n/a 160 0.73
J5LC20C 27 6.6 42 0.36 n/a n/a
JCC2 50E n/a n/a n/a n/a 160 0.73
J5LC25C 63 7.7 64 0.43 n/a n/a
JCC2 60E n/a n/a n/a n/a 160 0.73
J5LC28C 65 11.4 75 0.79 n/a n/a
Notes:
Indoor
Mains Power
To
Compressor
Mains Power
Supply
Condenser Fan
Interconnecting
Cable
Indoor 3 Core
Indoor
Outdoor Unit
Evaporator Fan
Indoor Unit
230/1/50
Indoor
25230/1/50
1) LRA ~ Locked Rotor Amps
2) RRC ~ Rated Running Current
3 Core 32
3 Core230/1/50 20
3 Core
Model
16
Suggested Fuse
Rating
230/1/50

Issue: 01.02.2016 Page 6
Health and Safety
General information
Before Installation
 Ensure the units received are the correct models for the intended application.
 Ensure the refrigerant, voltage and MWP are all suitable for the proposed application.
 Check there is no damage to the units. Any damage should be advised to the supplier immediately.
 Check that the proposed equipment locations are suitable and provide adequate support for the weight of the units.
During Installation and subsequent maintenance
 Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations,
and experienced with this type of equipment.
 If lifting equipment is required, ensure that it is suitable for purpose, certificated and that the operatives are qualified to use it.
 Safe working methods are identified and operatives have suitable PPE.
 Ensure the working area has adequate ventilation during brazing procedures.
 The units contain moving machinery and electrical power hazards, which may cause severe injury or death. Disconnect and shut off
power before installation or service of the equipment.
 Refrigerant release into the atmosphere is illegal. Proper evacuation, recovery, handling and leak testing procedures must be
observed at all times.
 Units must be earthed and no maintenance work should be attempted prior to disconnecting the electrical supply.
 The electrical covers and fan guards must remain fitted at all times.
 Use of the units outside of the design conditions and the application for which the units were intended may be unsafe and be
detrimental to the units, regardless of short or long term operation.
 The units are not designed to withstand loads or stresses from other equipment or personnel. Such extraneous loads or stress may
cause failure/leak/injury.
Important Note:
Only a qualified refrigeration engineer, who is familiar with refrigeration systems and components
including all controls, should perform the installation and start-up of the system. To avoid potential injury,
use care when working around coil surfaces or sharp edges of metal cabinets. All piping and electrical
wiring should be installed in accordance with all applicable codes, ordinances and local by-laws.

Issue: 01.02.2016 Page 7
Installation
Unit location
 In order to achieve maximum cooling capacity, the installation location for the condensing unit should be carefully selected.
 Install the condensing unit in such a way so that hot air ejected by the condensing unit cannot be drawn in again (short circuit of hot
discharge air). Allow sufficient space for maintenance around the unit.
 Ensure that there is no obstruction to air flow into or out of the unit. Remove obstacles which block air intake or discharge.
 The location must be well ventilated, so the unit can draw in and distribute plenty of air thus lowering the condensing temperature.
 To optimize the unit running conditions, the condenser coil must be cleaned at regular intervals.
The indoor units can be mounted directly to a wall or to the ceiling utilizing the fixing holes on the rear of the unit or on the top of the
unit. No additional brackets are required. Position the indoor unit where the optimum airflow can be achieved. Avoid locating in corners
or in alcoves which may restrict airflows. A minimum 10mm rawlbolt type fixing is required with a large steel washer to bear the unit
weight. It is important to ensure that the wall/ceiling is able to withstand the unit weight and that all fixings are secure.
Both indoor and outdoor units must be level in all directions.


X
X

Issue: 01.02.2016 Page 8
Installation
Installation clearances
 The installation location should allow sufficient space for air flow and maintenance around the units:
Outdoor
Indoor
500mm 500mm
1500mm to
any obstruction
Minimum 1800mm from
floor level

Issue: 01.02.2016 Page 9
Installation
Field piping
To ensure satisfactory operation and performance, the following points should be noted for field piping
arrangements:
 Pipework routes must be as simple and as short as possible.
 Avoid low points on pipework where oil can accumulate.
 Use only clean, dehydrated refrigeration grade copper tube with long radius bends.
 When brazing use only silver alloy rods.
 Run braze without over filling to ensure there is no leakage into the tube.
 To prevent oxidization, blow oxygen free nitrogen through pipework when brazing.
 Protect the casing of the unit when brazing connections.
 Install insulation with a minimum wall thickness of 3/8” on both liquid and suction lines.
 Adequately support all pipe work at a maximum of 2 metre intervals.
Use of incorrect pipe sizes can affect system pressures/temperatures and gas velocity for proper oil return.
Important Note:
One of the main factors affecting equipment reliability and compressor service life is refrigeration
circuit contamination. During installation, circuit contamination can be caused by:
 Brazing & Welding Oxides
 Filings & Particles from de-burring pipework
 Brazing Flux
 Moisture & Air
Important Note:
Pipe sizes and maximum lengths/heights should be strictly as per the information given on page 4. All
local codes of practice must be observed in the installation of refrigerant piping

Issue: 01.02.2016 Page 10
Installation
Pressure testing
Both the indoor and outdoor units have been pressure tested in the factory prior to dispatch. The indoor unit
contains a holding charge of oxygen free nitrogen. The outdoor unit contains a charge of R410A refrigerant.
Once the pipework installation is complete, it should be pressure tested prior to evacuation to test for leaks.
A pressure leak test should be carried out using oxygen free nitrogen (OFN). NEVER USE OXYGEN FOR PRESSURE TESTING SYSTEMS. A
calibrated nitrogen pressure regulator must always be used. Before starting any pressure testing, ensure the area surrounding the system
is safe, inform relevant personnel and fit warning signs indicating high pressure testing. Also, use correct PPE as required.
A simple procedure for testing is as follows:
 Connect a pressure hose from the regulator to the schrader connection on the service port on the condensing unit.
 Pressure system slowly up to 3 bar (45 psi) for 5 minutes and check for any signs of leakage.
 Increase pressure slowly up to 10 bar (150 psi) for 5 minutes and check for any signs of leakage.
 Increase pressure slowly up to 20 bar (300 psi) and check for any signs of leakage. Leave system under pressure for 24 hours.
Listen for any possible leaks and check all joints with bubble spray. If any leaks are discovered, release pressure slowly from system until
empty, repair leak and then restart pressure testing procedure. Never attempt to repair a leak on a pressurized system.
A strength test should also be incorporated according to local regulations.
Once testing has been completed satisfactorily, release the pressure from the system gradually and safely to external atmosphere.
Important Note:
Do not open the service valves on the condensing unit until pressure testing and
evacuation procedures have been carried out.

Issue: 01.02.2016 Page 11
Installation
Evacuation & Charging
Once pressure testing has been completed, the system can now be evacuated to remove air and any moisture from the piping. This can
be done as follows:
 Ensure any nitrogen charge is safely released from the system.
 Connect a gauge manifold to the schrader connection on the service valve on the condensing unit.
 Connect a vacuum pump and vacuum gauge to the system.
 Evacuate the system until vacuum is below 250 microns (0.25 torr).
Note: A triple evacuation procedure is recommended for all new systems or where moisture is suspected.
Once the system is isolated and the vacuum pump is switched off, any rise in pressure indicates that either there may be a leak in the
system or moisture is still present. In this case, recheck the system for leaks, repair as necessary, and then restart the evacuation
procedure. Once completed satisfactorily, the vacuum pump and vacuum gauge can be removed.
At this point, any additional refrigerant charge can be added to the system as required. Additional refrigerant must be charged in the
liquid phase. Use calibrated weighing scales to add the correct amount.
With the gauge manifold connected and closed, slowly open both of the service ports fully on the condensing unit. This will release the
refrigerant charge from the condensing unit into the system.
Systems are pre-charged with refrigerant for pipe runs up to 7.6 metres
Additional refrigerant charge (Note: Revised charges)
 JCC2 25E matched with J5LC15C – Pre Charged with 0.83kg R410A
Additional Charge – 10g per metre up to maximum permissible
 JCC2 40E matched with J5LC20C – Pre Charged with 1.38kg R410A
Additional Charge – 15g per metre up to maximum permissible
 JCC2 50E matched with J5LC25C – Pre Charged with 1.54kg R410A
Additional Charge – 15g per metre up to maximum permissible
 JCC2 60E matched with J5LC28C – Pre Charged with 1.80kg R410A
Additional Charge – 20g per metre up to maximum permissible
Important Note:
Moisture prevents proper functioning of the compressor and the refrigeration system. Ensure that
a good quality vacuum pump is used to pull a minimum vacuum of 250 microns (0.25 torr).

Issue: 01.02.2016 Page 12
Installation
Drainage
The drain fitting is aluminum alloy with a 3/4” BSP male thread. A locknut is supplied to secure to the drain pan. The locknut only requires
hand tightening and then pinching up with a spanner. Do not over tighten or the threads may strip from the nut and also damage the
tray. To fit the drain fitting, remove the drip tray (unscrew the seven screws that secure it), locate the fitting then refit the tray.
A minimum suggested size of drain from the indoor unit is 20mm or 3/4”. This can be either copper or plastic. Flexible hose is not
recommended as it can easily kink causing a blockage and water to back up in the unit.
Important Note:
The evaporator drain pan fitting is supplied loose and must be fitted on site. It is attached to the indoor
unit fan guard with a cable tie. Correct fitting is vital to ensure leak – free operation. The lock nut on the
drain fitting must be fitted the right way around; otherwise it will not tighten against the drip tray. One
side of the nut has an angled recess – this must be facing towards the drip tray. The fitting does not
require any sealant but a small amount of silicon sealant can be applied between the flared face of the
fitting and the drip tray if so desired.

Issue: 01.02.2016 Page 13
Installation
Electrical
Cable type and sizing must be selected for the particular application and the electrical installation should conform
to the current local standards. All indoor and outdoor units are Single Phase.
 Cables to the indoor unit should be routed through the ‘U’ shaped cut-out in the bottom of the removable air grille at the side of
the unit and into the rear of the electric box.
 Cables to the outdoor unit should be routed under the plastic pipe / electrical connection cover on the end of the unit.
 The interconnecting cable between the indoor and outdoor unit should be 3 core (2 core + E).
 Connect the mains supply and interconnecting cables as per the wiring diagrams on page 20.
Access to the electrical terminals and components on the indoor unit is via the removable cover plate on the front of the unit. Removal of
the cover plate gives access to the outdoor unit contactor, the terminal block as well as the electronic controller and rocker switch
connections.
Important Note:
The mains electrical supply to the indoor unit must be via a suitably rated isolator and motor rated
circuit breaker or fuse. There is no isolator fitted to either the indoor or the outdoor unit. The rocker
switch on the front of the indoor unit is for isolating the indoor fan and electronic controller only.
J & E Hall JCC cellar systems require a 230 volt / 1 phase / 50Hz supply which must include a Neutral
and Earth. They are not suitable for any other supply voltages (other than a deviation of +/- 10% of
the above values) and are not suitable for 60 Hz supplies.

Issue: 01.02.2016 Page 14
Installation
Commissioning
Switch on the power at the mains isolator and then switch on the rocker switch on the front of the indoor unit. Set the required operating
temperature on the electronic controller and check the system parameters in the controller are as required (the controllers are pre-
programmed in the factory to suggested settings).
Run the system to the required temperature and check system pressures, gas charge and running currents of motors to ensure correct
operation.
Carry out a manual defrost (press the defrost button on the controller for more than 2 seconds) to ensure the defrost period is adequate
to clear any frost build up on the evaporator coil.
Carry out final leak test and ensure all covers are fitted and securing screws are tightened.
Log all information along with system model and serial numbers for future reference.
Ensure that the customer / responsible person is provided with basic operating instructions and where electrical isolators are situated in
case of emergency.
Important Note:
Before starting the system, ensure that all electrical connections are correctly made and tight, service
ports are in the correct position and all covers and guards are fitted.
Important Note:
An anti short-cycle timer is built into the controller to prevent the compressor from stop/starting too
quickly, which can result in the compressor tripping on its internal overload. If the overload trips,
please allow time for it to reset before restarting.

Issue: 01.02.2016 Page 15
Service & Maintenance
The units are designed to give long life operation with minimum maintenance. However, they should be routinely checked and the
following service schedule is recommended under normal circumstances:
1. Indoor and Outdoor units – Inspect at regular intervals
 Check for refrigerant leaks on all joints and fittings.
 Check mountings for tightness and wear.
 Inspect pipework for any damage.
 Check all electrical connections.
 Ensure that no abnormal noise or vibration is detected during test run.
2. Condenser & Evaporator Fan Motors & Blades – Clean and inspect at regular intervals
 Check for abnormal noise, vibration and fan imbalance.
 Ensure that the fan motors are clean and spin freely.
 Check that the fan blades are clean and free from restriction and damage/imbalance.
 Note: The Fan Motors are pre-lubricated and factory sealed so no maintenance is necessary.
3. Condenser & Evaporator Coils – Clean and inspect at regular intervals
 Check and remove the dirt and debris between the fins using a soft brush and/or a suitable chemical coil cleaner then rinse with
clean water.
 Check and remove any obstacles that may hinder the airflow through the coils.
 Repair any damage to fins and ensure any guards are fitted correctly.
 DO NOT USE HIGH PRESSURE WASHERS ON COILS – THEY DAMAGE THE FINS.
4. Controls
 Check controller settings and operation.
 Check calibration of temperature probe reading.
5. Power Supply – Inspect at regular intervals.
 Check the running current and voltage for the units.
 Check the electrical wiring and tighten the wires onto the terminal blocks if necessary.
6. Refrigerant Charge
 Check the refrigerant charge by ensuring that the system is operating correctly and the system pressures are as expected.
 Carry out a full leak test.
7. Unit decommissioning and disposal
 At the end of the system’s useful life, a suitably qualified engineer should decommission it. The refrigerant and compressor oil
are classed as hazardous waste and as such must be reclaimed and disposed of in the correct manner, including completion of
waste transfer paperwork. The system components must be disposed of or recycled as appropriate in the correct manner.
Important Note:
Warning!
–
Disconnect the mains electrical supply before servicing or opening the
units.

Issue: 01.02.2016 Page 16
F-Gas Information
From 1/1/2015, a new F-Gas Regulation (EC 517/2014) comes into force replacing the old Regulation (EC 842/2006. This will affect
system labelling, information supplied within documentation and also the way in which thresholds for frequency of leak testing
refrigeration systems are calculated. Please be aware of the following:
 The outdoor unit models covered in this Technical Manual contains fluorinated greenhouse gases.
 The indoor unit models come from the factory pressurized with OFN (Oxygen Free Nitrogen) only.
 The GWP (Global Warming Potential) values of refrigerants which are specified for use in this equipment along with the three
new thresholds for leak testing requirements based on TCO₂Eq (Tonnes CO₂Equivalent) are as follows:
RefrigerantCharge‐kg
5T 50T 500T
Refrigerant GWP CO₂Eq CO₂Eq CO₂Eq
R410A 2087.5 2.4 23.9 239
 
 Changes to leak testing requirements are as follows:
OLDLEGISLATION NEWLEGISLATION LEAKCHECKINGFREQUENCY
3‐30kgs 5‐50TCO₂Eq Every12monthsbutcanbeincreasedto24monthsif
fittedwithafixedleakdetectionsystem.
30‐300kgs 50‐500TCO₂Eq Every6monthsbutcanbeincreasedto12monthsif
fittedwithafixedleakdetectionsystem.
300+kgs 500+TCO₂Eq Every6months‐howeverautomaticleakdetection
systemismandatorywhichrequiresservicingevery12
months
Please note: For systems with a charge below 3kg, the changes to the leak checking regime will not apply until 2017. Currently, there is
no requirement for regular leak testing of systems with a total charge below 3kg.
A refrigerant charge label is supplied with each unit manufactured from January 2015. The refrigerant charge for the system must be
entered on the label with indelible ink and must be adhered in the proximity of the product charging port.
①= Unit refrigerant pre-charge amount
②= Additional refrigerant charge added at site (if required)
①+②=Total system refrigerant charge

Issue: 01.02.2016 Page 17
Drawings
Indoor unit dimensions (25E & 40E)

Issue: 01.02.2016 Page 18
Drawings
Indoor unit dimensions (50E & 60E)

Issue: 01.02.2016 Page 19
Drawings
Outdoor unit dimensions
MODEL A B C D E F G H I J K L M N O P Q R S T
J5LC15C 700 521 250 475 170 37 93 100 93 63 441 130 110 14 23 25 3 20 85 65
J5LC20C 855 628 328 508 181 44 93 149 101 113 603 126 164 17 49 32 3 23 73 75
J5LC25C 855 730 328 513 182 44 93 149 101 113 603 126 164 17 47 32 3 23 73 75
J5LC28C 855 730 328 513 182 44 93 149 101 113 603 126 164 17 47 32 3 23 73 75

Issue: 01.02.2016 Page 20
Drawings
Electrical wiring diagrams
Indoor (Pre March 2015) Indoor (Post March 2015)
Note: Units manufactured from March 2015 are fitted with an extra terminal (P3) at the terminal block to provide a wiring
connection point when used with JABC-1 Fresh Air Unit.
Outdoor
CL CN E2