Hillphoenix ADP-M0152-L0000, ADP-M0048-L0000, ADP-M0198-L0000, ADP-M0079-L0000, ADP-M0178-L0000 Installation And Operation Manual
...
INSTALLATION AND OPERATION
Contents
Important Notices............................................... 2
General Information ............................................ 3
AdaptaPAK
Two Fan AdaptaPAK
Three Fan AdaptaPAK
Two Fan AdaptaPAK
Three Fan AdaptaPAK
Four Fan AdaptaPAK
AdaptaPAK
Key to Codes in AdaptaPAK
®
Product Information.............................. 5
®
Unit................................... 4
®
Unit................................. 5
®
Unit....................................... 8
®
Unit................................... 10
®
Unit.................................... 12
®
Models Overview................................ 14
®
Model Numbers................ 16
DX Refrigeration Systems..................................... 17
Refrigeration System Components ........................ 17
multiMAXTM Controller for AdaptaPAK
multiMAX
AdaptaPAK
TM
Controller I/O Connections..................... 23
®
Installation ...................................... 29
®
...................... 21
Systems Start-Up Checklist................................. 43
AdaptaPAK® Maintenance and
Troubleshooting Procedures................................... 45
P096412C ∙ V2 10/31/2018
Due to our commitment to continuous improvement, all specifications shown in this manual are subject to change without notice.
Copyright© 2018 by Hillphoenix
All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means—
electronic or mechanical, including photocopying or recording; or any other information storage and retrieval
system—without express written permission from Hillphoenix.
AdaptaPAK® Parallel Refrigeration System
2
Thank You!
The Hillphoenix AdaptaPAK® refrigeration system provides customers with a compact refrigeration
package designed to remove heat from both medium- and low-temperature loads. Such a system,
as selected by the customer, is built to closely match the necessary heat removal capacity. It is a
DX system with a refrigerant charge matched to the needs of the facility where it is installed. Each
The fans and condensing units are sized to provide for sufficient heat rejection under the most
demanding ambient conditions.
Each Unit utilizes a comprehensive controls system which monitors the refrigeration system to
minimize energy and optimize performance.
The controls system allows field networking to the store’s Building Management System. In
addition, local networks may be installed to create coordinated case defrosts on a common
schedule, similar to traditional refrigeration circuits of traditional remote systems.
Important Notices
Hillphoenix designates important information in all Hillphoenix installation and operations
handbooks with alert symbols. These notices provide information about potential dangers to
personal health and safety – as well as case damage – if these instructions are not carefully
followed.
ATTENTION!
Indicates important information that is
critical to proper system performance.
CAUTION!
Indicates the threat of potential injury if all
instructions are not followed carefully.
DANGER!
Indicates an immediate threat of serious injury
or death if all instructions are followed carefully.
Service Notes
To ensure optimum unit performance, we strongly recommend that Hillphoenix refrigeration
units be installed and serviced by trained and qualified technicians who have experience working
with commercial refrigerated systems, piping, display cases and storage cabinets. For a list of
Hillphoenix-authorized installation and service contractors, visit hillphoenix.com/dealer-group.
AdaptaPAK® Parallel Refrigeration System
General Information
This manual covers general installation and operational information for the Hillphoenix AdaptaPAK® refrigeration
system. Hillphoenix recommends you retain a copy for future reference
Store Conditions
Hillphoenix refrigeration systems are designed to operate in ASHRAE conditions: a climate-controlled store that
maintains a 75 oF (24 oC) interior temperature and a maximum 55% relative humidity. System and display case
operation will be adversely affected by exposure to excessively high ambient temperatures and/or humidity.
Receiving Units
Inspect received units carefully. In the event of shipping damage and/or shortages, please contact the Hillphoenix
Service parts Department at 800-283-1109.
Unit Damage
Claims for damage must be: (1) noted on either the freight bill or the express reciept, and (2) signed by the carrier’s
3
agent. Otherwise, the carrier may refuse the claim. If damage becomes apparent after the cases are unpacked,
retain all packing materials and submit a written request (along with photos of the damage) to the carrier for
inspection within 14 days of receipt of the unit.
Missing Items
Hillphoenix refrigeration systems are inspected before shipping to ensure the highest level of quality. Any claim for
missing items must be made to Hillphoenix within 48 hours of receipt of cases.
Technical Support
For technical support issues regarding this unit, contact the Hillphoenix Systems Division Technical Support
at 1-800-518-6630.
Ordering Unit Parts
If you need to contact Hillphoenix regarding specic xtures or parts, call 800-283-1109 and ask for a Service Parts
If the part does not have a barcode afxed to it, provide the following information:
• Model number and serial number of the unit for which the part is intended. The serial number may be found
on the serial plate located on the unit.
• Length of the part, if applicable.
• Color of part (if painted) or color of polymer part.
• Whether the part is for a left-handed or a right -handed application.
• Quantity of parts
• Ship-to location.
If Hillphoenix Service Parts decides that a part must be returned instead of scrapped, you will be issured a Return
Material Authorization number.
Hillphoenix Part Barcode
Part Number located at bottom left.
AdaptaPAK® Parallel Refrigeration System
4
AdaptaPAK® Parallel Refrigeration System
Section 1:
AdaptaPAK® Product Information
Hillphoenix offers the AdaptaPAK® range of parallel refrigeration systems to
provide customers with an effective alternative to centralized parallel systems.
The various versions of AdaptaPAK® are designed to meet a wide range of
requirements.
AdaptaPAK® Features and Benets
The Hillphoenix AdaptaPAK® parallel system works like any conventional DX refrigeration system, with the main
difference being that there may be one or more individual systems required to serve the full range of refrigeration
loads in a store. The arrangement is different than the installation of one, single, large centralized refrigeration
system, the multiple condensers are an integral part of the unit.
5
It is also designed specically to improve on the
performance of low and/or medium temperature
refrigeration installations in drug stores, convenience
stores, and other smaller-footprint retail establishments.
An AdaptaPAK® parallel system shares suction,
discharge, and an integrated condenser across several
compressors. As a result, compressor capacity may
be varied to match the required loads—a much more
efcient design.
Multiple, single units with compressors running
constantly at maximum output waste energy and reduce
component life. Parallel installations, on the other hand,
do just the opposite. Because compressor capacities are allowed to vary to match refrigeration loads, there is a
marked savings of energy utilized—20% or more compared to single compressor unit—as well as positive benets on
the live of all system components.
There is also a savings in initial capital outlay with a parallel system. Shared suction, discharge, and an integrated
condenser among compressors virtually guarantees cost savings versus the expense inherent in purchasing
several, self-contained single units. Plus, the single point electrical connection along with a single roof curb and roof
penetration add up to additional savings in installation costs.
Hillphoenix AdaptaPAK® parallel systems are available in a 2 fan unit, a 3 fan unit, and a 4 fan conguration. The
compressors would be arranged in up to two suction groups, with one loop per suction group.
AdaptaPAK® Parallel Refrigeration System
6
Whether a 2 fan unit or a 3 fan unit, the AdaptaPAK® system will arrive fully designed for your load conguration,
and ready for placement at the site in your designated pad or roof location. Placement would most commonly be
performed with a cable/rope with proper rigging (refer to drawings for details).The remaining tasks would include
charging with refrigerant, making electrical connections, and completing the connection of the AdaptaPAK® unit up
to your refrigeration loads.
Dimensions of AdaptaPAK® Units
The 2 fan unit is 139 1/4 inches long by 50 1/2 inches wide by 51 1/4 inches high.
The 3 fan unit is 180 inches long by 50 1/2 inches wide by 51 1/4 inches high.
The 4 fan unit is 220 inches long by 50 1/2 inches wide by 51 1/4 inches high.
Clearances for AdaptaPAK® Units (2 fan and 3 fan)
Air Intake: 36 inches recommended
Air Exhaust: 36 inches recommended
Piping Clearance: 36 inches (minimum) recommended
Hinged Front Door: 36 inches (outward from door) by 50 inches (width)
NEC Electrical: 36 inches (outward from door) by 50 inches (width)
Weights of AdaptaPAK® Units (2 fan and 3 fan)
Fans Compressors Estimated Weight
2 4 3,000 lbs
3 6 3, 500 lbs
4 8 4,000 lbs
AdaptaPAK® Units’ Standard Features
The following features are provided as standard equipment on AdaptaPAK® units (2 fan, 3 fan, and 4 fan):
• Pre-painted, galvanized steel cabinet (pueblo tan).
• Refrigerants available are R-407A and R-448A/R-449A
• Uncoated copper tube/aluminum n condenser coil.
• Main power is 208V.
• Scroll compressors (only).
• Digital scroll compressor as the lead compressor per suction group
• Receiver includes analog liquid level indicator/alarm.
• Replaceable core lter/drier and sight glass.
• Oversized receiver.
• Fixed speed AC condenser fan motors.
AdaptaPAK® Parallel Refrigeration System
• One low pressure control per suction group.
• One high pressure control per compressor.
• OMB electronic oil oat per compressor.
• Discharge centrifugal oil separator with integral oil reservoir.
• Through-the-door power disconnect for serviceability.
• Phase loss monitor with brownout protection.
• IEC contactors for all compressors.
• Convenient service control switches for compressors.
• Off cycle and electric defrost are available.
• Remote defrost panel (when required) will be shipped loose for eld installation.
• Hillphoenix multiMAX™ control system installed in control panel.
Note that the AdaptaPAK® units are designed for outdoor placement, and thus are constructed with a painted
steel nish for durability. Each unit has its own designated lifting points to facilitate easy lifting and site placement.
Removable panels and hinged access doors provide for both equipment protection and serviceability.
7
In addition to the standard equipment detailed in the list above, customer-selectable options may have been include
on the unit being installed. Please check the customer order or the Hillphoenix acknowledgement to determine
which custom options have been provided for your specic unit. These options are detailed below.
Available AdaptaPAK® Unit Options
The following features are available as optional equipment on AdaptaPAK® units:
• Variable speed EC condenser fan motors.
• 460V main power.
• Electron coated condenser coil.
• Heat reclaim valve package (remote only).
• Cold Weather Package - split condenser and heated/insulated receiver
• Hail guard.
• Digital liquid level indicator/alarm.
• Low-pressure control per compressor.
AdaptaPAK® Parallel Refrigeration System
8
Two Fan AdaptaPAK® Unit
As noted earlier, this unit has two condenser fans and up to two condensers sized appropriately for the design-
specied refrigeration heat removal loads.
The dimensions of the two fan unit, as well as the required clearances for operation and serviceability were provided
earlier in this section.
Of course, the design-specied refrigeration heat removal load would be the determining the number/capacity of the
compressors, the receiver size, and the details of the parallel system.
A rear, isometric view of the two fan AdaptaPAK® unit is shown below. Note that on this drawing the access panels
and doors have been removed.
Two Fan AdaptaPAK® Unit
Rear Isometric View
Access Panels Removed
For Clarity
Note that the condenser coil(s) are located at the rear of the unit. The two fans on the top of the unit would draw
ambient outdoor air in through the condenser coil(s) and exhaust that air through the fans on top. As noted
previously, sufcient clearances are required for proper unit operation.
AdaptaPAK® Parallel Refrigeration System
The layout drawing provided below shows the front view of the two fan unit, as well as the two end views.
Two Fan AdaptaPAK® Unit
LEFT END VIEW FRONT VIEW RIGHT END VIEW
Also, as previously noted. a drawing is supplied which depicts the lifting points on the two fan AdaptaPAK® unit, and
details an appropriate lifting jig and the necessary rigging for the cable/rope to perform a level lift and successful
placement of this unit.
9
Two Fan AdaptaPAK® Unit
Lifiting
Detail
AdaptaPAK® Parallel Refrigeration System
10
Three Fan AdaptaPAK® Unit
This unit has three condenser fans and two condensers sized appropriately for the design-specied refrigeration
heat removal loads.
The dimensions of the three fan unit, as well as the required clearances for operation and serviceability were
provided earlier on page two.
Of course, the design-specied refrigeration heat removal load would be used in determining the number/capacity of
the compressors, the receiver size, and the details of the parallel system.
A rear, isometric view of the three fan AdaptaPAK® unit is shown below. Note that on this drawing the access panels
and doors have been removed
Three Fan AdaptaPAK® Unit
Rear Isometric View
Access Panels Removed
For Clarity
Note that the condenser coil(s) are located at the rear of the unit. The three fans on the top of the unit would
draw ambient outdoor air in through the condenser coil(s) and exhaust that air through the fans on top. As noted
previously, sufcient clearances are required for proper unit operation.
AdaptaPAK® Parallel Refrigeration System
The layout drawing provided below shows the front view of the three fan unit, as well as the two end views.
Three Fan AdaptaPAK® Unit
LEFT END VIEW FRONT VIEW RIGHT END VIEW
Also, as previously noted. a drawing is supplied which depicts the lifting points on the three fan AdaptaPAK®
unit, and details an appropriate lifting jig and the necessary rigging for the cable/rope to perform a level lift and
successful placement of this unit.
11
Three Fan AdaptaPAK® Unit
Lifiting
Detail
AdaptaPAK® Parallel Refrigeration System
12
Four Fan AdaptaPAK® Unit
This unit has four condenser fans and two condensers sized appropriately for the design-specied refrigeration heat
removal loads.
The dimensions of the four fan unit, as well as the required clearances for operation and serviceability were provided
earlier on page two.
Of course, the design-specied refrigeration heat removal load would be used in determining the number/capacity of
the compressors, the receiver size, and the details of the parallel system.
A rear, isometric view of the four fan AdaptaPAK® unit is shown below. Note that on this drawing the access panels
and doors have been removed
Four Fan AdaptaPAK® Unit
Access Panels Removed
For Clarity
Rear Isometric View
Note that the condenser coil(s) are located at the rear of the unit. The four fans on the top of the unit would
draw ambient outdoor air in through the condenser coil(s) and exhaust that air through the fans on top. As noted
previously, sufcient clearances are required for proper unit operation.
AdaptaPAK® Parallel Refrigeration System
The layout drawing provided below shows the front view of the four fan unit, as well as the two end views.
13
Four Fan AdaptaPAK® Unit
LEFT END VIEW FRONT VIEW RIGHT END VIEW
Also, as previously noted. a drawing is supplied which depicts the lifting points on the four fan AdaptaPAK® unit, and
details an appropriate lifting jig and the necessary rigging for the cable/rope to perform a level lift and successful
placement of this unit.
Four Fan AdaptaPAK® Unit
Lifiting
Detail
AdaptaPAK® Parallel Refrigeration System
Model Overview
*Not available with split condenser due to single coil design-- available with heated and insulated re ceiver for low ambient application s
Model
Number
of Fans
#
Coils
#
Compressors
Unit
Weight
Connections
LT Sucti on
Connection
MT Suction
Connection
LT Liquid
Connection
MT Liquid
Connection
Power
Supply
MCA MOPD
Medium
Temp Units
ADP-M0048-L0000* 21 2 2600 1- 5/8 1-1/8 208.0 47. 3 60.0
ADP-M0079-L0000* 21 2 2600 1-5/8 1-1/8 208.0 60.9 80.0
ADP-M0106-L0000 22 2 2600 1- 5/8 1-1/8 208.0 85.7 110.0
ADP-M0152-L0000 22 3 2700 2-1/8 1-1/8 208.0 108.2 125.0
ADP-M0178-L0000 22 3 2700 2-1/8 1-1/8 208.0 134.2 150.0
ADP-M0198-L0000 22 4 2800 2 -1/8 1-1/8 208.0 1 30.7 150.0
ADP-M0253-L0000 32 6 3400 2-1/8 1-1/8 208.0 185.5 200.0
ADP-M0299-L0000 32 6 3500 2-1/8 1-1/8 208.0 208.0 225.0
ADP-M0349-L0000 32 6 3200 3 -1/8 1-1/8 208.0 194.0 225.0
ADP-M0403-L0000 42 6 4000 3 -1/8 1-1/8 208.0 232.0 250.0
ADP-M0442-L0000 42 6 4000 3 -1/8 1-1/8 208.0 240.0 250.0
Lo w Te mp
Units
ADP-M0000-L0032* 21 2 2600 1-5/8 7/8 208.0 62.2 80.0
ADP-M0000-L0052* 21 2 2600 1-5/8 7/8 208.0 81.8 1 10.0
ADP-M0000-L0076* 21 3 2700 2-1/8 7/8 208.0 105.7 125.0
ADP-M0000-L0099 22 4 2800 2-1/8 7/8 208.0 129.6 150.0
ADP-M0000-L0122 22 5 2950 2-1/8 7/8 208.0 153.5 175.0
ADP-M0000-L0145 22 6 3100 2-1/8 7/ 8 208.0 1 7 7. 4 200.0
ADP-M0000-L0161 32 6 3200 3-1/8 7/8 208.0 18 7. 0 20 0.0
ADP-M0000-L0190 32 6 3250 3 -1/8 7/8 208.0 213.0 225.0
Dual Temp
Units
ADP-M0048-L0012*^ 21 4 2800 7/8 1-5/8 1/2 1-1/8 208.0 64.3 80.0
ADP-M0079-L0012*^ 21 4 2800 7/ 8 1-5/8 1/2 1-1/8 208.0 77. 9 100.0
ADP- M0106 -L0012^ 22 4 2800 7/ 8 1-5/8 1 /2 1-1/8 208.0 97. 9 125.0
ADP- M0152- L0012^ 22 5 2950 7/ 8 2-1/8 1/2 1-1/8 208.0 120.2 150.0
ADP- M0178-L0012^ 22 5 2950 7/ 8 2-1/8 1/2 1-1 /8 208.0 14 6.2 175.0
ADP-M0048-L0032* 21 4 2800 1-5/8 1-5/8 7/8 1-1/8 208.0 86.8 100.0
ADP-M0079-L0032 22 4 2800 1-5/8 1-5/8 7/ 8 1-1/8 208.0 100 .4 110.0
ADP-M0106-L0032 22 4 2800 1-5/8 1-5/8 7/8 1-1/8 208.0 120.2 150.0
ADP-M0152-L0032 22 4 2950 1-5/8 2-1/8 7/8 1-1/8 208.0 142.7 175 .0
ADP-M0048-L0052 22 4 2800 1- 5/8 1-5/8 7/ 8 1-1/8 208.0 106.4 125.0
ADP-M0079-L0052 22 4 2800 1- 5/8 1-5/8 7/ 8 1-1/8 208.0 12 0.0 150.0
ADP-M0106-L0052 22 4 2800 1-5/8 1-5 /8 7/8 1-1/8 208.0 139.8 175.0
ADP-M0048-L0076 22 5 2950 2-1/8 1-5/8 7/8 1-1 /8 208.0 130.3 150.0
ADP-M0079-L0076 22 5 2950 2-1/8 1-5/8 7/8 1-1/8 208.0 14 3.9 175.0
ADP-M0106-L0076 22 5 2950 2-1/8
1-5/8 7/8 1-1 /8 208.0 16 3.7 175.0
TM
Model Overview
*Not available with s plit condenser due to single coil d esign--availabl e with heated and insulated rece iver for low ambient application s
^ Uses fixed spe ed scroll in lieu of digital scro ll on low temp due to compressor avail ability
Model
Number
of Fans
#
Coils
#
Compressors
Unit
Weight
Connections
LT Su cti on
Connection
MT Suction
Connection
LT Liquid
Connection
MT Liquid
Connection
Power
Supply
MCA MOPD
Medium
Temp Units
ADP-M0048-L0000* 21 2 2600 1-5/8 1-1/8 208.0 47. 3 60.0
ADP-M0079-L0000* 21 2 26 00 1-5/8 1-1/8 20 8.0 60.9 80.0
ADP-M0106-L0000 22 2 260 0 1-5/8 1-1/8 208 .0 85.7 110.0
ADP-M0152-L0000 22 3 270 0 2-1/ 8 1-1/8 208.0 108.2 125.0
ADP-M0178 -L0000 22 3 2700 2 -1/8 1-1/8 208 .0 13 4.2 150.0
ADP-M0198-L0000 22 4 280 0 2-1/8 1-1/8 208 .0 1 30 .7 15 0.0
ADP-M0253-L0000 32 6 3400 2-1/8 1-1/8 208.0 185.5 200.0
ADP-M0299-L0000 32 6 3500 2-1 /8 1-1/8 208.0 208.0 225.0
ADP-M0349-L0000 32 6 320 0 3-1/8 1-1/8 208 .0 194.0 225.0
ADP-M0403-L0000 42 6 4000 3-1/ 8 1-1/8 208.0 232.0 250.0
ADP-M0442-L0000 42 6 4000 3-1/8 1-1 /8 20 8.0 240.0 25 0.0
Low Temp
Units
ADP-M0000-L0032* 21 2 2600 1-5/8 7/8 208.0 62.2 80.0
ADP-M0000-L0052* 21 2 2600 1-5/8 7/8 208.0 81.8 110.0
ADP-M0000-L0076* 21 3 2700 2-1 /8 7/8 208.0 105 .7 125.0
ADP-M0000-L0099 22 4 28 00 2-1/8 7/8 208.0 129.6 150.0
ADP-M0000-L0122 22 5 2950 2-1 /8 7/8 208.0 153.5 175 .0
ADP-M0000-L0145 22 6 310 0 2-1/8 7/8 208.0 17 7.4 200.0
ADP-M0000-L0161 32 6 3200 3 -1/8 7/8 208.0 1 87. 0 20 0.0
ADP-M0000-L0190 32 6 3 250 3-1/8 7/8 208.0 213.0 225.0
Dual Temp
Units
ADP-M0048-L0012*^ 21 4 2800 7/8 1-5/8 1/2 1-1/8 2 0 8.0 6 4.3 8 0.0
ADP-M0079-L0012*^ 21 4 2800 7/ 8 1-5/8 1/2 1-1/8 208.0 7 7. 9 100.0
ADP- M0106- L0012^ 22 4 280 0 7/8 1-5 /8 1/2 1-1/8 208.0 9 7. 9 125.0
ADP- M0152-L0012^ 22 5 2950 7/ 8 2-1/8 1/2 1-1/8 208.0 120.2 150.0
ADP- M0178-L0012^ 22 5 2950 7/ 8 2-1/8 1/2 1-1/8 208.0 146.2 175. 0
ADP-M0048-L0032* 21 4 2800 1-5/8 1-5/8 7/ 8 1-1/8 2 08.0 8 6.8 100.0
ADP-M0079-L0032 22 4 2800 1- 5/8 1-5/8 7/ 8 1- 1/8 20 8.0 100.4 1 10.0
ADP-M0106-L0032 22 4 2800 1- 5/8 1-5/8 7/ 8 1-1/8 20 8.0 120.2 150.0
ADP-M0152-L0032 22 4 2950 1-5/8 2-1/8 7/ 8 1-1/8 20 8.0 142 .7 175.0
ADP-M0048-L0052 22 4 280 0 1-5/8 1-5/8 7/ 8 1-1/8 2 08.0 106.4 1 25.0
ADP-M0079-L0052 22 4 2800 1- 5/8 1-5/8 7/ 8 1-1 /8 20 8.0 120.0 15 0.0
ADP-M0106-L0052 22 4 2800 1- 5/8 1-5/8 7/ 8 1-1/8 20 8.0 139.8 175.0
ADP-M0048-L0076 22 5 2950 2-1 /8 1-5/8 7/8 1-1/8 208.0 130.3 150.0
ADP-M0079-L0076 22 5 2950 2-1/8 1-5/8 7/ 8 1-1 /8 20 8.0 143.9 175.0
ADP-M0106-L0076 22 5 2950 2-1/8
1-5/8 7/ 8 1-1/8 208.0 16 3.7 175 .0
14
^ Uses fixed speed scroll in lieu of digital scroll on low temp due to c ompres sor availability
ADP-M0048-L0076 22 5 2950 2-1/8 1-5/8 7/8 1-1 /8 208.0 130.3 150.0
ADP-M0106-L0076 22 5 2950 2-1/8
ADP-M0079-L0076 22 5 2950 2-1/8 1-5/8 7/8 1-1/8 208.0 143.9 175.0
ADP-M0048-L0052 22 4 2800 1- 5/8 1-5/8 7/ 8 1-1/8 208.0 106.4 125.0
ADP-M0106-L0052 22 4 2800 1-5/8 1-5 /8 7/8 1-1/8 208.0 139.8 175. 0
ADP-M0079-L0052 22 4 2800 1- 5/8 1-5/8 7/ 8 1-1/8 208.0 12 0.0 150.0
Dual Temp
Units
ADP-M0152-L0032 22 4 2950 1-5/8 2-1/8 7/8 1-1/8 208.0 142.7 175 .0
ADP-M0048-L0032* 21 4 2800 1-5/8 1-5/8 7/8 1-1/8 208.0 86.8 100.0
ADP- M0152- L0012^ 22 5 2950 7/ 8 2-1/8 1/2 1-1/8 208.0 120.2 150.0
ADP-M0106-L0032 22 4 2800 1-5/8 1-5/8 7/8 1-1/8 208.0 120.2 150.0
ADP- M0178-L0012^ 22 5 2950 7/ 8 2-1/8 1/2 1-1/8 208.0 146.2 175.0
ADP-M0079-L0032 22 4 2800 1-5/8 1-5/8 7/ 8 1-1/8 208.0 100 .4 110.0
ADP-M0048-L0012*^ 21 4 2800 7/8 1-5/8 1/2 1-1/8 208.0 64.3 80.0
ADP-M0079-L0012*^ 21 4 2800 7/ 8 1-5/8 1/2 1-1/8 208.0 7 7. 9 100.0
ADP- M0106 -L0012^ 22 4 2800 7/ 8 1-5/8 1 /2 1-1/8 208.0 97. 9 125.0
ADP-M0000-L0190 32 6 3250 3 -1/8 7/8 208.0 213.0 225.0
ADP-M0000-L0161 32 6 3200 3-1/8 7/8 208.0 1 87. 0 200.0
Lo w Te mp
Units
ADP-M0000-L0099 22 4 2800 2-1/8 7/8 208.0 129.6 150.0
ADP-M0000-L0122 22 5 2950 2-1/8 7/8 208.0 153.5 175.0
ADP-M0000-L0145 22 6 3100 2-1/8 7/ 8 208.0 1 7 7. 4 200.0
ADP-M0000-L0032* 21 2 2600 1-5/8 7/8 208.0 62.2 80.0
ADP-M0000-L0052* 21 2 2600 1-5/8 7/8 208.0 81.8 110.0
ADP-M0000-L0076* 21 3 2700 2-1/8 7/8 208.0 105.7 125.0
ADP-M0403-L0000 42 6 4000 3-1/8 1-1/8 208.0 232.0 250.0
ADP-M0349-L0000 32 6 3200 3 -1/8 1-1/8 208.0 194.0 225.0
ADP-M0442-L0000 42 6 4000 3-1/8 1-1/8 208.0 240.0 250.0
Temp Units
Medium
ADP-M0299-L0000 32 6 3500 2-1/8 1-1/8 208.0 208.0 225.0
ADP-M0253-L0000 32 6 3400 2-1/8 1-1/8 208.0 185.5 200.0
ADP-M0198-L0000 22 4 2800 2-1/8 1-1/8 208.0 130.7 150.0
ADP-M0152-L0000 22 3 2700 2-1/8 1-1/8 208.0 108.2 125.0
ADP-M0178-L0000 22 3 2700 2-1/8 1-1/8 208.0 134.2 150.0
ADP-M0048-L0000* 21 2 2600 1- 5/8 1-1/8 208.0 47. 3 60.0
ADP-M0079-L0000* 21 2 2600 1-5/8 1-1/8 208.0 60.9 80.0
ADP-M0106-L0000 22 2 2600 1- 5/8 1-1/8 208.0 8 5.7 110.0
Model
Number
of Fans
Coils
#
Compressors
#
Weight
Unit
Connection
LT Sucti on
1-5/8 7/8 1-1 /8 208.0 16 3.7 175.0
MT Suction
Connection
Connection
LT Liquid
Connections
Connection
MT Liquid
Supply
Power
MCA MOPD
Model Overview
AdaptaPAK® Parallel Refrigeration System
TM
*Not available with split condenser due to single coil design-- available with heated and insulated re ceiver for low ambient application s
^ Uses fixed speed scroll in lieu of digital scroll on low temp due to c ompres sor availability
TM
TM
15
Model Overview continued...
MCA MOPD
Power
Supply
MT Liquid
Connection
Connections
LT Liquid
Connection
Connection
MT Suction
LT Sucti on
Connection
Unit
Weight
#
Compressors
#
Coils
of Fans
Number
Model
ADP-M0178-L0076 32 6 3500 2-1/8 2-1/8 7/8 1-1/8 208.0 219.1 250.0
ADP-M0152-L0076 32 6 3500 2-1/8 2-1/8 7/ 8 1-1/8 208.0 193.1 225.0
ADP-M0178-L0052 32 5 3400 1- 5/8 2-1/8 7/8 1-1/8 208.0 195.2 225.0
ADP-M0178-L0032 32 5 3400 1- 5/8 2-1/8 7/8 1-1/8 208.0 175 .6 200.0
ADP-M0152-L0052 32 5 3400 1- 5/ 8 2-1 /8 7/ 8 1-1 /8 208.0 169.2 200.0
Dual Temp
ADP-M0161-L0095 32 6 3300 2-5/8 2-1/8 7/8 5/8 20 8.0 196.0 225.0
ADP-M0131-L0095 32 5 3200 2-5/8 2-1/8 7/8 5/8 208.0 182.0 200.0
ADP-M0221-L0052 32 5 3250 2 -1/8 2-5/8 5/8 7/ 8 208.0 184.0 200.0
ADP-M0221-L0095 32 6 3400 2-1/8 2-5/8 7/ 8 7/ 8 208.0 223.0 25 0.0
ADP-M0108-L0090 32 5 3200 2-5/8 2-1/8 7/8 5/8 208.0 169.0 175.0
Units
Continued
ADP-M0221-L0062 32 5 3250 2-1/8 2-5/8 5/8 7/ 8 208.0 193.0 225.0
*Not available with split condenser due to single coil design-- available with heated and insulated re ceiver for low ambient application s
^ Uses fixed speed scroll in lieu of digital scroll on low temp due to c ompres sor availability
AdaptaPAK® Parallel Refrigeration System
16
Key to Codes in AdaptaPAK Model Numbers
ADP-MXXXX-LXXXX- ______
ADP = AdapatPAK Platform
(X) - Number of Condenser Fans
MXXXX = Medium Temperature Load in KBTUs
LXXXX = Low Temperature Load in KBTUs
SUFFIX - KEY TO OPTIONS
SPLIT
EC
COATED
HAIL
HE AT
LP
CONDENSER
S E C H R P
Example: ADP-M0079-L0012-ER
MOTOR
COIL
GUARD
RECLAIM
SWITCH/COMPR
ADAPTAPAK Model Breakdown
(the number in parentheses is the number of condenser fans)
LOW TEMP
SINGLE SUCTION
ADP(2)-M0000-L0032 ADP(2)-M0048-L0000 ADP(2)-M0048-L0012 ADP(3)-M0178-L0032
ADP(2)-M0000-L0052 ADP(2)-M0079-L0000 ADP(2)-M0079-L0012 ADP(3)-M0152-L0052
ADP(2)-M0000-L0076 ADP(2)-M0106-L0000 ADP(2)-M0106 -L0012 ADP(3)-M0178-L0052
ADP(2)-M0000-L0099 ADP(2)-M0152-L0000 ADP(2)-M0152-L0012 ADP(3)-M0152-L0076
ADP(2)-M0000-L0122 ADP(2)-M0178-L0000 ADP(2)-M0178-L0012 ADP(3)-M0178-L0076
ADP(2)-M0000-L0145 ADP(2)-M0198-L0000 ADP(2)-M0048-L0032 ADP(4)-M0221-L0052
ADP(4)-M0000-L0161 ADP(3)-M0253-L0000 ADP(2)-M0079-L0032 ADP(4)-M0221-L0062
ADP(4)-M0000-L0190 ADP(3)-M0299-L0000 ADP(2)-M0106-L0032 ADP(4)-M0221-L0095
MED TEMP
SINGLE SUCTION
ADP(4)-M0349-L0000 ADP(2)-M0152-L0032
ADP(4)-M0403-L0000 ADP(2)-M0048-L0052
ADP(4)-M0442-L0000 ADP(2)-M0079-L0052
MEDIUM TEMP AND LOW TEMP
DUAL SUCTION
ADP(2)-M0106-L0052
ADP(2)-M0048-L0076
ADP(2)-M0079-L0076
ADP(2)-M0106-L0076
ADP(4)-M0108-L0090
ADP(4)-M0131-L0095
ADP(4)-M0161-L0095
AdaptaPAK® Parallel Refrigeration System
Section 2:
DX Refrigeration Systems
Direct expansion (DX) refrigeration is one of the most common methods
used for the removal of heat. Such a system takes heat from a place where
it is unwanted and removes it to a place where it is unobjectionable. The
Hillphoenix® AdaptaPAK® units utilize DX refrigeration to remove heat from
store display cases and walk-in coolers/freezers, and transfer it to an outdoor location where it can be rejected.
Refrigeration Through Vapor Compression
Refrigeration is accomplished through application of various mechanical principles that occur as part of a
continuous cycle, commonly known as the Vapor Compression Refrigeration Cycle.
17
In the vapor compression cycle, heat is absorbed as the liquid refrigerant in the evaporator changes to a vapor. The
refrigerant boils at the new saturation point in the evaporator (located in the display case or cooler) where it changes
to a superheated vapor. From the evaporator, the superheated refrigerant vapor enters the compressor and the
refrigerant is compressed and changed from a low pressure superheated vapor to a high pressure superheated
vapor (more on this later), It then ows to the condenser. In a simple refrigeration system, the ambient air outside of
the condenser ows through the coils of the condenser where it absorbs heat from the vapor refrigerant causing it to
change back to its liquid state before moving through the metering device where it crosses from the high pressure
side of the system to the low pressure side. On the low pressure side, the refrigerant returns to the evaporator and
the process (refrigeration cycle) is then repeated.
Refrigeration System Components
Knowing how the refrigeration process works helps in understanding where in the sequence of operation the major
components of the mechanical system are, and the functions they perform. Almost any refrigeration system is built
around four main components.
The four main components are:
• Compressor
• Condenser
• Metering Device (also known as an expansion valve)
• Evaporator
Beginning on the next page, these main components are individually presented and discussed.
AdaptaPAK® Parallel Refrigeration System
18
Compressor
The compressor in a mechanical, vapor compression refrigeration system performs a basic function. It generates the
pressure differential to move the refrigerant through the complete refrigeration cycle. It accomplishes its function in
several simple steps. These steps are:
• The compressor draws in the low pressure refrigerant vapor from the evaporator (compressor suction side).
• Through mechanical means, the compressor compresses the refrigerant vapor to a high pressure.
• The high pressure refrigerant vapor is forced to exit the compressor through a discharge line.
The compressor performs work on the refrigerant by compressing it and raising its pressure and temperature. It thus
adds energy to the refrigerant vapor.
Different types of compressors are used in different systems for various reasons. Some, called reciprocating
compressors, draw the refrigerant into a cylinder, compress it, and then discharge it at a higher pressure. Other types
compress the vapor between mating pairs of off-center scrolls (scroll compressors). Regardless of the method used, all
types of compressors are designed to compress the refrigerant vapor, and thereby increase its pressure and move it
through the refrigeration system.
Condenser
The condenser in a refrigeration system is designed to reject the heat energy that was picked up in the evaporator
and the compressor, and reject it to the cooler outside ambient air. This process causes the high pressure
refrigerant vapor to condense and become a high pressure liquid. The condenser operates as follows:
• The high pressure/temperature refrigerant vapor enters the condenser via the compressor discharge line.
• As the hot vapor enters the condenser and begins to ow through tubes of the condenser coil, lower temperature
ambient air is drawn across the outside of the condenser’s tubes/ns. An operating fan is often used as the
motive force to move the air through the condenser coil.
• Due to the temperature difference, heat is transferred from the hot refrigerant to the cooler ambient air.
• As the hot refrigerant vapor gives up its heat, it changes state (condenses) and becomes a liquid.
• This liquid refrigerant then leaves the condenser via the “liquid line,” and travels to the metering device.
All refrigeration systems utilize a condenser, with one of the most common types being air-cooled. The tubes of the
condenser have copper or aluminum ns attached to them which act to dissipate the heat more effectively (other
materials are used, but copper and aluminum are the most common).
Pressure is controlled in the condenser by a variety of means. On air-cooled condensers, a valve in the condenser’s
return line closes at a preset pressure in order to maintain pressure in the coil. As the pressure increases, the valve
modulates so that a consistent pressure is maintained. The fans that force ambient air through the condenser are
also cycled on and off to assist in the heat transfer process as needed.
AdaptaPAK® Parallel Refrigeration System
Metering Device (Expansion Valve)
After the condenser, the high pressure liquid refrigerant reaches the metering device (expansion valve). The metering
device meters, or controls, the ow of refrigerant from the high pressure, high temperature side of the system to the
low pressure, low temperature evaporator. Important functions include:
• The metering device (expansion valve) regulates how much liquid refrigerant ows and enters the evaporator.
• The small opening for liquid refrigerant ow takes different forms. In some systems the metering device is a
small thin copper tube known as a capillary tube; in others it is a small orice that regulates ow; and in other
refrigeration systems it is a thermostatic expansion valve (TEV or TXV).
• Control of the size of the opening for ow is crucial. It determines how much liquid refrigerant is allowed to
pass. The size of this opening determines the temperature difference that exists between the saturated suction
temperature (SST) and the temperature at the outlet of the evaporator. This temperature difference is so
important that it has its own specic name—superheat.
One of the most common types of metering device is the thermostatic expansion valve (often referred to as a
TXV or TEV). The opening/closing of these valves is controlled by the pressure and temperature at the exit of the
19
evaporator.
Evaporator
Liquid refrigerant enters the evaporator from the metering device. The evaporator is located in the space that is being
refrigerated. Several things happen in the evaporator:
• The liquid refrigerant entering the evaporator from the metering device (expansion valve) undergoes an
instantaneous large pressure decrease (per the P-T chart, this is also a large temperature decrease).
• As it enters the evaporator, the liquid refrigerant immediately begins to absorb heat from the warm air owing
over the tubes and ns of the evaporator coil.
• With the absorption of heat, the liquid refrigerant also begins to change state (boil) to become a vapor.
• As the refrigerant continues to ow through the tubes of the evaporator, the continued absorption of heat results
in more and more of the liquid refrigerant changing state to become a vapor.
• Prior to its exit from the evaporator, the refrigerant will have completely changed over to the superheated vapor
state, and will then enter the suction line and head back to the compressor.
Inside the evaporator is where the refrigerant absorbs heat to carry it away from the refrigerated space. This could be
the refrigerated space of a display case, a reach-in cooler. or walk-in freezer in which frozen foods are kept.
The basic principle at work here is that heat always moves from areas of higher temperature to areas of lower
temperature. The refrigerant absorbs heat in the evaporator because it is at a lower temperature than the air moving
across the evaporator. This temperature difference (TD) between the refrigerant and the air is approximately 8 to 10 °F.
Other components of refrigeration systems besides these basic ones are mainly just combinations of accessories
and options that expand the capabilities of the system. Several of these are discussed later in this manual.
AdaptaPAK® Parallel Refrigeration System
20
multiMAX™ Controller for AdaptaPAK®
Section 3:
multiMAX™ Controller for
AdaptaPAK®
The standard system controller that Hillphoenix installs in the AdaptaPAK®
parallel refrigeration system is the Hillphoenix® multiMAX™ control system. It
is installed in the control panel of this unit.
The multiMAX™ control system is designed to perform all of the necessary control functions awlessly. It is a terric
choice for automatic control of all AdaptaPAK® parallel system control functions. It does a great job of controlling
compressors and condensers, as well as other functions such as: oil management and heat reclaim. It includes
standard alarming functions with and audible buzzer and a ashing red light. It also records system conditions and
provides for alarm logging for easy troubleshooting and system documentation.
21
The Hillphoenix® multiMAX™ controller can perform a large number of different functions.
Hillphoenix multiMAX™ Controller
multiMAX™ Controller for AdaptaPAK®
22
Parallel Rack AdaptaPAK®
The following items apply to the control of the Hillphoenix AdaptaPAK® parallel rack refrigeration system.
Compressors:
• Two suction lines with control by pressure or temperature
• Compressors can be controlled with neutral zone band management
• Controls scroll compressors
• Maximum of 6 compressors
• Four different compressor rotation types: time, LIFO, FIFO, and custom
(LIFO - last in, rst out; FIFO - rst in , rst out)
• Standard compressor alarms featuring; high and low suction, inverter warning, superheat, oil, discharge,
etc.
Condensers:
• Controlled by pressure or temperature
• Proportional band and neutral zone control
• Maximum control of 3 or 2 fans
• Four different condenser fan rotation types: time, LIFO, FIFO, and custom
• Fans can be congured for modulation (pwm or 0 - 10 volts)
• Standard condenser fan alarms: high and low condensing psi and fan overload alarms
Other Functions:
• Oil management, subcooling, liquid injection, and heat reclaim are available features for optimum
compressor control
• Generic functions allow auxiliary functions to be congured for custom applications
Alarms:
• Standard alarming with audible buzzer and ashing red light
• Alarm logging for easy troubleshooting and system documentation
Inputs/Outputs
• All controller Inputs/Outputs are fully congurable (0-5v, 0-1v, 0-10v, and 4-20mA),
( PT1000, NTC, HT-NTC, SPKP, PTC, PT500, and PT100)
• Controller has an I/O test mode for pre-testing of program
multiMAX™ Controller for AdaptaPAK®
Hillphoenix® multiMAX™ Controller (showing input and output connections)
23
Denitions of Inputs and Outputs corresponding to the multiMAX™ Controller I/O.
J12 and J13 - Compressor Enable, Normally Open Relays
J12: Compressors 1, 2, 3 and J13: Compressors 4, 5, 6
Compressor Enable = a Normally Open (NO) relay that is used by the controller to energize one or more compressors
in a given suction group. Energizing or de-energizing compressors is done in order to maintain the proper saturated
suction pressure for the rack.
J14 - Split Condenser Control, Normally Open Relay
J14: Split Condenser Valve
If split condenser operation is called for, the relay will close and only one portion of the condenser will receive
refrigerant ow.
J16 - Condenser Fan Control, Normally Open Relay
J16: Condenser Fans 1, 2, 3
As required to meet system operational demands, condenser fans will be turned on or off. (Cycled to maintain drop
leg pressure.)
J17 - Optional, Water Heat Reclaim, Normally Open Relay
J17: Water Heat Reclaim Valve
With this option, controller would close the relay and thus opening a valve to heat water in a heat exchanger.
multiMAX™ Controller for AdaptaPAK®
24
J18 - Optional, Air Heat Reclaim, Normally Open Relay
J18: Air Heat Reclaim Valve
With this option, controller would close the relay and thus opening a valve to heat air in a heat exchanger.
J21 - Rack Alarm Output, Normally Open Relay
J21: Air Heat Reclaim Valve
If any rack alarm conditions are met, the controller will close the relay, activating rack alarms.
INPUTS
J1 - INPUT PWR, 24V AC/DC
J1: 24VAC Power to Controller
J2 -NTC/PRESS INPUTS
J2: Suction Pressure 1, Discharge Pressure, Drop Leg Pressure
J3 -TEMP INPUTS
J3: Suction Temperature 1, Ambient Temperature
J4 - 0-10VDC OUTPUTS
J4: 24 VAC Power, EC Fan Speed, Digital Compressor 1 Speed, Digital Compressor 2 Speed
J5 - 24V AC/DC DIGITAL INPUTS
J5: Rack Oil Alarm, Phase Loss Alarm 1, Receiver Level SW, Water Heat Reclaim
J6 - NTC/PRESSURE INPUTS
J6: Suction Temperature 2, Suction Pressure 2, Air Heat Reclaim
multiMAX™ Controller for AdaptaPAK®
HILLPHOENIX multiMAX™ CONTROLLER INSTALLED IN AN ADAPTAPAC CONTROL PANEL
25
SEE NEXT PAGE FOR A FULL TWO-PAGE SPREAD OF HILLPHOENIX multiMAX CONTROLLER WIRING
multiMAX™ Controller for AdaptaPAK®
26
Hillphoenix AdaptaPAK - multiMAX™ Controller Input-Output Schedule - left side
multiMAX™ Controller for AdaptaPAK®
27
Hillphoenix AdaptaPAK - multiMAX™ Controller Input-Output Schedule - right side
multiMAX™ Controller for AdaptaPAK®
28
AdaptaPAK® Installation
Section 4:
AdaptaPAK® Installation
Hillphoenix warrants all refrigeration systems and equipment it manufactures.
In order for Hillphoenix to honor this warranty, it is essential that the systems
and equipment be properly installed and started up by a qualied refrigeration
technician. This section goes through the proper installation practices for
AdaptaPAK® refrigeration systems and equipment.
Careful execution of the installation procedures for any refrigeration system is critical to the safe, effective, and
efcient operation of the system. Every step must be followed in the exact order and the manner described,
otherwise the equipment may not function properly It is also critical that only the materials specied in the
procedures be used
29
Installation Materials
The process of installing AdaptaPAK® systems generally involves a variety of materials. In addition to the equipment
itself, the items that are required to install a system often include:
• Valves (stop, pressure relief, solenoid, etc.)
• Refrigeration piping
• Insulation
• Filter dryers
• Assorted hardware and miscellaneous items
• Wiring
• Drain lines and traps
• Hangers, piping supports and other installation materials
Specications for materials standards generally come from the customer but at a minimum always conform to
published ASRAHE requirements.
Refrigeration Piping
Piping connects the components of a refrigeration system together. Refrigeration piping involves extremely complex
relationships in the ow of, not only refrigerant, but also the oil that is required by the compressors for lubrication.
The three types of piping material commonly used in refrigeration systems are:
• Type K (Heavy Wall)
• Type L (Medium Wall)
• Type M (Light Wall)
AdaptaPAK® Installation
30
The piping connects the refrigeration circuit together so that compressors are connected to cases or other types of
refrigeration loads, and cases are connected to other cases. The type of piping material that is used to connect the
circuits must have the capacity to perform one of three refrigeration system functions:
• Suction
• Liquid
Types K and L are used for most refrigeration applications. But the type of piping chosen for a particular function
depends on a combination of factors. These include, for instance, the type of refrigerant and ow for which the
piping will be used. It is, therefore, useful to be able to estimate the weight of a refrigerant when sizing pipes.
REFRIGERANT. Line
Size
3/8
1/2
5/8
R-404A
or
R-507
7/8
1 1/8
1 3/8
1 5/8
2 1/8
2 5/8
3 1/8
3 5/8
4 1/8
LIQUID HOT GAS SUCTION GAS WITH NOMINAL SUPERHEATi
3.6
6.6
10.8
22.3
38.0
58.0
82.0
143.0
220.0
-
-
-
POUNDS PER 100 LINEAL FEET OF TUBE
-40°F -20°F 0°F 20°F 4 0°F
0.29
0.53
0.86
1.80
3.10
4.70
6.60
11.30
17.60
-
-
-
0.02
0.04
0.07
0.14
0.24
0.38
0.64
0.95
1.46
2.09
2.83
3.68
0.04
0.06
0.10
0.22
0.37
0.56
0.80
1.36
2.14
3.06
4.12
5.38
Refrigerant Weights in Type L Copper Tubing.
Both types of tubing, K and L, are manufactured by either of two means:
• Drawn
0.06
0.13
0.17
0.36
0.61
0.92
1.31
2.28
3.51
5.02
6.76
8.82
0.08
0.14
0.23
0.48
0.83
1.28
1.81
3.13
4.85
6.93
9.36
12.20
0.11
0.20
0.33
0.86
1.16
1.76
2.49
4.35
6.69
9.54
12.92
16.81
• Annealed
Drawn tubing is typically referred to as hard drawn and annealed as soft drawn. Most of the piping used for
refrigeration is of the latter type, hard drawn. Because soft drawn, as it name implies, is malleable, it can be bent
into curves and angles. Consequently, it is most often used in tight locations, such as in cases where it can be bent
to reach coils that would otherwise be difcult to reach using only rigid hard drawn pipe.
When discussing refrigeration piping, it is appropriate to consider the type of joint that connects one section of piping
to another. Installation specications often call for brazing joints with “only a suitable silver solder alloy on suction and
liquid lines.” (
Heatcraft Installation and Operation Manual
caused by oxide and impurities (i.e., contamination) that enter the joint in the molten metal of an impure brazing alloy
and impede the brazing alloy ow. Wherever there is contamination, the alloy ows around it, leaving pinholes in the
joint. These pinholes are like tiny doors through which refrigerant gas can leak out.
) The greatest concern with brazed joints is leaks. Leaks are
AdaptaPAK® Installation
Phosphorus/copper and silver/phosphorus/copper alloys are used to braze copper to copper and copper to brass.
Characteristics of Common Brazing Alloys.
31
The phosphorus content in these alloys makes them self-uxing on copper. The characteristics of certain alloys
provided by one manufacturer are shown in the table on the previous page.
Pipe Fittings
Pipe ttings are used to route pipe runs in different directions. Two main types of ttings are short radius 90s (90
degrees) and long radius 90s. Long radius 90s are more often used than short radius 90s, the latter being primarily
of use when space limitations are a factor.
Other types of ttings include T’s, airs, and air nuts. Although good piping practice calls for avoiding the use of the
latter, air nuts are sometimes found in certain applications, and if installed properly, can work well. However, sweat
ttings should be used instead, whenever possible.
Besides the three general uses of piping mentioned earlier, other specic applications for refrigeration systems
include:
• Circuit Piping -- compressor to cases
• Inside the store -- case to case
• Discharge
• Condensate
• Heat Reclaim
• Hot Gas Defrost
Insulation
Among the most common insulation material used for refrigeration piping is a type that goes by the brand name
Armaex®. This material uses a closed-cell, elastomeric foam with very low thermal conductivity properties – in other
words, it has a high insulation value.
AdaptaPAK® Installation
32
Other types of insulation that are used include:
• Rigid cellular phenolic foam
• Cellular glass closed-cell
• Polyisocyanurate closed-cell rigid
A number of considerations go into selecting the type of insulation to use for a particular application. These include:
• The application (uid) temperature
• Ambient conditions such as:
− dry-bulb temperature
− relative humidity
− surrounding air velocity
• Insulation Material
• Desired Performance
The application temperature is the temperature at which the refrigerant is intended to move through the piping. The
ambient conditions are generally divided into three broad categories:
• Mild Conditions – maximum severity of 80°F dry bulb temperature, 50% relative humidity, and 0 ft/min air
velocity
• Normal Conditions – maximum severity of 85°F dry bulb temperature, 70% relative humidity, and 0 ft/min
air velocity
• Severe Conditions – maximum severity of 90°F dry bulb temperature, 80% relative humidity, and 0 ft/min
air velocity
The mild design condition is typical of most indoor climate-conditioned environments in the U.S. A typical
supermarket indoor design point of 75°F dry bulb temperature and 55% relative humidity can be considered
equivalent to this mild condition for the purpose of sizing insulation. Although insulation thickness is usually based
on the more demanding conditions of “normal” and “severe”, determining which of these to use ultimately depends
on local ambient conditions and must be evaluated for each installation site. It is also important to realize that in
some air-conditioned environments, air at, or near the ceiling or, roof can be warmer (sometimes considerably so)
than elsewhere in the building; that consideration of these conditions is extremely important for systems containing
overhead piping.
Two widely used types of insulation, polystyrene and urethane foam,
have the following R-values::
• Polystyrene 3.5 to 5.0 per inch of thickness
• Urethane 5.5 to 6.0 per inch of thickness
AdaptaPAK® Installation
In practice, insulation specications will often be simply stated in terms such as:
“All medium temperature suction lines are to be insulated with ½-inch wall insulation, from the point of xture
penetration or walk in box coil, all the way to the compressor service valve or suction header and/or all liquid lines
are to be insulated with 3/8-inch wall insulation.”
And/or:
“All low temp suction lines are to be insulated with ¾-inch wall insulation from the point of xture penetration or walk
in box coil all the way to the compressor service valve or suction header.”
Valves
Depending on the application, a number of different types of refrigeration valves are often eld-installed. The most
typical kinds are:
• Ball — typically used on larger pipes and where the valve is not intended to be readily adjusted without use
of a wrench
33
• Hand — used most often in smaller spaces and where adjustment can be done by hand .
Both ball and hand valves generally serve the same function — shutting off ow for isolation
• Pressure relief — usually manufacturer-installed and used as check valves that open once pressure
reaches a certain point, then releasing the pressure until it falls back into range and the valve closes
Typically mounted on receivers to protect the system from reaching dangerously high pressure level,
pressure relief valves vent excess pressure and consequently release refrigerant
• Solenoid — either of a combination of two sets of functions; temperature control or isolation, and either
normally open or normally closed
Another functional variation is that solenoids can be either one-way or two-way ow-permitting
Three-way — used for split condensers, heat reclaim, or in some applications for hot gas defrost
• Thermostatic expansion valves (TEV, referred to by some manufacturers as TXV) — all types work as
metering devices regardless of whether mechanically or electrically operated
TEVs come in a wide variety of congurations, including SMS (Superheat Management System) used on
Hillphoenix Coolgenix™ cases
• Check – (including pressure relief) allow ow in only one direction and prevent ow in the opposite
direction, and are usually one of two congurations; differential or normal Normal check valves prevent
back ow, allowing free ow in only one direction
Other types of valves found in certain specic applications include:
• Inlet Pressure Regulator — controls inlet pressure at the valve
• EPR — Evaporative Pressure Regulating valves are usually located on the rack, but in some applications may
be needed on the circuit
• Outlet Pressure Regulator — performs the opposite function of the inlet pressure regulator; controls
pressure at the outlet of the valve
AdaptaPAK® Installation
34
• Defrost Differential — on Hillphoenix systems, located on hot gas racks
Filter and Filter/Driers
Filters are used to protect components in refrigeration systems from contaminants and other foreign material that
accumulate in the system. A particular type of lter, called a lter/dryer, also removes moisture from the system.
Three main types of lters used for refrigeration systems are:
• Liquid Line Driers
• Suction Filters
• Oil Filters
Assorted Hardware and Other Installation Items
A number of various other types of hardware and other items are usually needed for any installation. These include,
but are not limited to:
• Refrigerant and oil
• Pipe supports and ttings
• Strainers
• Flexible line
• Heating tape
• Pipe and conduit penetration covers
• Access ttings
Refrigerant and Oil
Every refrigeration system is designed to operate a specic refrigerant and type of oil. During installation, the proper
refrigerant and oil must be added to the system. The refrigerants primarily used in commercial refrigeration are
classied into three main groups:
• CFC – chlorouorocarbons (R-11 and R-12)
• HCFC – hydrochlorouorocarbons (HCFCs R-22 and R-124)
• HFC – hydrouorocarbons (HFCs R-134a, R-404a and R-507, R-407a, R-448/449)
Because of their harmful effects on the environment, CFC refrigerants have been phased out andsome HFC
refrigerants are being phased out.
Most AdaptaPAK® units today use HFC type refrigerants, such as R-407a or R-448/449.
Refrigeration systems, like many other kinds of machinery with moving parts, use oil for lubrication. The movement
of metal against metal generates friction (a form of heat), and friction in turn impedes the movement of those parts.
By continuously coating the metal surfaces of the moving parts in the system, oil acts to reduce friction. Lubrication
oil is essential to the operation of most compressors and other moving parts in refrigeration systems.
In refrigeration systems, the refrigerant and lubricating oil mix together. The oil dissolves in the refrigerant at most
AdaptaPAK® Installation
temperatures and pressures. Liquid refrigerant and oil are said to be completely miscible—that is, that they can be
mixed in any proportions. When mixed, they exist in a single phase. The extent to which they are miscible depends on
the type of oil and refrigerant that are mixing together.
The most commonly used lubricants in refrigeration systems are based on three different types of oils:
• Polyol Ester Oil (POE)
• Mineral Oil (MO)
• Alkyl Benzene Oil (AB)
The particular type of oil a refrigeration system uses is determined largely by the refrigerant it uses. A table showing
which oil works (is compatible) with which refrigerant is provided in the table that appears below.
R-407a, and
R-448/449
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Key to Table: P=Preferred Lubricant Choice; A= Acceptable Alternative;
M=Mixture of Miner Oil and Alkyl Benzene (AB) with 50% AB.
(Information obtained from Heatcraft/Copeland)
It is important to use only the grade and type of oil that is specied by the manufactureer. Refrigerant and oil must
only be handled by qualied personnel.
Pipe Supports and Fittings
Pipe supports and ttings are also referred to as mechanical fasteners. The material used for these purposes, of
course, must be of sufcient strength to support the weight of the pipe.
Unistrut
, a particular type of pipe support, is widely used for refrigeration piping. Angled steel, pipe clamps with
plastic or rubber compound liner material that is held in place by an outer steel layer, along with wires and bands are
also commonly used. These latter items are typically used in place of Unistrut. Bands used for pipe supports tend to
be made of either metal or ber. Fiber material, such as nylon, is preferred since it is unlikely to rip or tear insulation
which can happen with metal. Painted or galvanized steel, however, generally works better than other types of
unnished metal. Plastic can also be used as long as it meets the criteria mentioned above, that it is strong enough
to adequately support the weight of the pipe. In fact, even (nylon) cable ties are used in some cases.
AdaptaPAK® Installation
36
Flexible Metal Line
Flexible metal line is sometimes used for discharge piping from the compressors. Because the compressors
vibrate during operation, the lines connected to them are themselves subject to vibration. Flexible metal lines are
sometimes referred to as vibration eliminators.
Vibration eliminators reduce line breakage that can otherwise result from the vibrating movement of the compressor.
This type of line is generally made of seamless bronze corrugated hose that is covered with a bronze wire braid.
Standard copper tube ttings are attached at each end. Because of the way they are constructed, care must be
taken when working with exible line. For instance, ux must be immediately removed after brazing or soldering
since the chlorides they contain are harmful to the material. During brazing or soldering, care must be taken not to
heat the material either. When installed, lines subject to condensation, must be wrapped with a water-tight material
to prevent ice from forming.
Vibration eliminators are most effective when installed perpendicular to the motion of the equipment to which they
are attached. The xed end of the equipment should be securely anchored as close as possible to the vibration
eliminator. When major motion occurs in two directions, two lines should be installed.
He ating Tape
An electrical resistance tape is used to prevent freezing of drains in cold applications. Heating tape comes in a
number of variations. Varieties of heating tape include self-regulating, adjustable, and continuously on.
Pipe and Conduit Penetration Covers
Exterior penetrations are used whenever any part of a system is located outside of the building. For instance, the
piping that connects exterior-set mechanical houses, Weather Pac units (typically roof- mounted), and condensing
units to the interior of the building must enter and exit through penetration covers. Properly designed and installed
penetration covers keep the exterior elements out and the building’s climate controlled conditions in. They create a
solid barrier between the two environments and around the system’s piping.
Installation plans usually include a penetration detail that indicates the type of penetration required.
Piping Practices
Hillphoenix refrigeration systems are always piped in accordance with ASHRAE refrigeration piping principles and
practices. These can be found in, among other codes, ASHRAE 15, Safety Code for Mechanical Refrigeration.
AdaptaPAK® systems supplied by Hillphoenix are leak-checked, evacuated, and dehydrated at the factory. During
installation, care must be taken to prevent foreign matter from entering the system.
Install all refrigeration system components in accordance with applicable local and national codes and in
compliance with good practice required for the proper operation of the system. For instance, interconnecting pipe
sizes are not necessarily the same size as the stub-out on the condensing unit or the evaporator. In any case, the
AdaptaPAK® Installation
refrigerant pipe size should be selected from an engineering table or from the manufacturer’s legend or schedule.
Wherever the information is provided, always nd the correct size and never guess as to what size to use.
The basic principles for piping practices, listed below, spell out how piping for supermarket refrigeration systems
should be installed. One overriding principle that applies to piping, as well as, all other aspects of refrigeration
system installation is that verication should be documented during the entire process to ensure adherence to
quality and performance standards.
Basic Piping Principles
Certain basic principles must be followed in piping refrigeration systems:
1. Verify components
2. Adhere to legend line sizes and use only clean dry piping
3. Properly size:
a. lines to reduce pressure drop to 1 to 2 pounds maximum to ensure correct velocities
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b. line lengths that are subject to expansion and contraction
4. Provide proper support and clamping to refrigeration lines
5. Properly brazed joints
6. Insulate suction lines
7. Pressure test line sets
8. Properly evacuate system
Careful consideration of each step includes:
1. Verify components—positively conrm (as with all other aspects of the installation process) that all components
match each other, i.e., all TEVs have the same refrigerant as the rack legend.
2. Adhere to legend line sizes and use only clean dry piping—only use those line sizes shown on the legend for the
system; any discrepancies in the line size, as well as the refrigeration loads, must be brought to the attention of
the customer and Hillphoenix.
3. Properly size:
a. Lines to reduce pressure drop to 1 to 2 pounds maximum to ensure correct velocities—lines should be sized
to minimize pressure drop, while maintaining sufcient velocity to return the lubricating oil to the compressor
crankcases—liquid lines should be of adequate size to provide proper refrigerant feed to the evaporators
(restrictions in liquid lines, due to poor piping practices, increase pressure drop and promote ashing, further
increasing the pressure drop due to turbulence).
AdaptaPAK® Installation
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b. Line lengths that are subject to expansion and contraction—suction, liquid and remote condenser lines are
subject to expansion and contraction and must be sized accordingly—depending on design considerations
(typically long runs or hot gas), an expansion loop may need to be installed (may be indicated on the plan,
but not always).
4. Provide proper support and clamping to refrigeration lines—line breakage must be avoided on all lines,
particularly on long, straight runs of suction lines where expansion loops must be used with types of hangers
that allow for longitudinal movement of piping and, as a result of closer placement, reduce sagging and
vibration, discourage oil from collecting in xture coils and piping through consistent sloping, and maintain
proper lubrication in the compressors; all piping must be adequately supported with hangers that can
withstand the combined weight of tubing, insulation, valves, and refrigerant in the tubing.
5. Properly brazed joints—all joints must be brazed according to the customer’s specication after being
thoroughly cleaned. Dry nitrogen at 1/2 psi must be owing through the tubing while joints are brazed to avoid
internal scale buildup. Limit the soldering paste or ux to the minimum required to prevent contamination of the
solder joint internally. Flux only the male portion of the connection, never the female. After brazing, excess ux
should be removed
6. Insulate suction lines—use only material listed in the customer specication. Insulation must be thick enough
to keep heat from getting in, and moisture (sweating) getting out. Maintaining proper return gas temperatures
cools compressor windings and prevents water damage and mold growth by keeping suction lines from
sweating. When using subcooled liquid, the liquid line may also need to be insulated.
7. Pressure test line sets—use dry nitrogen to test for leaks in brazed joints to conrm they are able to hold
pressure. Always take care to not over-pressurize any components.
8. Properly evacuate system—use a vacuum pump capable of 50 microns. Acceptable industry practice calls for a
triple evacuation. A system that does not hold a vacuum has a leak. Never use a compressor.
Other Considerations
Several other important considerations should always be kept in mind about piping for any refrigeration system
installation. For instance, all refrigeration piping must be sized in accordance with the capacity, and or size,
recommended by the case, coil, and condensing unit manufacturers or engineering tables.
Tubing Material
Another important consideration is that all refrigeration tubing (unless otherwise noted, such as when soft drawn
piping is specied for leading into coils) should be either type K or L hard drawn, cleaned and factory-sealed.
Tube Cutting
Any cutting of tubing should be done using a wheel type cutter, whenever possible. In order to keep out dirt and
moisture, tubing should never be left open.
AdaptaPAK® Installation
Pipe Turns
Turns in refrigeration piping should always be accomplished by the use of long radius 90 degree elbows. Short radius
elbows and 45 degree elbows should be avoided due to higher pressure drops. 45 degree elbows have thinner walls
due to the manufacturing process. On gas defrost systems, expansion loops (containing four 90’s) or piping offsets
(containing two 90’s), should be installed.
Pipe Routing
When piping any copper-to-copper contact, heat transfer will occur. Generally copper lines should not touch one
another even when it is necessary to cross pipes. Heat transfer will result from contact. Instead, they must be offset
or insulated so as to insure that no copper to-copper contact occurs. There may, however, be times when heat
transfer is benecial. But careful consideration must be given to any possible trade-offs in efciency when allowing
contact.
Before starting, visually lay out piping to minimize 90 degree turns in order to reduce pressure drop.
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Refrigerant piping should also not ever come into contact with electrical conduit or, certain dissimilar grounded
metals, in order to avoid corrosion that can cause failure of the pipe.
Insulation
The Installation Contractor should always furnish and install adequate insulation to prevent condensation on all
refrigeration suction piping in the sales area from the pits to the cases, at the point of piping entrance to the case,
and insulate all refrigeration suction piping that is located in non-air conditioned areas. If ambient or mechanical
sub-cooling is used, all liquid refrigerant lines should also be insulated. The more insulation that is used, the less
heat gain the system absorbs. For instance, typical insulation for medium temperature suction lines is 3/4 inch, and
on the same system for low temperature suction lines, 1 inch.
Regardless of the type of insulation, always follow the manufacturer’s guidelines.
Oil Traps
Oil traps accumulate oil until pressure builds sufciently to move oil up the riser. Oil traps should be installed before
vertical risers and/or when recommended by the manufacturer. Vertical risers should also be sized in accordance
with piping specications shown on the refrigeration schedule.
Multiple coils should use an inverted trap that prevents the oil from owing from one evaporator to another.
Exterior Piping
Where refrigerant pipes penetrate building or cooler walls, the pipes should be insulated and the openings properly
sealed by caulking with a suitable material. For refrigeration lines that pass through larger openings into the machine
room or through the building roof, the lines should be insulated and the openings sealed. Lines that penetrate into
walk-in boxes should also be sealed.
AdaptaPAK® Installation
40
Evacuation
The system should be able to hold a vacuum for 24 hours with no micron increase and no vacuum pump attached.
The vacuum should then be broken with refrigerant type used in the system from a factory lled cylinder. Always
follow acceptable industry practices and customer specications when evacuating systems.
It is important to recognize that the evacuation process does not remove liquid water, but reduces pressure to the
point where liquid water boils into a vapor, which is then removed through evacuation.
Some things to consider when evacuating a system are:
• Make sure all system valves are open so that the entire system receives a vacuum, and that no part of the
system is isolated from the vacuum.
• Copper line is generally considered best for connecting vacuum pumps to the system.
• Make multiple connections (depending on the size of the system, use more pumps) to the system so that
both the high-side and low-side have vacuum.
• Always isolate the vacuum pump before shutting it off.
• Always read the micrometer at the furthermost point of the system from the vacuum pump.
• Make sure to change the oil in the systems as necessary during evacuation.
Fittings and Connections
All ttings and connections for components should be sweat type unless otherwise specied. For instance, a safety
relief valve of the proper pressure rating should be piped with a sweat (or in some cases, threaded) connection and
vented to the outside a minimum of 30 feet from all intakes, or per local codes, if more stringent. In the event that a
threaded connection is used, the proper thread sealant needs to be applied as determined by the type of refrigerant
and oil used in the system.
Job Installation
In addition to piping, installation includes a number of other steps that must be performed. These include
procedures to:
• Set and install racks
• Set and install condensers, cases, walk-ins and walk-in coils
• Choose and install lines for circuit piping
• Complete individual circuit piping inside cases, case-to-case, walk-ins and gas defrost
• Complete piping for condensers and heat reclaim
• Install drains for coils and cases
• Label equipment
• Install plan holders
AdaptaPAK® Installation
Set and Install Unit
A basic part of the installation process is setting the unit for the system. As part of this process, an adequate
number and type of vibration isolation units, or pads, should be installed to ensure that unit vibration is not
transmitted to the rest of the store through the building’s structure.
It is also quite important that the unit be installed such that it is level. Ensure that this occurs.
Set and Install Condensers, Cases, Walk-Ins and Walk-In Coils
Another basic part of the installation process is setting and installing condensers, cases, walk-ins and walk-in coils.
Install these components according to the customer and manufacturer specications. The exact steps necessary
to complete the process may vary from manufacturer to manufacturer, so always make certain to follow the specic
steps provided by the manufacturer.
Choose and Install Lines for Circuit Piping
Considerations for circuit piping include checking for:
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• Pipe size
• Insulation
• Riser sizing
• Hangers and clamps
• Line slope and traps
• Heat reclaim
• Vibration elimination
• Building penetrations
• Condenser types (i.e., evaporative, air, plate-to-plate)
• Split condensers
• Opportunities to reduce piping through suction line sizing
Complete Individual Circuit Piping Inside Cases, Case-to-Case, Walk-Ins, and Gas Defrost
Keeping in mind that these considerations differ from those of general circuit piping considerations, as applied
specically to inside cases, case-to-case piping, walk-ins and gas defrost:
• Pipe size
• Insulation
• Ball valves
• Check valves
Along with these considerations, drains for coils and cases and heat tape and insulation for drains subject to
freezing, must also be addressed.
AdaptaPAK® Installation
42
On both the suction and liquid sides of the system, considerations for hot gas defrost (if part of the system) should
include the use of return headers.
Complete Piping for Condensers and Heat Reclaim
Insulation, vibration eliminations, ball valves, check valves, hangers and clamps, risers, and building penetrations
should be installed in accordance with customer and manufacturer specications for condensers and heat reclaim
systems.
Labeling Equipment
Every component of the system should be clearly labeled. All racks, control panels, and cases should be labeled with
information that may include the following:
• System number
• Unit match (circuits matched to racks and vice-versa)
• Refrigerant type
Ensure that labels are attached to, or printed on, condensers, circuits, and cases, and that they match labels that
appear elsewhere in the unit.
Install Plan Holders
A nal step that is either sometimes specied by the customer, or should be part of the standard installation
practice, is to install a plan holder. Usually these are placed near the refrigeration system (typically attached to the
wall inside the unit) and contain a set of as-built plans for the system, as well as an updated refrigeration schedule
and oor plan. These documents should be stored in such a way as to protect them from loss or damage.
Other Responsibilities
In addition to the installation steps listed above, the installation contractor in most situations has certain other
responsibilities. These typically include, but are not always limited to:
1. Coordinating release of customer-furnished equipment to the customer’s designated representative (usually their
engineering staff or department).
2. Securing crane service, where needed, to hoist equipment to the mounting position.
3. Providing supervision and labor for setting customer-furnished equipment.
4. Providing labor to unload and set refrigeration equipment scheduled or shown on drawings.
5. Making nal electrical connections to customer-furnished equipment.
6. Verifying controller operation and programming
AdaptaPAK® Installation
Startup Procedures
As with other aspects of installing a system, following proper startup procedures is of critical importance to the
eventual safe and effective operation of the system. Although unique characteristics of every installation may
require some variation, the following procedures should be followed as closely as possible. All refrigeration startups
should be performed by a qualied refrigeration technician.
Startup Checklists
An essential part of any startup is the careful and detailed verication of the necessary steps needed to get the
system operating. Verication, therefore, should be documented during the process to ensure adherence to all
quality and performance standards listed below, as well as, any that might be provided by the customer.
Typically the steps in the startup process include:
• Pressure testing
• Evacuating the piping
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• Adding oil
• Adding refrigerant
• Installing liquid line driers and suction lters
Whether customers provide one or not, a startup checklist like the one included here (beginning on next page)
should always be used. The checklist provides space for two types of entries, information to be lled in, and items to
be checked off. Unless an item is not applicable to the installation, all items should be lled in or checked off.
SYSTEMS START-UP CHECK LIST
CUSTOMER NAME: _________________________ DATE: ______
UNIT MODEL #: ______________________________________
UNIT SERIAL #: _______________________________________
1. Verify that all electrical connects have been made and properly tightened. ____ _
2. Verify the Main Power Voltage readings and phasing of voltage against equipment requirements prior to turning on
the power source:
L 1 > GD ______________ A > B ______________
L 2 > GD ______________ A > C ______________
L 3 > GD ______________ B > C ______________
3. Verify the Control Voltage. ___ __
4. On condensers check for proper operation and fan rotation including split valve operation and pump-out
solenoids. _____
AdaptaPAK® Installation
44
5. Check the oil pressure control on each compressor for proper operation by allowing each one to trip. Check the
crankcase heater operation on each compressor. _____
6. Set the low pressure control according to the customer’s specication. ____ _
7. Set the high pressure control to cut out at specied psi. _____
8. Turn on the circuit switches and verify that they are wired correctly. _____
9. Turn on the compressors and check the AMP draw of each phase. _____
10. Check and record oil pressure for compressors. _____
11. Check all evaporator fans for proper operation. _____
12. For electric defrost, check operation and load balancing. ___ __
13. If the system has EPR’s, make sure they have been set before the rack is allowed to run unattended. _____
14. Check and set superheat on all condenser valves. _____
15. If the rack has heat reclaim, verify that it is operating correctly. ____ _
16. Check and record the suction temperature, suction pressure, and rack superheat. ___ __
17. Check and record the drop leg temperature and pressure. _____
18. Check and record the discharge pressure. _____
19. Check and record the ambient temperature.
20. Check low pressure and high pressure switch operation. _____
21. Verify all controller set points match manufacturer’s specications and case alarms are cleared from controller.
_____
Checklist Completion
When all the steps have been completed, review the list to verify that they all have been performed properly and
that no issues have arisen. If issues do remain, however, carefully assess the procedures to make sure no steps
were omitted, or were not properly performed. If problems continue, despite whatever immediate action is taken to
address them, the troubleshooting steps described in the next lesson should be followed to address the situation.
Contact Hillphoenix concerning any problems that persist.
AdaptaPAK® Maintenance and Troubleshooting
Section 5:
AdaptaPAK® Maintenance and
Troubleshooting Procedures
Supermarket refrigeration systems like the AdaptaPAK® system
are complex arrangements of equipment and machinery involving
numerous components spread among a variety of subsystems that
provide refrigeration to the store’s different circuits and loops. In order
to keep all that equipment and machinery running safely and efciently,
regularly scheduled maintenance must be performed. However, regardless of how well maintained the equipment is,
problems will occur from time to time. Like any other kind of machinery, and especially like other complex systems,
something will eventually fail to work as designed. In those cases, there are troubleshooting procedures that aid in
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determining the causes of various problems. This section presents the maintenance and troubelshooting procedures
for Hillphoenix AdaptaPAK® refrigeration systems.
Maintenance Procedures
Refrigeration equipment has been noted to account for approximately 50% of the total electrical power consumption
of the typical supermarket. In DX systems the compressors generally consume the greatest portion. As such, there is
considerable potential for conservation measures to have a huge impact on the store’s operating costs through the
application of proper maintenance procedures.
Foremost among the maintenance procedures for DX systems is checking the system’s safety and operating
controls. The checks to be performed also include verication that the original settings are maintained.
Operating Strategies — Maintaining Compressor Efficiency
One means of reducing a compressor’s electrical consumption (and a store’s resulting operating costs) is to lower
the discharge (head) pressure. The head pressure will be at its highest during the heat of summer, when the ambient
temperature is close to design conditions. This is also when the compressor motor amperage will be at its highest.
Because more work is required to compress a vapor to a higher pressure, it logically follows that more electrical
energy is required to accomplish this. There is a proportional relationship between head pressure and compressor
motor current draw. When head pressure is either raised or lowered, the motor current draw will increase or
decrease in proportion. For example, one manufacturer’s 20 HP compressor, using R-404A, and operating at
-25ºF SST (13 psig) and 110ºF SCT (272 psig), with 5ºF liquid subcooling, and a 50ºF return gas temperature, will
deliver 61,389 Btu/h. Under these conditions the compressor motor’s current draw is 40 amps. A 30ºF reduction
in condensing temperature (110ºF to 80ºF) will reduce the current draw to 37.3 amps. While a 6.75% reduction is
signicant, it is only part of the story.
AdaptaPAK® Maintenance and Troubleshooting
46
Typical supermarket compressor racks run reasonably constant suction pressure, regardless of head pressure. The
suction pressure is determined by the saturated suction temperature requirement of the lowest operating system
connected to the rack, and maintained by the energy management system. Unless the suction pressure requires
readjustment, the ONLY reduction in compression ratio (ratio of absolute discharge pressure/absolute suction
pressure) will come from lowering the head pressure. In this case, lowering the condensing temperature to 80ºF (175
psig) will yield a signicantly lower compression ratio (10.35:1 vs. 6.87:1). Using the same compressor data, the net
result of this lower compression ratio is a 31% increase in compressor capacity.
So, in addition to a 6.75% reduction in current draw, the 31% increase in compressor capacity means that FEWER
compressors will be required to operate to achieve the same pumping capacity. This is where the real savings come
from:
INCREASED COMPRESSOR VOLUMETRIC EFFICIENCY
Safety and Operating Controls
As should be clear by now, the safe and efcient operation of Hillphoenix refrigeration systems is of the utmost
importance to the company. Therefore it is essential that the safety and operation controls installed on each system
.
are functioning correctly. As part of regular maintenance, these should be checked at specic intervals.
Refrigeration systems include operating controls that cycle on and off in order to maintain certain temperatures.
They also require safety controls to stop operation if unsafe conditions occur. There are many varieties of controls.
Different types work in response to temperature, pressure, humidity, liquid levels, and other inputs.
The basic controls on a refrigeration system govern the operation of three essential components:
• Compressor
• Condenser fan motor
• Evaporator fan motor
The basic controls that are necessary for these components to safely operate are the:
• Thermostatic control
• Low pressure control
• High pressure control
• Oil failure switch
Thermostatic Control
In a basic system, such as a single unit cooler, a thermostatic control switch, called a T-Stat for short, opens and
closes to call for refrigeration whenever the temperature of the cooler rises beyond a certain, or set, point. When
the T-Stat closes, the compressor goes On-Cycle and provides refrigerant to the evaporator thereby lowering the
temperature of the cooler below the set point and causing the T-Stat to open. The compressor at that point then
goes Off-Cycle.
AdaptaPAK® Maintenance and Troubleshooting
The T-Stat senses the changes in temperature that cause the control to open and close through a device called
a sensing bulb. The sensing bulb is mounted so that it reacts to the evaporator inlet air. Due to the continuous
operation of the evaporator fan, the temperature of the recirculating air in the cooler is an average of the product
temperature, the wall temperature, and any inltrated air and any other loads such as those caused by a person
entering the cooler. When the air temperature reaches the cut-in point of the control it calls for refrigeration.
In most medium temperature applications, the on-cycle set point at which the system calls for refrigeration is
40 ºF. This set point is usually referred to as the cut-in point. In most medium temperature applications, the system
will continue running until the lower, or cut-out, set point is reached; 37 ºF is typically used for the cut-out point. The
difference between the set points allows the compressor to cycle on and off without short cycling. Each compressor
start causes wear. Too much starting and stopping (short cycling) shortens the life of the compressor and increases
the maintenance required to keep it running. The best way to avoid short cycling is to spread the set points wide
enough apart that the system is not continuously calling for refrigeration.
The upper set point, the Cut-in, in this example is 40 ºF. Above 40 ºF, bacterial growth rates increase dramatically,
and below 40 ºF, they decline. So a basic product safety check for any system should always be that the Cut-out and
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Cut-in points are properly set.
In addition to temperature controls, refrigeration systems also commonly rely on pressure control schemes.
These work in basically the same manner as the temperature differential controls except that the set points are
determined in psig instead of degrees F. To imagine how such a system would work, in the example described above,
substitute pressure in psig for temperature in ºF, and 68 psig and 64 psig, respectively, for the Cut-in and Cut-out
points (on R-22 systems).
Low Pressure Control
A device called a Low Pressure Control (LPC) monitors the pressure in the system.
Besides controlling the set points in the system, pressure controls also almost always work as safety controls. In
some systems, both T-Stats and LPCs are used.
In these cases, the LPCs protect the system from a loss of refrigerant charge by being set to cut-out at a pressure
that is lower than anticipated low-side operating pressure.
Any time the compressor operates with an undercharge, the windings on the motor are apt to overheat and
signicant damage can then occur. As long as the system operates above the minimum pressure, the LPC remains
in what is called the normally closed (NC) position. Small leaks that cause a gradual loss of refrigerant, and
minute drops in pressure, initially trip the LPC to the open position which briey stops the compressor. As the leak
increases, the LPC trips more and more frequently until it eventually gets to the point where the system only runs for
a few seconds before cutting out. At that point the high and low side pressures will equalize and the system will try
starting once again. This again results in short cycling. As already noted, short cycling is not good, but destroying the
compressor by operating indenitely with an undercharge is worse.
AdaptaPAK® Maintenance and Troubleshooting
48
High Pressure Control
Another control commonly found on most systems is for high pressure. High Pressure Controls work exactly opposite
of LPCs. Often the two kinds of controls are combined into a single unit called a dual pressure control. The two
sections of the control can be easily recognized due to fact that the low pressure side requires a larger bellows
assembly since it must react to a lesser amount of force than the high pressure side.
Oil Failure Switches
The nal safety system to consider is the one that controls against a loss of oil. Oil failure switches are used primarily
on reciprocating compressors. These switches work by monitoring the refrigerant oil pressure of the oil pump
discharge. The refrigerant oil pressure
MUST
be higher than the suction pressure. If the refrigerant oil pressure is
lower than the suction pressure of the compressor, an oil leak is occurring. Oil leaks could be due to:
• An oil pump failing
• Refrigerant leaking and loss of oil
• Liquid refrigerant ooding back to compressor and “washing” the oil out of the crankcase
When a loss of pressure is detected, an alarm indicator light turns on to indicate that an oil failure has occurred.
The oil failure switch should never be reset without determining and xing the cause of the problem. Otherwise, the
compressor will undoubtedly fail.
The safe and efcient operation of the system depends on the regular inspection of these controls as part of
standard maintenance procedures. Each one should always be carefully checked and the appropriate action taken if
any problem is indicated.
Visual Inspection
In addition to the safety checks to be performed on the system, it is also necessary to further examine its operation
for any other problems that might occur. Some of the checks listed below should be performed regularly and other
less frequently, but at consistent intervals.
The areas of the system on which inspections should be focused are the:
• Electrical and mechanical components of the system
• Case coils
• Condensers
Regular Inspections
The following checks should be routinely performed on AdaptaPAC systems:
1. Check compressor discharge and suction pressures—if not within system design limits, determine why and take
corrective action
AdaptaPAK® Maintenance and Troubleshooting
2. Check liquid line sight glass and expansion valve operation—if there are indications that more refrigerant is required,
leak test all connections and system components (including cases) and repair any leaks before adding refrigerant
3. Using suitable instruments, carefully check line voltage and amperage at the compressor terminals; voltage must be
within +/- 10% of that indicated on the compressor nameplate—if high or low voltage is indicated, notify the power
company; If amperage draw is excessive, immediately determine the cause and take corrective action (on 3 phase
motor compressors, check to see that a balanced load is drawn by each phase)
4. Check that the maximum approved settings for high pressure controls on air cooled condensing equipment are not
exceeded
5. On air-cooled systems, also check as follows:
a. Make sure all condenser fans come on and run
b. Check the amp draw of all condenser fan motors
c. Disconnect the fan motors or block the condenser inlet air
49
e. Watch high pressure gauge for cutout point
6. Check head pressure controls for pressure settings
7. Check crankcase heater operation (if used)
8. Re-check all safety & operating controls for proper operation and adjust if necessary
Monthly Inspections
Approximately once a month the following inspections should be performed:
1. Clean drain pan interior. Dirt and other impurities, which have washed into the drain pan, should be hosed from
the drain pan area. Shut off water to the oat valve and open the drain connection for ushing.
2. Clean suction strainer, if equipped.
3. Check water operating level. Adjust oat arm as required.
(
DO NOT BEND FLOAT ARM
4. Check, and adjust as needed, belt tensioning on open-drive compressors and condensers, if equipped.
)
5. Inspect the fan motor(s), water and water circulation and lubricate per the lubrication nameplate or manufacturer’s
recommendations.
6. Inspect fan wheels, housing and inlet screens removing any debris, which may have accumulated during
operation.
7. Inspect the water distribution system to insure that nozzles and spray orices are functioning correctly. The
inspection should done with the circulation pump on and fans off.
AdaptaPAK® Maintenance and Troubleshooting
50
Other Checks
All electrical connections (including those at the compressor terminals) should be periodically checked for tightness.
Loose connections contribute to low-voltage conditions that may cause motor failure.
Refrigerant connections should be inspected to insure that they have not loosened. Whenever it is necessary to add
refrigerant, a careful leak check of all refrigerant connections should be made.
The oil level in the compressor crankcase should be at the specied level in the sight glass at all times. If the oil
level is low, more oil should not be added until the cause of the oil migration is corrected. Check the expansion valve
adjustment, the size of the risers and traps and the head pressure control valve settings.
If the oil level continues to remain low, pump the system down a few times to see if it will bring the oil back. On hot
gas systems, put a few cases in defrost. Check the evaporator coils and make sure none are iced up. Check the oil
in the oil reservoir, and if there is plenty of oil in the reservoir but a compressor that is low, adjust the oil oat on that
compressor. Make sure oil is not pumping out of the compressor through a bad valve plate or bad cylinder.
Dirty, discolored oil may indicate one of two things:
• Contaminants such as moisture, air, etc., trapped in the system. If the discoloration is not severe, a new
liquid line lter-drier and 1 or 2 oil lters are usually enough to remove contamination and clean the oil. If
the discoloration is severe and caused by contamination alone, the oil should be replaced and a new liquid
line lter-drier and oil lter installed as many times as necessary to eliminate the contamination.
• Excessive system pressure drop or improper control settings. Compressors that operate in a vacuum result
in oil discoloration due to motor overheating. The resulting inadequate suction cooling causes overheating
of the motors.
Preventive Maintenance
Preventive maintenance, as the name suggests, is intended to stop problems before they happen. Preventive
maintenance, when performed at the intervals specied below, reduces problems and keeps the system running
smoothly.
Preventive maintenance should, in particular, be performed on unit coolers, air-cooled condensers, and uid coolers
that are connected to the AdaptaPAK® systems.
Unit Coolers
At every six month interval, or sooner if local conditions cause clogging or fouling of air passages through the nned
surface, the following items should be checked:
1. Visually inspect unit
a. Look for signs of corrosion on ns, cabinet, copper tubing and solder joints.
b. Look for excessive or unusual vibration for fan blades or sheet metal panels when in operation. Identify fans
causing vibration and carefully check motor and blade.
AdaptaPAK® Maintenance and Troubleshooting
c. Look for oil stains on headers, return bends, and coil ns. Check any suspect areas with an electronic leak
detector.
d. Check drain pan to ensure that drain is clear of debris, obstructions or ice buildup, and is freely draining.
2. Clean evaporator coil and blades
a. Periodic cleaning can be accomplished by using a brush, pressurized water or a commercially available
evaporator coil cleaner or mild detergent. Never use an acid based cleaner. Follow label directions for
appropriate use. Be sure the product you use is approved for use in your particular application.
b. Flush and rinse coil until no residue remains.
c. Pay close attention to drain pan, drain line and trap.
3. Check the operation of all fans and ensure airow is unobstructed
a. Check that each fan rotates freely and quietly. Replace any fan motor that does not rotate smoothly, or makes
an unusual noise.
51
b. Check all fan blade set screws and tighten, if needed.
c. Check all fan blades for signs of stress or wear. Replace any blades that are worn, cracked or bent.
d. Verify that all fan motors are securely fastened to the motor rail.
e. Lubricate motors if applicable.
4. Inspect electrical wiring and components
a. Visually inspect all wiring for wear, kinks, bare areas and discoloration. Replace any wiring found to be
damaged.
b. Verify that all electrical and ground connections are secure, and tighten if necessary.
c. Check operation/calibration of all fan cycle and defrost controls, when used.
d. Look for abnormal accumulation of ice patterns and adjust defrost cycles accordingly.
e. Compare actual defrost heater amp draw against unit data plate.
f. Visually inspect heaters to ensure even surface contact with the coil. If heaters have crept, decrease defrost
termination temperature and be sure you have even coil frost patterns. Realign heaters as needed.
g. Check drain line heat tape for proper operation (supplied and installed by others).
5. Refrigeration Cycle
a. Check unit cooler superheat and compare reading for your specic application.
b. Visually inspect coil for even distribution.
AdaptaPAK® Maintenance and Troubleshooting
52
Air-Cooled Condensing Units
A number of checks should be performed at the intervals listed below.
Quarterly
On a quarterly basis visually inspect the unit to:
1. Look for signs of oil stains on interconnection piping and condenser coil. Pay close attention to areas around
solder joints, building penetrations and pipe clamps. Check any suspect areas with an electronic leak detector.
Repair any leaks found and add refrigerant as needed.
2. Check condition of moisture indicator/sightglass in the sight glass, if so equipped. Replace liquid line drier if there
is indication of slight presence of moisture.
3. Check moisture indicator/sightglass for ash gas. If found, check entire system for refrigerant leaks and add
refrigerant as needed after repairing any leaks.
4. Check compressor sightglass (if equipped) for proper oil level.
5. Check condition of condenser. Look for accumulation of dirt and debris (clean as required).
6. Check for unusual noise or vibration. Take corrective action as required.
7. Inspect wiring for signs of wear or discoloration and repair, if needed.
8. Check and tighten are connections, if necessary.
Semi-Annually
On a semi-annual basis, the following checks should be performed:
1. Repeat all quarterly inspection items.
2. Clean condenser coil and blades
a. Periodic cleaning can be accomplished by using pressurized water and a commercially available foam
coil cleaner. If foam cleaner is used, it should not be an acid based cleaner. Follow label directions for
appropriate use.
b. Rinse until no residue remains.
3. Check operation of condenser fans.
a. Check that each fan rotates freely and quietly. Replace any fan motor that does not rotate smoothly or
makes excessive noise.
b. Check all fan blade set screws and tighten, as required. Check all fan blades for signs of cracks, wear or
stress. Pay close attention to the hub and spider. Replace blades, as required.
AdaptaPAK® Maintenance and Troubleshooting
c. Verify that all motors are mounted securely.
d. Lubricate motors, if applicable. Do not lubricate permanently sealed, ball bearing motors.
4. Inspect electrical wiring and components
a. Verify that all electrical and ground connections are secure; tighten as required.
b. Check condition of compressor and heater contacts. Look for discoloration and pitting. Replace, as required.
c. Check operation and calibration of all timers, relays, pressure controls and safety controls.
d. Clean electrical cabinet. Look for signs of moisture, dirt, debris, insects and wildlife. Take corrective action as
required.
e. Verify operation of crankcase heater by measuring amp draw.
5. Check refrigeration cycle.
a. Check suction, discharge and net oil pressure readings. If abnormal, take appropriate action.
53
b. Check pressure drop across all lters and driers. Replace, as required.
c. Verify that superheat at the compressor conforms to specication (i.e., 30°F to 45°F).
d. Check pressure and safety control settings and verify proper operation.
Annually
Finally, once a year, perform the following checks:
1. In addition to quarterly and semi-annual maintenance checks, submit an oil sample for analysis.
a. Look for high concentrations of acid or moisture. Change oil and driers until test results read normal.
b. Investigate source of high metal concentrations, which normally are due to abnormal bearing wear. Look for
liquid refrigerant in the crankcase, low oil pressure or low superheat as a possible source.
2. Inspect suction accumulator (if equipped).
a. If the accumulator is insulated, remove insulation and inspect for leaks and corrosion.
b. Pay close attention to all copper to steel-brazed connections.
c. Wire brush all corroded areas and peeling paint.
d. Apply an anticorrosion primer and paint, as required.
Re-insulate, if applicable.
AdaptaPAK® Maintenance and Troubleshooting
54
Air-Cooled Condensers
At every six month interval, or sooner if local conditions cause clogging of air passages through the nned surface, the
following items should be checked.
1. Visually inspect unit.
a. Look for signs of corrosion on ns, cabinet, copper tubing and solder joints.
b. Look for excessive or unusual vibration for fan blades or sheet metal panels when in operation. Identify fan cell(s)
causing vibration and check motor and blade carefully.
c. Look for oil stains on headers, return bends, and coil ns. Check any suspect areas with an electronic leak
detector.
2. Clean condenser coil and blades.
a. Periodic cleaning can be accomplished by using brush, pressurized water or a commercially available coil
cleaning foam. If a foam cleaner is used, it should not be an acid based cleaner. Follow label directions for
appropriate use.
b. Clear unnecessary trash and debris away from condenser.
3. Check the operation of all fans.
a. Check that each fan rotates freely and quietly. Replace any fan motor that does not rotate smoothly or makes an
unusual noise.
b. Check all fan set screws and tighten, if needed.
c. Check all fan blades for signs of stress or wear. Replace any blades that are worn, cracked or bent.
d. Verify that all fan motors are securely fastened to the motor rail.
e. Lubricate motors, if applicable (most Heatcraft condenser motors are permanently sealed, ball bearing type and
do not require lubrication).
4. Inspect electrical wiring and components.
a. Visually inspect all wiring for wear, kinks, bare areas and discoloration. Replace any wiring found to be
damaged.
b. Verify that all electrical and ground connections are secure, tighten, if necessary.
c. Check operation/calibration of all fan cycle controls, when used.
Fixture Cleaning
The evaporator coils in most refrigeration cases are, by design, located at the bottom of the case. This arrangement
keeps the piping, valves and fans needed to operate the cases out of sight and places the product closer to
AdaptaPAK® Maintenance and Troubleshooting
the customer. From a merchandising perspective, this approach makes for sound design. From a maintenance
perspective, however, it’s somewhat problematic.
Refrigeration case evaporator coils, because of their placement, are subject to fouling from product and packaging
debris that settles to the bottom of the case. Dust and other airborne material that settles on the coils between
defrost cycles may also accumulate. This material must be removed and the cases kept clean in order for the coils
to operate efciently.
Cleaning Procedures
A periodic cleaning schedule should be established to maintain proper sanitation, insure maximum operating
efciency, and avoid the corrosive action of food uids on metal parts that are left on for long periods of time.
Hillphoenix recommends cleaning once a week by performing the following procedures:
1. To avoid shock hazard, be sure all electrical power to the case (or other type of refrigeration unit) is turned off
before cleaning. In some installations, more than one disconnect switch may have to be turned off to completely
de-energize the case.
55
2. Check the waste outlet to insure that it is not clogged before starting to clean and avoid introducing water faster
than the case drip pipe can carry it away.
3. Avoid spraying cleaning solutions directly on fans or electrical connections.
4. Place a temporary separator between the cases being cleaned and ones adjacent to it.
5. Keep cases turned off long enough to clean any frost or ice from coil and ue areas.
6. Remove and clean the honeycomb discharge grill. It may be necessary to use spray detergent and a soft, long
bristle brush.
7. Use mild detergent and warm water to clean with. When necessary, water and baking soda solution will help
remove case odors. Avoid abrasive scouring powders or pads.
8. Use the following specialty cleaning products for difcult stains that may appear on polymer exterior bumper
parts:
- 3M brand© Stainless Steel Cleaner and Polish
- 3M brand© Troubleshooter Cleaner
- 3M brand© Sharpshooter, Extra Strength No Rinse Cleaner
- Revere© aluminum powder for tank liner
- Armor All© for polymer parts
AdaptaPAK® Maintenance and Troubleshooting
56
Troubleshooting Procedures
Supermarket refrigeration systems are complex congurations of equipment. Like any other types of complex
machinery, regardless of the care and attention given to their installation and startup, refrigeration systems will
occasionally run into problems. In most cases, the safety and operating controls with which the system is equipped
will give some indication of the problem. In other cases, however, the causes will not be so clear. For those
situations, various troubleshooting procedures have been developed so that the causes of problems in the system
can be identied and the appropriate actions taken to get the system up and running.
Sometimes when problems, occur they can be determined rather quickly to involve a certain part of the system. At
other times, it may be necessary to check the entire system in order to isolate the cause of a problem. The following
charts provide guidelines for both general and specic indications of trouble in the system.
General System Troubleshooting
Specic aspects of system troubleshooting focus on the following areas:
• Compressors
• Discharge pressure
• Suction pressure
• Oil pressure
Problems observed with the operation of the compressors in the refrigeration system can often lead to root causes
in one or more of these areas (Tables 1 through 8). Table 1: Compressor Will Not Run; Table 2: Compressor Noisy/
Vibrating; Table 3: Compressor High Discharge Pressure; Table 4: Compressor Low Discharge Pressure; Table 5:
Compressor High Suction Pressure; Table 6: Compressor Low Suction Pressure; Table 7: Compressor Loses Oil;
Table 8: Compressor Protector Switch Open.
AdaptaPAK® Maintenance and Troubleshooting
1 - TROUBLESHOOTING - COMPRESSOR WILL NOT RUN
SYMPTOMS SYMPTOMS POSSIBLE ACTIONS
Compressor will
1. Main switch open
1. Close switch
57
not run
2. Blown Fuses
3. Thermal overloads
tripped
4. Defective contactor or
coil
5. System shut down by
safety devices
2. Check electrical
circuits and motor
winding for shorts or
grounds
Investigate for possible
overloading
Replace fuses after fault
has been corrected
3. Overloads are
automatically reset
Check unit closely when
it comes back online
4. Repair or replace
defective component
5. Determine type and
cause of shutdown and
correct it before resetting
6. No cooling required
7. Liquid line solenoid will
not open
8. Motor electrical trouble
safety switch
6. None; wait until
system calls for cooling
7. Repair or replace coil
8. Check motor for open
windings, short circuit, or
burnout
AdaptaPAK® Maintenance and Troubleshooting
58
1 - TROUBLESHOOTING - COMPRESSOR WILL NOT RUN (continued)
SYMPTOMS SYMPTOMS POSSIBLE ACTIONS
Compressor will
9. Loose wiring
9. Check all wire
not run
2 - TROUBLESHOOTING - COMPRESSOR NOISY/VIBRATING
SYMPTOMS SYMPTOMS POSSIBLE ACTIONS
Compressor is
10. Phase loss monitor
inoperative
1. Flooding of refrigerant
junctions and tighten all
terminal screws.
10. Turn power off at
disconnect switch
Swap any two of the
threee power input wires
Turn power on, indicator
light should glow and
compressor should start
Observe motor for
correct rotation
1. Remove the
noisy or vibrating
into crankcase
2. Improper piping support
on suction or liquid line
3. Worn compressor
4. Scroll compressor
rotation reversed
noncondensables
2. Remove excess
3. Open valve
4.. Rewire for phase
change
AdaptaPAK® Maintenance and Troubleshooting
3 - TROUBLESHOOTING - COMPRESSOR HIGH DISCHARGE PRESSURE
SYMPTOMS SYMPTOMS POSSIBLE ACTIONS
High compressor
1. Non-condensables in
1. Remove the non-
59
discharge
pressure
4 - TROUBLESHOOTING - COMPRESSOR LOW DISCHARGE PRESSURE
SYMPTOMS SYMPTOMS POSSIBLE ACTIONS
Low compressor
the system
2. System is overcharged
with refrigerant
3. Discharge shutoff valve
partially closed
4. Fan not running
5. Head pressure control
setting
6. Dirty condenser coil
1. Faulty condenser
condensables
2. Remove excess
3. Open valve
4. Check electrical circuit
5. Adjust
6. Clean it
1. Check condenser
discharge
pressure
5 - TROUBLESHOOTING - COMPRESSOR HIGH SUCTION PRESSURE
SYMPTOMS SYMPTOMS POSSIBLE ACTIONS
High compressor
suction pressure
temperature regulation.
2. Suction shutoff valve
partially closed
3. Insufcient refrigerant
in system
4. Low suction pressure
5. Variable head pressure
valve
1. Excessive load
2. Expansion valve is
control operation
2. Open valve
3. Check for leaks; repair
and add charge
4. See corrective steps
for low suction pressure
5. Check valve setting
1. Reduce load or add
additional equipment
2. Check Remote bulb;
overfeeding
regulate superheat
AdaptaPAK® Maintenance and Troubleshooting
60
6 - TROUBLESHOOTING - COMPRESSOR LOW SUCTION PRESSURE
SYMPTOMS SYMPTOMS POSSIBLE ACTIONS
Low compressor
1. Lack of refrigerant
1. Check for leaks; repair
suction pressure
2. Evaporator dirty or iced
3. Clogged liquid line lter
drier
4. Clogged suction line or
compressor suction gas
strainers
5. Expansion valve
malfunctioning
6. Condensing
temperature is too low
7. Broken internal
compressor part
and add charge
2. Clean/Check Remote
3. Replace cartridge(s)
4. Clean strainers
5. Check and reset for
proper superheat
6. Check means for
regulating condensing
temperature
7. Fix component; repair
or replace compressor
7 - TROUBLESHOOTING - COMPRESSOR LOSES OIL
SYMPTOMS SYMPTOMS POSSIBLE ACTIONS
Compressor
loses oil
1. Lack of refrigerant
2. Excessive compression
ring blow-by
3. Refrigerant “ood back”
4. Improper piping or traps
1. Check for leaks, and
repair; add refrigerant
2. Replace compressor
3. Maintain proper
superheat at compressor
4. Correct piping
AdaptaPAK® Maintenance and Troubleshooting
8 - TROUBLESHOOTING - COMPRESSOR THERMAL PROTECTOR OPEN
SYMPTOMS SYMPTOMS POSSIBLE ACTIONS
Compressor
1. Operating beyond
1. Add components
61
thermal protector
switch open
If, after performing the steps above, problems persist and you are not able to determine their cause, you may need
to contact Hillphoenix Field Service for assistance.
design limits.
2. Discharge valve
partially shut
3. Blown valve plate and/
or gasket
4. Dirty condenser coil
5. Overcharged system
to bring conditions
within acceptable limits
(i.e., CPR/EPR valves,
additional condenser
surface, liquid injection,
etc.)
2. Open valve
3. Replace valve plate or
and/or gasket
4. Clean coil
5. Reduce charge
AdaptaPAK® Maintenance and Troubleshooting
62
Evaporator Troubleshooting
Evaporators, because of where they are located in the cases (or walk-ins), may experience problems that affect the
performance of the case. Many of these problems can be addressed at the source—the evaporator.
EVAPORATOR TROUBLESHOOTING CHART
SYMPTOMS SYMPTOMS POSSIBLE ACTIONS
Fan(s) will not
1. Main switch open
1. Close switch
operate
Case or Walk-In
temperature is
too high
2. Blown Fuses
3. Defective motor
4. Defective timer or
defrost thermostat
5. Unit in defrost cycle
6. Coil does not get
cold enough to reset
thermostat
1. Thermostat set too high
2. Superheat too high
3. System low on
refrigerant
4. Coil iced up
2. Replace fuses, check
for short circuits or
overload conditions
3. Replace motor
4. Replace defective
component
5. Wait for completion of
cycle
6. Adjust fan delay setting
of thermostat, check
defrost thermostat
1. Adjust thermostat
2. Adjust thermal
expansion valve
3. Add refrigerant
4. Manually defrost coil,
check defrost controls
Ice accumulating
around the
evaporator or
accumulating
near the fan(s)
5. Unit cooler located too
close to doors
6. Heavy air inltration
1. Defrost duration is too
long
2. Fan delay not delaying
fans after defrost period
3. Defective defrost
thermostat or timer
4. Too many defrosts
for malfunction
5. Relocate unit cooler or
add strip curtain to door
opening
6. Seal all unwanted
openings
1. Adjust defrost
termination thermostat
2. Defective thermostat or
not adjusted properly
3. Replace defective
component
4. Reduce no. of defrosts
Coil not clearing
AdaptaPAK® Maintenance and Troubleshooting
EVAPORATOR TROUBLESHOOTING CHART
1. Coil temperature not
1. Check heater operation
63
of
frost during
defrost cycle
Ice accumulating
in drain pan
Uneven coil
getting above freezing
point during defrost
2. Not enough defrost
cycles per day
3. Defrost cycle too short
4. Defective timer or
defrost thermostat
1. Defective heater
2. Unit or pan not pitched
properly
3. Drain line plugged
4. Defective drain line
heater
5. Defective timer or
thermostat
1. Defective heater
2. Adjust timer for more
defrost cycles
overload conditions
3. Adjust defrost
thermostat or timer for
longer cycle
4. Replace defective
component
1. Replace heater
2. Check and adjust if
necessary
3. Clean drain line
4. Replace heater
5. Replace defective
component
1. Replace heater
frosting
2. Location is too close to
door or opening
3. Defrost termination set
too low
4. Incorrect or missing
distributor nozzle
2. Check and adjust if
necessary
3. Adjust defrost
termination setting to
be higher
4. Add or replace nozzle
with appropriately sized
orice for conditions
AdaptaPAK® Maintenance and Troubleshooting
64
Defrost Troubleshooting
Although the defrost system is relatively simple and trouble-free in operation, there are certain basic components
that may cause problems. For systems with electric defrost, the components to check when problems occur include
the following:
• Timer
• Fan motor
• Fan delay and defrost termination control
• Defrost heater
• Drain pan
Timer
If the system does not go through its proper sequence:
1. Check timer operation through a defrost cycle.
2. Check for loose wires or terminals.
3. Check other components before replacing the timer.
Other steps can be taken for systems equipped with certain types of timers that are commonly installed.
Fan Motor
If the motor does not operate, or it cycles on thermal overload, remove the motor leads from the terminal block and
test it by applying the correct voltage across the leads. If the motor still does not operate satisfactorily, it must be
replaced. Before starting the unit, rotate the fan blades to make sure they turn freely and have sufcient clearance.
Fan Delay & Defrost Termination Control
These controls generally use a single-pole, double-throw switch. Usually the red lead wire is wired to common.
The black wire is then wired in series with the fan motors. A brown wire is often wired in series with the defrost
termination. When controls are wired this way, the brown and red contacts close and the black and red contacts
open when the temperature is above the ON set-point (e.g., 55ºF). The black and red contacts close and the brown
and red contacts open when the temperature is below the
OFF
set-point (e.g., 35ºF).
On the initial call for refrigeration, or pull-down, the fan will not start until the coil temperature reaches approximately
35ºF (in this example). If the case is still comparatively warm (e.g., 60ºF) when the fan starts, then blowing this warm
air over the coil may cause it to warm up to 55ºF and thus cause the fan to stop. Therefore, the fan may recycle on
initial pull down. This cycling of the fan is normal and will cease as the case gets down to temperature. This control
cannot be adjusted.
If the fan motor fails to start when the control is below the set-point, disconnect the fan motor leads and check
the motor as described above for fan motors. Also check whether current is being supplied at the “N” and the “4”
terminals from the timer. The fan delay control must be below 35ºF when checking for a closed circuit.
AdaptaPAK® Maintenance and Troubleshooting
Defrost Heater
If a defrost heater unit shows little or no evidence of defrosting, and does not heat, disconnect the heater and check
to see if it is burned out. To test, apply the correct voltage across the heater or use a continuity ashlight battery
tester.
Drain Pan
If a drain pan has a build-up of ice, the drain line may be frozen. The drain line should be pitched sharply, and exit
the cabinet as quickly as possible. Sometimes the location of the drain and the ambient air temperature at the drain
outside of the case may cause the drain pan to freeze-up. A drain line heater may be required to correct the freeze-
up condition. To avoid this condition, any traps in the drain line must be located in a warm ambient temperature
location (often the case for case drains).
Finally, after correcting any faulty condition, it is essential that the coil and case be free of ice before placing the
case back into the automatic mode of operation.
65
If you should have questions about the steps or procedures listed in this manual, be sure to contact your Hillphoenix
Field Service Representative.
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