Hussmann RFLN Installation Manual

Page 1
®
RFLN & RFMN
Freedom Line
Low or Medium Temperature
Compressor Ready
Narrow Footprint
Reach-in
Merchandisers
IMPORTANT
Keep in store for future reference!
Manual - Installation & Operation Freedom RFLN & RFMN
Installation &
Operation Manual
Shipped With Case Data Sheets
P/N 0520677_J
July 2015
French P/N 0532421
Page 2
Page 3
P/N 0520677_J iii
®
TABLE OF CONTENTS
INSTALLATION
NSF Certication Freedom Line Description Location
........................... 1-1
Shipping Damage Exterior Loading Merchandisers Shipped with End Installed Shipping Braces Moving Merchandisers (Narrow Entrance)
................... 1-1
............ 1-1
.................... 1-2
.................... 1-2
1-2
..................... 1-2
1-3
Final Location ...................... 1-6
Leveling Door Adjustment Joining
............................ 1-7
.................... 1-7
............................ 1-8
REFRIGERATION / ELECTRICAL / SAFE-NET III
Refrigerant Field Installation of Condensing Unit About Quick Connect Couplings Connect Lines Insulate Refrigerant Lines Field Wiring Safe-NET III Display Condensate Water and Pump Safe-NET III User Instructions Display Start-Up Temperature Adjustment Alarms and Codes Manual Defrost Sensor Location Controls and Adjustments Merchandiser Electrical Data Electrical Connections Identication of Wiring
......................... 2-1
... 2-2
........ 2-3
...................... 2-3
............. 2-4
........................ 2-4
................ 2-4
.......... 2-4
......... 2-6
............................ 2-7
........................... 2-7
............. 2-9
................... 2-9
..................... 2-9
.................... 2-10
............ 2-11
......... 2-12
............... 2-12
.............. 2-12
FACADE AND SPLASHGUARDS
Install Facade ...................... 3-1
Installing Splashguard Brackets Installing Splashguards
............... 3-4
Sealing Splashguard to Floor Installing Bumpers
................... 3-6
........ 3-3
.......... 3-5
START UP / OPERATION
Expansion Valve Adjustment .......... 4-1
Prior to Start Up Checklist Start Up Checklist Defrost
............................ 4-3
................... 4-2
Checklist After 12 Hour Run Time Load Limits Stocking
........................ 4-4
........................... 4-4
............ 4-2
...... 4-3
Installing FDA/NSF
Required Thermometer .............. 4-4
MAINTENANCE
Care and Cleaning ................... 5-1
Cleaning Honeycomb Assemblies Cleaning Stainless Steel Surfaces Cleaning Coils
...................... 5-2
Top Mount Cleaning & Maintenance Cleaning Under Merchandisers Removing Scratches from Bumper
....... 5-2
....... 5-2
.... 5-3
........ 5-4
...... 5-4
SERVICE
Replacing Fan Motors and Blades ...... 6-1
Replacing Electric Defrost Heaters Replacing Drain Pan Heater Servicing Vertical Lighting Servicing Doors and Frames Repairing Aluminum Coil
............. 6-4
........... 6-4
............. 6-4
...... 6-2
........... 6-3
OPTIONAL DRIP PIPING
Waste Outlet and Water Seal ........... 7-1
Installing Drip Piping
................ 7-1
WARRANTY
IMPORTANT
KEEP IN STORE FOR FUTURE REFERENCE
Quality that sets industry standards!
12999 St. Charles Rock Road • Bridgeton, MO 63044-2483
®
®
U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900
www.hussmann.com
© 2015 Hussmann Corporation
Page 4
iv Contents
REVISION HISTORY
REVISION J
Updated “Connect Lines,” Page 2-3 Insulate “Refrigerant Lines,” Page 2-4 “Run Time”, Page 4-3
* * * * * * * * * * * * * * * * * * * * * * * * * *
ANSI Z535.5 DEFINITIONS
• DANGER – Indicate[s] a hazardous situation which, if not avoided, will result in death or serious injury.
REVISION H
Excel Note 5.5 inch clearance, Page 1-1.
REVISION G – November 2014 Added California Warning label, Page 1-2 Added Optional Drip Piping, Page 7-1
REVISION F – May 2014 Updated Cover Page; Warning Page 2-1. Added Page 3-5 3-6. New Page 4-2
REVISION E – June 2013 Updated drawings and wording on Page 3-2 and 3-3 to optional light channel and optional crown molding. Set pressure contols on Page 4-1 added disconnect hoses on Page 5-1
REVISION D – March 2013 Section 1: Revised caution box on page 1-2. Section 2: Added leveling to condensate pan. Section 5: Added Cleaning Coils.
REVISION C – November 2012 Section 2: Added Safe-NET startup code and optional audible alarm
• WARNING – Indicate[s] a hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION – Indicate[s] a hazardous situation which, if not avoided, could result in minor or moderate injury.
• NOTICE – Not related to personal injury – Indicates[s] situations, which if not avoided, could result in damage to equipment.
REVISION B – August 2012 Section 1: Added disassembly / reassembly procedure for tting cases through smaller doors and passage ways. Section 7: Added Emerson Electonic Unit Control Instructions
REVISION A – October 2011 Original Issue
PN 052677_J
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P/N 0520677_J 1-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
INSTALLATION
NSF CERTIFICATION
These merchandisers are manufactured to meet ANSI / National Sanitation Foundation
®
(NSF
) Standard #7 requirements. Proper in­stallation is required to maintain certication. Near the serial plate, each case carries a label identifying the type of application for which the case was certied.
ANSI/NSF-7 Type I – Display Refrigerator / Freezer
Intended for 75°F / 55%RH Ambient Application
ANSI/NSF-7 Type II – Display Refrigerator / Freezer
Intended for 80°F / 55%RH Ambient Application
ANSI/NSF-7 – Display Refrigerator
Intended for Bulk Produce
FREEDOM LINE DESCRIPTION
The Freedom Line RFLN and RFMN cases are designed to be ready for remote installation of a top-mounted air-cooled condensing unit, such as Hussmann’s TCLA through TCMD series of condensing units. They are controlled by the Safe-NET III electronic control. The case temperature is controlled by cycling the compressor based on the discharge air temperature input. The sensor for this input is located above the interior top panel at the right door. Another sensor, located on the bottom center evaporator coil return bend, is used for defrost termination. The Safe-NET III control is pre-programmed for both ice cream and frozen food operation, and is adjusted for the required temperature by the control knob located on the front of the controller, which is on the top of the case.
RFLN cases running on individual condensing units may be installed as stand-alone cases with ends, or as a part of a lineup. When installed in a lineup, Hussmann recommends that par­titions be installed between individual cases to prevent frost buildup and other issues that might result from different defrost schedules and operating temperatures.
LOCATION
These merchandisers are designed for displaying products in air conditioned stores where tem­perature is maintained at or below the ANSI/ NSF-7 specied level and relative humidity is maintained at or below 55%. Placing refriger­ated merchandisers in direct sunlight, near hot tables or near other heat sources could impair their efciency. Like other merchandisers, these are sensitive to air disturbances. Air currents passing around merchandisers will seriously impair their operation. Do NOT allow air con­ditioning, electric fans, open doors or windows, etc. to create air currents around the merchan­disers.
To prevent sweating on the exterior surfaces of merchandisers, there must be
clearance of 4 inches (102 mm) between
a minimum
the merchandisers and other xtures or walls.
A 5.5 inch (140 mm) space is required between facade top and the ceiling. A louvered Facade Panel kit is available that will allow for a top spacing minimum clearance of 3 inches (76 mm).
Product should always be maintained at proper temperature. This means that from the time the product is received, through storage, preparation and display, the temperature of the product must be controlled to maximize the life of the product. Condensing units installed on top of the merchandiser require air circulation to operate properly. Blocking or restricting air ow will adversely affect performance and may
damage the refrigeration system. If the ceiling and/or walls are built up around the merchan­diser, allow for a sufcient gap above or behind the merchandiser to provide adequate air cir­culation. When merchandisers are installed in a lineup, case must be taken to ensure that warm condenser air is not blown from one unit into the condenser of the adjacent unit.
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
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1-2 InstallatIon
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1-2 InstallatIon
SHIPPING DAMAGE
All equipment should be thoroughly examined for shipping damage before and during unloading. This equipment has been carefully inspected at our factory. Any claim for loss or damage must be made to the carrier. The carrier will provide any necessary inspection reports and/or claim forms.
Do not store items or flammable
materials atop the unit.
Do not walk on case.
EXTERIOR LOADING
Apparent Loss Or Damage
If there is an obvious loss or damage, it must be noted on the freight bill or express receipt and signed by the carrier’s agent; otherwise, carrier may refuse claim. The carrier will supply neces­sary forms.
Concealed Loss Or Damage
When loss or damage is not apparent until after equipment is uncrated, a claim for concealed damage is made. Upon discovering damage, make request in writing to carrier for inspection within 15 days and retain all packing. The car­rier will supply inspection report and required claim forms.
For California Businesses:
This product may contain chemicals known
to the State of California to cause cancer, birth defects, or other reproductive harm.
This warning is the result of the California State law known as the California Safe Drinking Water and Toxic Enforcement Act of 1986, which is commonly referred to as “Proposition 65.”
This warning does not mean that Hussmann products will cause cancer or reproductive harm, or is in violation of any product-safety standards or requirements. As claried by the California State government, Proposition 65 can be considered more of a ‘right to know’ law than a pure product safety law. When used as designed, Hussmann believes that our products are not harmful. We provide the Proposition 65 warning to stay in compliance with California State law. It is your responsibility to provide accurate Proposition 65 warning labels to your customers when necessary. For more information on Proposition 65, please visit the California State government website.
Do NOT walk on top of merchandisers or damage to the merchandisers and serious personal in­jury could occur.
designed To supporT excessive exTernal loading such as the weight of a person. Do
They are noT sTrucTurally
not store items or ammable materials atop the case.
MERCHANDISERS SHIPPED WITH END INSTALLED
If the case was shipped with the end installed, two long bolts were used to hold the shipping brace to the end. If the shipping bolts are reinserted after removing the brace, they will extend into the product area and may damage the coil.
Th e s e bolTs w iTh Th e s horTer b o lTs pr o v ided.
Th e r efore, b e sure T o replac e
Be careful not to damage the factory-installed end while moving the merchandiser. Make sure that tools are positioned past the end and be­neath the merchandiser’s support bar.
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P/N 0520677_J 1-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
SHIPPING BRACES
Move the merchandiser as close as possible to its permanent location and then remove all packaging. Check for damage before discarding packaging. Remove all separately packed accessories such as kits and shelves.
Locate the shipping block in the center of the heat exchanger (see illustration), and remove it before piping the merchandiser. This block was installed to minimize shipping vibration.
MOVING MERCHANDISER THROUGH NARROW STORE ENTRANCES
Some exterior merchandiser parts may be disassembled for transit access through small doors or passage ways. The minimum door opening is 36 in. x 83 in. This procedure takes approximately 30 minutes to disassemble and reassemble one case. Contact your Hussmann representative to see if store merchandisers have this kit option.
2. Remove the front bumper. Pull from the bottom and set aside.
3. Remove Lower Front Panel
Remove the front panel as follows: remove screws from front panel tabs, then lift the front panel. Refer to the illustration below.
Follow the steps below to decrease the Freedom prole for narrow access:
1. Remove the door handles.
Remove Screws from Door Handle
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1-4 InstallatIon
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4. Remove the screws that attach the wireway pan to the bottom assembly.
5. Detach the rubber and plastic gromets from the wireway pan.
7. Slide the wireway pan out, and remove it from the case. Bumper brackets and supports are attached to wireway pan. Removing the pan will remove the entire assembly.
8. Remove the back, external braces from the rear of the case as shown below. Braces will slide straight back away from the case when nuts and screws are removed.
6. Remove the screws that attach the grounding lug to the wireway pan.
6 nuts and 1
bottom screw per
external brace
Bottom screw is located approximately 10 inches inboard from the rear of the case. Bottom screw location on removed rear brace.
Page 9
P/N 0520677_J 1-5
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
9. Remove the braces and exible insulation from the hoses at the rear of the case.
NOTE: Care must be taken to ensure that insulation is not damaged during removal or replacement.
10. Remove the sealing gum from around the refrigeration tubing.
11. Pull the hoses to the inside of the case.
Do not suspend these components by their wire conduits. The case height without these
components installed on top is 82.75 in. (2102 mm). Case depth is 35.5 in. with handles, raceway pan and external frames removed.
Be sure to replace all screws and to secure all components. The condensing unit produces vibration that can cause screws to loosen.
Check the following before the rear of the case is positioned at its final location according to the store plan:
Avoid bending tubing sharply to prevent damaging the tubes.
A. Check that all wiring is secured inside of the case and wireway.
B. Check that all hoses are tucked away.
C. Use tie-wraps to secure any loose wires or hoses.
The electrical box, GFCI receptacle and evaporation pan are mounted on top of the case. They can be temporarily detached and suspended if required to provide clearance for door openings during shipment and installation.
1. Make sure all electrical and refrigeration is installed and secured on the back and top of the case.
2. Ensure refrigeration tubing is attached sealed and insulated at the rear of the case as shown.
Secure Flex Hoses When
Detached
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1-6 InstallatIon
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3. The external braces must be reinstalled with (6) nuts per brace, torqued to 24 foot pounds.
4. Replace and secure condensate tubing.
FINAL LOCATION
Once the case reaches its nal location, reassemble the wireway and door handles as follows:
1. Reinstall wireway pan in reverse order of removal.
2. The ground lug must be reinstalled using the two screws provided.
3. Replace the conduit connectors and plastic gromets to the wireway pan.
4. Replace wireway cover, bumper and door handles.
5. Use Sealing gum around refrigeration to seal each side of the merchandiser.
At completion of all electrical work, installation contractor shall re-install the front panels using care to ensure all panels are centered and properly fastened.
Use sealing gum around refrigeration
lines both inside and outside
of the merchandiser.
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P/N 0520677_J 1-7
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
LEVELING
Merchandisers must be installed level to ensure proper operation of the refrigeration system and to ensure proper drainage of defrost water. When leveling merchandisers, use a carpenter’s level as shown.
Metal leveling shims or wedges are provided with each merchandiser for use if needed.
NOTE:
po I n t of th e store f l o or.
Be g I n lIneu p levelI n g from t h e hIghes t
Place shims under the rail and make sure that they are positioned at a base component (cross­bar). This transfers the weight directly from the loaded case through to the oor.
See illustration on next page
Placing shims at other locations will cause uneven distribution of weight leading to piping leaks, as well as sagging or wracked doors.
DOOR ADJUSTMENT
After leveling and joining the merchandisers, adjust and level doors according to manufacturer’s instructions shipped with each product. Factory settings may be lost due to vibration during shipment.
Page 12
1-8 InstallatIon
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Correct Shim Location is Critical
JOINING
Sectional construction means that two or more merchandisers may be joined in line yielding one long continuous display requiring only one pair of ends. Joining kits and instructions are
shipped with each merchandiser.
To join like xtures, a joining kit is required. To join unlike xtures, or like xtures operating at different temperatures, a 1
1
/2inch (38mm) partition kit is required. To join same tempera­ture merchandisers on different defrost cycles, a plexiglass partition kit is required.
all joinTs musT be air-TighT To prevenT
formaTion of ice or condensaTion.
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P/N 0520677_J 2-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
REFRIGERANT
The correct type of refrigerant will be stamped on each merchandiser’s serial plate. The serial plage is located on the left-hand end of the interior top liner.
When brazing pipes be sure to use the
insulation blanket shipped with the
merchandiser to prevent damage to
the plastic case bottom.
Refrigeration lines are under pressure. Depressurize and recover refrigerant before attempting any connection or repair.
Refrigerant vapor is hazardous to your health and can cause death. Avoid breathing refrig­erant and lubrication vapor or mist. Exposure may irritate eyes, nose and throat. If acciden­tal system discharge occurs,ventilate work area before resuming service.
Always wear safety goggles and protective gloves when working with refrigerants. Contact with refrigerant may cause injury. Disconnect hoses with extreme caution! All hoses may contain liquid refrigerant under pressure.
Be sure that any room where you are working is thoroughly ventilated, especially if a leak is suspected.
Read all safety information regarding the safe handling of refrigerant and refrigerant oil, in­cluding the Material Safety Data Sheet. MSDS sheets can be obtained from your refrigerant supplier.
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
Page 14
2-2 RefRigeRation/electRical/Safe-net iii
P/N 0520677_J
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REFRIGERATION / ELECTRICAL / SAFE-NET III
FIELD INSTALLATION OF CONDENSING UNIT
A mounting plate is provided on top of the case with pilot holes that provide specic attachment points for the condensing unit base. The mounting plate is located above the next to last door on the right.
Front of Case
Mounting Plate
After mounting the condensing unit, the electrical box and GFCI receptacle must be re-attached to the top. The condensate pan, if provided, is packed inside the case and must also be installed and leveled on top of the case, then plugged into the 120V GFCI outlet provided. The TCMA, TCMB, and TCLA units have integral condensate pans, so an external pan is not required.
Exact component location is not critical; however, the components should be mounted in the general locations shown to ensure that electrical connections reach, and the con­densate pan has adequate air ow from the condenser, and the Safe-NET adjustment knob is accessible.
Evaporator
Pan
Electrical Box
GFCI Receptacle
Safe-NET control knob on this side of elec­trical box
Front of Case
Condensing Unit
Recommended Component Locations
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P/N 0520677_J 2-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
ABOUT QUICK CONNECT COUPLINGS
Quick Connect ttings are provided on both the case inlet and outlet lines, and on Hussmann’s TCL and TCM series of con­densing units. The case and condensing unit are pre-charged with the correct amount of R404A refrigerant, and the lines are sealed. Connecting the Quick Connects together breaks the seals to connect the refrigera­tion lines of the unit to the case. The Quick Connects must be properly torqued to avoid refrigerant leaks.
CONNECT LINES
Mount the suction line and liquid line to the condensing unit. When ready to connect, re­move protector caps and plugs from the Quick Connect couplings.
Tighten a ¼ turn after the coupling bottoms out to ensure a leak proof seal (equivalent to the foot pounds shown below).
Coupling Foot Pounds Size (Ft. Lbs.)
3
/8 in. 10-12
5
/8 in. 35-45
If necessary, carefully wipe coupling seats and threaded surfaces with a clean cloth to prevent the inclusion of dirt or any foreign material in the system.
Lubricate male half of diaphragm and synthetic rubber seal with refrigerant oil. Thread the coupling halves together by hand to ensure proper mating of threads. Use proper size wrenches (on coupling body hex and on union nut) and tighten until coupling bodies “bottom” or a denite resistance is felt.
Hex Wrench Coupling Size
3
/8 in. Male
3
/8 in. Female
5
/8 in. Male 1 1/16 in.
5
/8 in. Female 1 5/16 in.
3
/4 in.
13
/16 in.
Inlet Quick Connect
Outlet Quick Connect
Inlet Quick Connect
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2-4 RefRigeRation/electRical/Safe-net iii
P/N 0520677_J
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INSULATE REFRIGERANT LINES
Suction lines are insulated to prevent con­densation; extra insulation is provided to cover the eld connected tubing sections. These exposed sections must be covered with insulation. Check that all suction lines are adequately covered with insulation from case penetration to compressor; including suction service valves as some insulation may have been dislodged during shipping and instal­lation. Do not locate the tubing above the electrical box in order to prevent condensation from dripping onto electrical components.
Insulation
The disconnect switch to switch off power to all case components and the condensing unit is on top of the case, on the front of the electrical box. When this switch is off, some electrical terminals in the case wireway may be energized. The wiring connection for the condensing unit is provided with 5-ft leads and
1
4-inch terminals. The conduit must be con- nected to the condensing unit electrical box, and the leads are connected to the condensing unit input terminals. The heated condensate pan, if provided, is plugged into the 120V GFCI receptacle at the top of the case.
Safe-NET III DISPLAY
Insert the Safe-NET III display from the front into the opening provided in the facade.
Compressor
FIELD WIRING
All wiring must be in compliance with NEC and local codes. Field wiring must be sized for component amperes stamped on the serial plate. Actual ampere draw may be less than specied.
Terminal blocks are used for eld connection of the 120V single phase and 208/230V single phase power supply. The terminal blocks are located inside the electrical box on top of the case. The wiring diagram and circuit require­ments are provided on the Technical Data Sheets provided with the case and condensing unit.
CONDENSATE WATER AND PUMP
The bottom drain for defrost water from the evaporator coil of the RLN case is connected to an evacuation pump which uses
3
/8-inch plastic drain tubing to pump the water to the condensate pan on top of the case. The tubing should be inspected through its entire length to ensure that it has not been cut, kinked, obstructed, or damaged during shipping and installation.
The illustration on the next page shows the location of the condensate pump and drain.
Blocked drain lines will cause water to back up in the case and spill onto the floor, causing a slip hazard.
Page 17
P/N 0520677_J 2-5
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
Safe-NET III
Control
GFCI Outlet
Condensate
Evaporator Pan
Condensate Drain
Hose
Electrical Box
Page 18
2-6 RefRigeRation/electRical/Safe-net iii
P/N 0520677_J
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Safe-NET III
TEMPERATURE AND DEFROST CONTROLLER
SAFE-NET III™ USER INSTRUCTIONS
Your refrigerated case uses a Hussmann Safe-NET™ III temperature and defrost controller to precisely maintain the tempera­ture and prevent frost buildup on the cooling coil. LEDs indicate when the compressor or
• Controller LEDs:
refrigeration is on, when the case is in a defrost cycle, if the temperature is outside the desired range, or if there is a sensor failure.
An adjustment knob allows the temperature to be set within the congured range and can power off the controller and compressor. Your controller has been custom-congured to pro­vide the best temperature and defrost control for your chilled or frozen food.
Compressor Powered On LED (green): Lights while the compressor is running or the refrigeration valve is open. Defrost Cycle LED (yellow): Lights while the refrigeration coil is de­frosting. Temperature or Sensor Alarm (red): Lights if the temperature is too warm or too cold. Flashes if a sensor fails.
The front of the controller has an adjustment knob and status LEDs. The back of the controller has connections for sensors and switched equipment.
The Safe-NET III controller includes the following features and connections.
• Adjustment knob: Adjusts the temperature setpoint. Turn adjustment knob to OFF to turn off refrigeration system. Unplug merchandiser from power before servicing the unit.
• Audible Temperature Alarm (optional) See page 2-8 for alarm settings.
• Rear connections: – Case temperature sensor:
• Typically senses the temperature of the air in the case. Used by the controller to determine when to power on or power off the compressor or refrigeration.
– Evaporator temperature sensor:
• Senses the temperature of the refrigeration coil. Terminates a defrost cycle when refrigeration coil ice melts.
– Compressor or refrigeration relay:
• Switches on the compressor or refrigeration valve for cooling.
The evaporator fans remain ON when the adjustment knob is in the OFF position.
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P/N 0520677_J 2-7
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
DISPLAY
The display includes three red LEDs and two digits for temperature, defrost status, and error codes.
The three display LEDs are red; their behavior matches the LEDs on the controller.
START-UP
1. After the toggle switch is turned on, fans and lights will energize immediately.
The OFF Position does not disconnect line
voltage to the input terminal blocks.
2. After turning on the disconnect switch, wait for the self check to complete. During the self check, each LED ashes for one second, then all LEDs turn on for two seconds. If the LEDs do not ash, make sure the ad­justment knob is not in the Off position.
• After the self check, all LEDs turn off until the compressor starts. There may be a delay before the compressor starts. If the red Temperature or Sensor Alarm LED stays on after the self check.
• The green Compressor Powered On LED turns on when the compressor starts.
3. The compressor will continue to run until it reaches its cut-out temperature (pulldown). Door and frame anti-sweat heaters will energize after the evaporator temperature reaches a stable operating temperature, this may take 30 minutes or longer.
Product will be degraded and may spoil if
allowed to sit in a non-refrigerated area.
NOTE: Do NOT load product until AFTER merchandiser operates for 24 hours and reaches desired operating temperature.
1. The merchandiser temperature displays at
startup. The initial defrost starts twelve hours later. During defrost, the display shows “df.” This reading will remain displayed during defrost and until it times out, even though the refrigera­tion mode has been initiated. (The green LED will be lit.)
2. The compressor will start after a 30 second delay
once power is applied.
3. The compressor will continue to run until it
reaches its cut-out temperature (Pulldown).
4. The refrigeration cycle will continue for the next
subsequent scheduled (24-hours) or demand defrost.
5. The above process will repeat (steps3 and 4)
until the power is interrupted.
6. If power stops, the process will start over at step
1, and the time to subsequent defrost will reset.
7. Medium temperature is the same except for a
60-minute time terminated defrost
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2-8 RefRigeRation/electRical/Safe-net iii
P/N 0520677_J
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Safe-NET
Safe-NET
Low Temperature Freedom Safe-NET III Settings
Dial
Discharge
air Cut-In
Discharge
air Cut-Out
Avg Discharge Air
Temperature
Product Temperature
Range 0 Off 1 0 -6 -2 -5 to 10 4 -8 -14 -6 -11 to 5 7 -17 -23 -14 -18 to 0
Medium Temperature Freedom Safe-NET III Settings
Dial
Discharge
air Cut-In
Discharge
air Cut-Out
Avg Discharge
air Temperature
Product Temperature
Range 0 Off 1 38 32 36 32 to 42 4 35 29 33 29 to 39 7 33 27 31 27 to 37
Page 21
P/N 0520677_J 2-9
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
TEMPERATURE ADJUSTMENT
Rotate the adjustment knob counter clockwise for a warmer setpoint or clockwise for a colder setpoint.
• While the temperature is being adjusted, the optional display shows the setpoint (cut out value). A few seconds after the temperature is set, the display reverts to showing the sensed temperature in the merchandiser.
ALARMS AND CODES
Flashing TemperaTure or sensor alarm leD, e1 or e2
Alarm Settings
Low Temperature –7°F to 10°F Medium Temperature 43°F to 48°F
Alarm settings vary depending on temperature control setting. The Safe-NET control features an alarm delay to allow for stocking, pulldown after defrost, and startup.
MANUAL DEFROST
4
5
3
2
1
Warm
6
7
I
I
Cold
Note:
This procedure initiates a manual or forced defrost.
4
5
3
2
1
I
Warm
6
7
I
Cold
If the Temperature or Sensor Alarm LED (red) on the controller and display is ashing, a temperature sensor has failed. The display shows E1 if the case sensor has failed or E2 if the evaporator sensor has failed.
If the merchandiser sensor fails, refrigeration will run continuously. Turn off, or repeat a duty cycle of a few minutes on and a few minutes off.
When the Safe-NET control is powered up, a two-digit code will be displayed indicating that the current settings are installed.
Safe-NET Status Code
Low Temperature 68 Medium Temperature 69
4
5
3
2
1
Warm
6
7
I
I
Cold
IMPORTANT: Return the control knob to its original setting (Step1) once the manual de­frost has been initiated.
Page 22
2-10 RefRigeRation/electRical/Safe-net iii
P/N 0520677_J
U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM
8
9
10
11
Page 23
P/N 0520677_J 2-11
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
1. The Safe-NET III Controller controls refrig-
eration temperature. This is factory installed in the control panel. Adjust this control knob to maintain the discharge air temperature shown. Measure discharge air temperatures at the center of the honeycomb.
For low temperature models, defrosts are time initiated and temperature terminated. The de­frost setting is factory set as shown.
To ensure a thorough defrost, the defrost must be terminated by the temperature termination setting — not by time.
For medium temperature models, defrost is time initiated and time terminated.
— LOCK OUT / TAG OUT — To avoid serious injury or death from electrical shock, always disconnect the electrical power at the main disconnect when servicing or replacing any electrical component. This includes, but is not limited to, such items as doors, lights, fans, heaters, and thermostats.
Page 24
2-12 RefRigeRation/electRical/Safe-net iii
P/N 0520677_J
U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM
ELECTRICAL CONNECTIONS
ALWAYS CHECK THE SERIAL PLATE FOR
COMPONENT AMPERES
.
All wiring must be in compliance with NEC
and local codes. Electric Defrost is standard for low tempera­ture merchandisers and requires temperature termination. Off Time Defrost is standard for medium temperature merchandisers and is time terminated.
When two or more merchandisers with full length wireways are installed in line, remove the splashguards, end caps and wireway covers, and install the nipple and nuts (supplied) providing electrical passage from one merchandiser to the next. Following NEC and local codes is the
responsi bility of the electrical contractor.
IDENTIFICATION OF WIRING
Leads for all electrical circuits are identied by
MERCHANDISER ELECTRICAL DATA
colored plastic bands. These bands correspond
to the color code sticker (shown below) located Merchandiser data sheets for specic models
inside the merchandiser wireway. are shipped with this manual. The data sheets provide merchandiser electrical data, standard electrical schematics, parts lists and performance data. Refer to the merchandiser data sheets and
merchandiser serial plate for electrical infor­mation. Refer to the separate wiring diagrams shipped with the case for specic information about the merchandiser and any optional wiring kits that may have been applied.
Terminal block NOT for case-to-case wire
connection.
IN STA LLER
It is the contractor’s responsibility to install merchandiser(s) in accordance with all local
building and health codes.
Leads for all electrical circuits are identified by a colored plastic band: neutral wire for each circuit has either White insulation or a White plastic sleeve in addition to the color band.
Pink ...........RefRig. theRmoStat low temP. oRange oR
light Blue ...RefRig. theRmoStat noRm temP. tan ......... lightS
DaRk Blue .... DefRoSt teRm. theRmoStat maRoon .... RecePtacleS
PuRPle ........anti-Sweat heateRS Yellow* ... DefRoSt heateRS, 120V
BRown ........fan motoRS ReD* ....... DefRoSt heateRS, 208V
gReen* .......gRounD
WIRING COLOR CODE
*eitheR coloReD SleeVe oR coloReD inSulation
ELECTRICIAN NOTE: Use copper conductor wire only.
CASE MUST BE GROUNDED
theSe aRe maRkeR coloRS wiReS maY VaRY.
Page 25
P/N 0520677_J 3-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
FACADE AND SPLASHGUARD
INSTALL FACADE
Refer to the Hinge Location illustration to determine where hinges will be positioned on the top of the merchandiser.
A
Notice that hinge position will vary with the number of doors, or length, of the merchan­diser.
A
A
Facade Hinge Locations
Page 26
3-2 Facade and SplaShguard
U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COMP/N 0520677_J
Identify the corresponding positions on the facade panel, then fasten the hinges to the facade panel with provided screws.
Fasten Hinges to Facade
Attach reinforcement straps to the Facade
condensing unit and the electrical box. If necessary, the electrical box can be relocated.
Fasten Reinforcement Straps to Facade
Panel with provided screws.
Position the facade centered on case length and ush with the fascia as shown in the side view. below. One hinge will be between the
Fasten Facade and Baffle to Merchandiser
Fasten the hinge. Fasten the reinforcement straps after hinges are attached using provided screws.
Position Facade (Optional Light Channel)
Facade is centered on case length and recessed if optional light channel is provided as shown in side view below.
Position Facade
Page 27
P/N 0520677_J 3-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
Position the facade light channel (if provided) as shown below. Fasten to merchandiser using provided screws.
Position Facade
The end view below shows the correct place­ment of the light channel, facade, hinges and supports.
INSTALLING SPLASHGUARD BRACKETS
1. Attach splashguard retainer and splashguard retainer support to splashguard support bracket using two screws per bracket.
2. Install splashguard support brackets
before pIpIng case. The leveling brackets
have a maximum extension of one(1) inch (25mm) for uneven oors.
DO NOT
br a c kets.
place shims under splashguard
End View of Facade
Page 28
3-4 Facade and SplaShguard
U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COMP/N 0520677_J
INSTALLING SPLASHGUARDS
The splashguard is shipped inside each merchandiser. after merchandisers have been leveled and joined, and all drip piping, electrical and refrigeration work has been completed, re-install the front color panel, then install the splashguards.
First, position top of splashguard over the top edge of the bracket; second, push the lower edge of the splashguard toward the bottom of the bracket until it snaps into place.
Splashguard
Joint
Splashguards are joined with a galvanized metal splice connector that comes with the joint kit. Join the splashguards before installing on case.
Splashguard Retaining Bracket
Splashguard
Splice Connector
Side Detail
Page 29
P/N 0520677_J 3-5
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
SEALING SPLASHGUARD TO FLOOR
if required by local sanitation codes, or if desired by the customer, plastic splashguards may be sealed to the floor using silicone type sealer. The amount needed will depend on how much the floor is out of level.
• Remove all dirt, wax and grease from the area of the splashguard where adhesion will be necessary. This is to ensure a good, secure installation.
• Apply a good silicone type sealer along the bottom of the splashguard. Sealant must be removed and replaced when servicing.
Splashguard
Silicone-type
Sealer
OptiOnal stainless steel splashguards may be sealed to the floor using a vinyl cove base trim. The size of trim needed will depend on how much the floor is out of level.
To install the trim to the splashguard:
• Remove all dirt, wax and grease from the area of the splashguard where adhesion will be necessary. This is to ensure a good and secure installation.
• Apply a good contact cement to the cove trim and allow proper drying time according to the directions supplied with the cement.
• Install the trim to the splashguard so that it is lying flush with the floor. Do not seal the
trim to the floor.
If required by local health codes Cove Trim
may be sealed to the floor using a silicone type sealer. Sealant must be removed and replaced when servicing.
Splashguard
Cement
Cove Trim
Page 30
3-6 Facade and SplaShguard
U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COMP/N 0520677_J
INSTALLING BUMPERS
Offsetting the bumpers and top rails helps to disguise the joint locations, giving the lineup a smoother look.
Begin at the left end of the line-up. A starter bumper is factory-installed with end kits. Insert the internal joint trim, then add the full-length bumper.
Align each bumper section with its retainer and push into place, working from the end of the lineup. Install full length bumpers and internal joint trims offset across joints. Make sure that no gaps exist between sections. Continue in­stalling bumpers the length of the line up.
Do NOT install the last bumper sections at this time. These sections will be installed in the last step.
Once all except the last section of bumper have been installed, refrigerate the case line-up for at least six (6) hours. The last sections of bumper should be kept inside a refrigerated case or cooler during this time to allow the bumpers to contract.
Before installing the last full-length section, measure the remaining space. Use a miter box and ne-tooth saw to cut last bumper to length. Install the last section.
Remove protective lm from bumpers once installation is complete.
Optional end bumpers are factory-installed.
Page 31
P/N 0520677_J 4-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
START UP / OPERATION
EXPANSION VALVE ADJUSTMENT
Expansion valves must be adjusted to fully feed the evaporator. Before attempting to adjust valves, make sure the evaporator is either clear or only lightly covered with frost, and that the merchandiser is within 10 deg F (6.5 deg C) of its expected operating temperature. Adjust valves as follows:
Attach two sensing probes (either thermocouple or thermistor) to the evaporator. Position one under the clamp holding the expansion valve bulb; securely tape the other to the coil inlet line.
Some “hunting
of the expansion valve is normal. The valve should be adjusted so that during the hunting the greatest
difference between the two probes is 3–5degf (1.7–2.8degc).
With this adjustment, during a por­tion of the hunting the temperature difference between the probes will be less than 3degF (1.7degC) and at times 0.
Make adjustments of no more than
1
/4 turn for Balanced Port TEV and 1/2turn at a time for other valve models. Wait at least 15 min­utes before re checking the probe temperature or making further ad­justments.
Component Location in
RL / RM / RLN /
RLNI Models
Page 32
4-2 Start up
P/N 0520677_J U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM
START UP CHECKLIST
Start up should be performed
only by a qualified technician.
PRIOR TO START UP CHECKLIST
• Is the case connected to a power supply as specied on the nameplate?
• Is the power on at the breaker panel?
• Are the doors properly torqued? Are they self closing? Check each door from a fully open position and from about a 1-inch open positions.
• Are the evaporator fans plugged in? Do they rotate freely? (The fans can be inspected by lifting the deck pans in the bottom of the cases. Manually rotate each fan to conrm it is free and visually inspect to conrm that each fan is plugged into its receptacle.)
• Verify that refrigeration line shutoff valves are in the back-seated (open) position.
• Check that the Safe-NET control knob is in the correct position:
Low temperature: 7 for ice cream and 1 for frozen food Medium temperature: 7 for colder, 1 for warmer The unit will shut off when the knob is set to 0.
• Once the case is considered ready for start up, move the main switch on the electrical box to the “on” position.
This switch is located on the front of the
electrical box, on the top of the case. This toggle switch turns on the power to the condensing unit, and all case electrical components, including anti-sweat heaters, lights and fans.
• Check the reading on the Safe-NET III display; it should be displaying the case temperature. The display is located in the center of the front of the facade above the doors. The displayed temperature will show the merchandiser’s discharge air temperature.
• Set high and low pressure controls according to the merchandiser’s data sheet.
• Check the reading on the Safe-NET III display; it should be displaying the case temperature. The display is located in the center of the front of the facade above the doors. The displayed temperature will show the merchandiser’s discharge air temperature.
• Listen for any unusual sounds or events. For example: evaporator fan blade interference, compressor trip on overload, or high head due to excessive ambient temperature, circuit breaker trip, etc.
• Check the fan at each door to ensure all fans are running. The discharge air output at the top inside front of the case should be relatively even across the length of the case (honeycomb area).
Page 33
P/N 0520677_J 4-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
DEFROST
Defrost will occur 12 hours after switching the disconnect switch to the ON position. Defrost can be set to any time desired by switching the unit off, then back on again, 12 hours before the desired defrost time. “Df” is displayed on the Safe-NET display during defrost. It will show the discharge air temperature when the evaporator coil has returned back to stabilized operating temperature.
During defrost, the condensate pump will pump defrost water to the condensate pan located at the top of the merchandiser. On low temperature cases, the fans shut off during defrost, and electric defrost heaters energize to melt the frost off the evaporator coil. Defrost terminates when the evaporator coil reaches approximately 48°F. On medium temperature cases, the fans runs continuously, there are no defrost heaters, and defrost is time-terminated after 60 minutes.
CHECKLIST AFTER 12 HOUR RUN TIME
• Are all inspection plates and covers properly replaced?
• Inspect for any water accumulation result­ing from incorrect or unsealed penetrations where electrical or other lines pass through the case insulated walls.
• Check that the lights come on when the light switch is in the on position.
• Check that the condensate pump and conden­sate fan turns on. Condensate pump pumps water to the condensate pan during defrost Check to ensure there are no leaks. The pump will be on for only a few seconds. If conden­sate pan does not energize, GFCI may need to be reset.
• See the merchandiser’s Data Sheet Set for refrigerant settings and defrost requirements. Bring merchandisers down to the operating temperatures listed on the data sheet.
• Check case temperature.
• Verify that the fans are running. (The fans will be off if the case is in a defrost cycle. They will come back on after the completion of this cycle.)
• Initiate a defrost cycle and ensure the heaters are working properly. See the Safe-NET III instructions for how to force a defrost cycle. Check the amp draw at the terminal block, located in the front electrical raceway, just below the right most door of the case.)
• Check the door operation again, to ensure they close properly once the case is down to operating temperature.
Do not store items or flammable
materials atop the unit.
Do not walk on case.
Page 34
4-4 Start up
P/N 0520677_J U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM
LOAD LIMITS
Shelf life of perishables will be short if load limit is violated. at no time should merchandisers
be stocked beyond the load limits indicated.
Proper rotation of product during stocking is necessary to prevent product loss. Always bring the oldest product to the front and set the new­est to the back.
Air disChArge And return flues must re-
mAin open And free of obstruCtion At All times to provide proper refrigeration and air
curtain performance. Do not allow product, packages, signs, etc. to block these grilles. Do not use non-approved shelving, baskets, display racks, or any accessory that could hamper air curtain performance.
Do not prop doors open while stocking. And keep the doors closed as much as possible to prevent coil frosting and high merchandiser temperature.
STOCKING
Product should NOT be placed in merchandis­ers until all refrigeration controls have been adjusted and merchandisers are at proper oper­ating temperature.
All shelves and the lower deck are intended to display product. Shelf height is adjustable in one inch increments. Spacing of 12inches is recommended for most applications. Maximum load per shelf is 170pounds. Merchandisers may be ordered with optional “L” shaped wire shelves.
INSTALLING FDA/NSF REQUIRED THERMOMETER
The following pages provide the same informa­tion that ships with the thermometer.
This requirement does not apply to display refrigerators intended for bulk produce (refer to Page 1-1).
Please note that the tape cannot be exposed after installation.
Page 35
P/N 0520677_J 4-5
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
Sugge sted Mount ing Locati on s
This is an NSF-7 &
US FDA Food Code
Required
Thermometer
Thermometer — Hussmann Part TM.4911251
Hussmann Corporation • 12999 St. Charles Rock Road • Bridgeton, MO 63044-2483
U.S. & Canada 1-800-922-1919 • Mexico 1-800-522-1900 • www.hussmann.com
© 2007 Hussmann Corporation
in Single De ck G lass Front
Impact Me rcha ndis ers
Package Guard, Facin g Out
Doub le Stic k Tape
Flexible Plastic Fits in Price Tag Moldings
Hussmann P/N 0429971_C 10/2007
End Pane l
Price Ta g Moldin g
Suggested Mount ing Locati ons
in Multi-deck Mercha ndis ers
Page 36
4-6 Start up
P/N 0520677_J U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM
Important – Please read!
Food and Drug Administration (US FDA) Food Code [ http://www.fda.gov/ ]
National Sanitation Foundation (NSF / ANSI) Standard 7 [ http://www.nsf.org/ ]
This thermometer is provided in response to United States
and
Each installation will be different
depending on how the unit is
stocked, shopping patterns in the
department and ambient conditions
of the store. The suggested loca-
tions provided herein are possible
locations. It is the responsibility of
the purchaser / user to determine
the location within the food storage
area of the unit that best meets the
code requirements above.
The thermometer may need to be
moved several times to find the
warmest location. Mounting options
include flexible plastic for price tag
molding application, magnet
applied to back of flexible plastic for
steel end wall, and double stick
tape. Tape must not be exposed
after installation.
Questions about either code should
be addressed to local agencies or
other appropriate officials.
Keep with merchandiser
or give to store manager.
DO NOT DESTROY.
Page 37
P/N 0520677_J 5-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
MAINTENANCE
CARE AND CLEANING
Long life and satisfactory performance of any equipment is dependent upon the care it re­ceives. To ensure long life, proper sanitation and minimum maintenance costs, these merchandisers should be thoroughly cleaned, all debris removed and the interiors washed down, weekly.
Always*Clear™ Glass
Wipe inside of glass with isopropyl alcohol and a soft cloth. Allow surface to dry before closing door. Use of other cleaners or abrasives may damage the Always*Clear surface, and/or void the warranty. Refer to manual that ships with doors..
Exterior Surfaces
The exterior surfaces should be cleaned with a mild detergent and warm water to protect and maintain their attractive nish.
ers or scouriNg pads.
Never use abrasive cleaNs-
Interior Surfaces
The interior surfaces may be cleaned with most domestic detergents, ammonia based cleaners and sanitizing solutions with no harm to the surface.
Do No t Use:
• Abrasive cleansers and scouring pads, as these will mar the nish.
• Solvent, oil or acidic based cleaners on any interior surfaces.
• Ammonia based cleaners on acrylic surfaces.
Do :
• Remove the product and all loose debris to avoid clogging the waste outlet.
• Store product in a refrigerated area such as a freezer. Remove only as much product as can be taken to the freezer in a timely manner.
• First turn off refrigeration, then disconnect electrical power.
• Before washing, disconnect hose from con­densate pan on top of case, and discharge water into a drain.
• Thoroughly clean all surfaces with soap and hot water. do Not use steam or high
water pressure hoses to wash the iNterior. These will desTroy The
merchandiserssealing causing leaks and poor performance.
• Remove screws and lift hinged fan plenum for cleaning.
plenum afTer cleaning merchandiser.
Be sure To reposiTion The fan
• Take care to minimize direct contact be­tween fan motors and cleaning or rinse water.
• Rinse with hot water, but do NOT ood.
Never iNtroduce water faster thaN the
waste outlet caN remove it.
• Allow merchandisers to dry before
resuming operation.
• After cleaning is completed, turn on power and refrigerant to the merchandiser.
• Verify that merchandiser is working properly.
SHUT FANS OFF
Do NOT allow cleaning agent or cloth to
contact food product.
Product will be degraded and may spoil if
allowed to sit in a non-refrigerated area.
DURING CLEANING PROCESS.
Page 38
5-2 Maintenance
U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM
P/N 0520677_J
Fan Plenum
To facilitate cleaning, the fan plenum is hinged and also fastened with screws at each end. After cleaning be sure the plenum is properly lowered into position and that screws are rein­stalled
or producT loss will resulT due to
improper refrigeration.
CLEANING HONEYCOMB ASSEMBLIES
Honeycombs should be cleaned every six months. Dirty honeycombs will cause mer­chandisers to perform poorly. The honeycombs may be cleaned with a vacuum cleaner. Soap and water may be used if all water is removed from the honeycomb cells before reassembling. Be careful not to damage the honeycombs.
1. Remove the sheet metal screws located in the front metal retainer which holds the honey comb assembly in place.
CLEANING STAINLESS STEEL
SURFACES
Use non-abrasive cleaning materials, and al­ways polish with grain of the steel. Use warm water or add a mild detergent to the water and apply with a cloth. Always wipe rails dry after wetting.
Use alkaline chlorinated or non-chlorine containing cleaners such as window cleaners and mild detergents. Do not use cleaners containing salts as this may cause pitting and rusting of the stainless steel nish. Do not use bleach.
Clean frequently to avoid build-up of hard, stubborn stains. A stainless steel cleaning solution may be used periodically to minimize scratching and remove stains. Rinse and wipe dry immediately after cleaning. Never use hy­drochloric acid (muratic acid) on stainless steel.
2. Lift the honeycomb assembly out of the L-bracket to remove it.
3. Clean and dry the honeycomb.
4. After cleaning, reassemble in reverse order of removal.
Inte rnal
Frame
SIDE VIE W
Hone ycomb
Top Pane l
Screw
Adhe sive
Inte rior Top Pane l
Hone ycomb Reta iner
CLEANING COILS
NEVER USE SHARP OBJECTS AROUND COILS. Use a soft brush or vacuum brush to clean debris from coils. Do not puncture coils!
Do not bend ns. Contact an authorized service technician if a coil is punctured, cracked, or otherwise damaged.
ICE in or on the coil indicates the refrigeration and defrost cycle is not operating properly. Contact an authorized service technician to determine the cause of icing, and to make ad­justments as necessary. To maintain product integrity, move all product to a cooler until the unit has returned to normal operating temperatures.
Page 39
P/N 0520677_J 5-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
Mimimum Suggested Cleaning and Maintenance Frequency
with Separate TOP-MOUNTED Condensing Unit*
Average Total Type of Maintenance Maintenance Estimated Case Scheduled Frequency Duration Maintenance Component Maintenance (Times / Year)* (hours)* Time/Year (hours)
Evaporator Coil / Case Interior
Honeycomb
Return Air Grille
Drip Piping
Condenser Coil
Condensate Evaporation Pan
Condensate Evaporation Pan Heater
Condensate Pump
Compressor
Electromechanical Thermostats
Compressor Power Relays
Cleaning
Cleaning
Cleaning
Cleaning
Cleaning
Cleaning
None
Cleaning
None
Replacement
Replacement
1
1
12
6
4
4
N/A
6
N/A
0.2
0.2
2
0.05
0.1
0.1
0.1
0.2
N/A
0.05
N/A
1
1
2
0.05
1.2
0.6
0.4
0.8
N/A
0.03
N/A
0.2
0.2
*This table is provided for reference only. The suggested maintenance frequency is the minimum required to reduce unexpected equipment failure. Performance and efciency may be enhanced with more frequent cleaning. Individual cleaning schedules must take into account local environment and usage, as well as all applicable health codes.
Page 40
5-4 Maintenance
U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM
P/N 0520677_J
CLEANING UNDER MERCHANDISERS
Remove splashguards not sealed to oor. Use a vacuum with a long wand attachment to re­move accumulated dust and debris from under the merchandiser.
Do NOT use HOT water on COLD glass surfaces.
This can cause the glass to shatter and could
result in personal injury. Allow glass doors to
warm before applying hot water.
REMOVING SCRATCHES FROM BUMPER
Most scratches and dings can be removed using the following procedure.
1. Use steel wool to smooth out the surface area of the bumper or top rail.
2. Clean area.
3. Apply vinyl or car wax and polish surface for a smooth glossy nish.
Page 41
P/N 0520677_J 6-1
SERVICE
REPLACING FAN MOTORS AND BLADES
See cross section for location of evaporator fans. Should it ever be necessary to service or replace the fan motors or blades be certain that the fan blades are re-installed correctly.
For access to RLN / RMN fans:
1. Turn off power.
2. Remove bottom display pans.
3. Disconnect fan from wiring harness.
4. Remove fan blade.
Always disconnect the electrical power at the main disconnect when servicing or replacing any electrical component. This includes, but is not limited to, such items as fans, heaters, thermostats and lights.
5. Remove screws holding fan motor/bracket assembly to plenum and remove assembly.
6. Replace fan motor/bracket assembly and reinstall screws.
7. Reinstall fan blade.
8. Reconnect fan to wiring harness.
9. Turn on power.
10. Verify that motor is working and blade is turning in the correct direction.
11. Close air gaps under fan plenum. Warmer air moving into refrigerated air reduces effective cooling. If the plenum does not rest against the case bottom without gaps, apply foam tape to the bottom of the fan plenum to reduce improper air movement. Use silicone sealant to close other gaps.
12. Replace display pans. Bring merchandiser to operating temperature before restocking.
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
Hussmann recommends against frame heater cycling with Innovator doors to prevent door seals from freezing to the frames and tearing.
Page 42
6-2 Service
P/N 0520677_J U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM
Product will be degraded and may spoil if al-
lowed to sit in a non-refrigerated area.
5. Position new heater in bracket.
6. Bend tabs back to vertical to hold heater in bracket.
7. Replace the coil cover and lower fan plenum.
REPLACING ELECTRIC DEFROST HEATERS
Electric defrost requires a heater on the front and rear of the coil as shown. The heaters are held in place by tabs in the coil brackets.
Front Defrost Heater
1. Disconnect power.
2. Lift fan plenum up and back to access the heater.
3. Bend tabs holding heater to horizontal.
4. Remove heater from coil bracket.
Electric Defrost
8. Turn on power.
9. Verify that heater is working correctly.
10. Close air gaps under fan plenum. Warmer air moving into refrigerated air reduces effective cooling. If the plenum does not rest against the case bottom without gaps, apply foam tape to the bottom of the fan plenum to reduce improper air movement. Use silicone sealant to close other gaps.
11. Replace display pans. Bring merchandiser to operating temperature before restocking.
Rear Defrost Heater
1. Disconnect Power.
2. Remove coil cover.
Back Heater
3. Remove clips holding heater to coil tube.
4. Remove heater from slots in coil bracket.
5. Position new heater in slots.
Front Heater
Page 43
P/N 0520677_J 6-3
6. Replace clips.
7. Replace the coil cover.
Always disconnect the electrical power
8. Turn on power.
at the main disconnect when servicing or replacing any electrical component. This
9. Verify that heater is working correctly.
includes, but is not limited to, such items as fans, heaters, thermostats and lights.
10. Replace display pans. Bring merchandiser to operating temperature before restocking.
REPLACING DRAIN PAN HEATER — ELECTRIC AND GAS DEFROST (Low Temperature Only )
The drain pan heater is located as shown below.
Remove Drain Pan Heater
1. Disconnect power.
2. Pull heater out from under jiffy clips.
3. Position new heater under jiffy clips. Be sure offset is properly positioned around the drain. If jiffy clips are removed, make cer-
tain sealer is replaced.
4. Reconnect power.
5. Verify that heater is working correctly.
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
Page 44
6-4 Service
P/N 0520677_J U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM
SERVICING VERTICAL LIGHTING
Refer to door manufacturer’s manual for servicing of vertical lamps.
SERVICING DOORS AND FRAMES
See door manufacturer’s service manual for servicing information. One manual is shipped with each merchandiser.
REPLACING DOOR OR DOOR FRAME PARTS
Parts for Reach-in doors and door frame assemblies must be ordered direct from the door manufacturer This includes the glass doors, door frame assemblies, lamps, ballasts, door handles, hold open slides, and power cords. Refer to specic warranty supplied with the door. The manufacturers have a warranty against moisture penetration, a warranty against tempered glass breakage, and a warranty on ballasts. Lamps are not covered by Hussmann or the door manufacturer.
X-Ergon 1570 E. Northgate P.O. Box 2102 Irving, TX 75062 Phone: 1-800-527-9916
NOTE: Hussmann Aluminum melts at 1125°F (607°C) Aladdin 3-in-1 rod at 732°F (389°C) X-Ergon Acid core at 455°F (235°C)
Technique:
1. Locate Leak.
2. REMOVE ALL PRESSURE.
3. Brush area UNDER HEAT.
4. Use PRESTOLITE TORCH ONLY. Number6 tip.
5. Maintain separate set of stainless steel brushes and USE ONLY ON ALUMINUM.
REPAIRING ALUMINUM COIL
The aluminum coils used in Hussmann merchandisers may be easily repaired in the eld. Materials are available from local refrigeration wholesalers.
Hussmann recommends the following solders and technique:
Solders
Aladdin Welding Products Inc. P.O. Box 7188 1300 Burton St. Grand Rapids, MI 49507 Phone: 1-800-645-3413
6. Tin surface around area.
7. Brush tinned surface UNDER HEAT,
thoroughly lling the open pores around
leak.
8. Repair leak. Let aluminum melt solder, NOT the torch.
9. Don’t repair for looks. Go for thickness.
10. Perform a leak check.
11. Wash with water.
12. Cover with a good exible sealant.
Page 45
P/N 0520677_J 7-1
OPTIONAL DRIP PIPING
WASTE OUTLET AND WATER SEAL
Drip piping must be installed for cases with­out evaporation pans. Drip piping is located between the front merchandiser base and the splashguard xture and runs parallel to the mer­chandiser (see Data Sheet for exact locations).
INSTALLING DRIP PIPING
Poorly or improperly installed drip pipes can seriously interfere with the merchandiser’s op­eration and result in costly maintenance and product losses. Please follow the recommenda­tions listed below when installing drip pipes to ensure proper installation.
Never use drip piping smaller than the nominal diameter of the pipe or water seal supplied with the merchandiser.
Splashguard brackets MUST be installed
before piping merchandiser.
Provide a suitable air break between ood rim of the oor drain and outlet of drip pipe. To meet code on low base merchandisers, it may be necessary to install a eld-supplied drip pipe reducer. An alternative is to cut the last section of drip pipe at an angle.
When connecting drip piping, the water seal must be used as part of the drip piping to prevent air leakage or insect entrance. Never use two water seals in series in any one drip pipe.
ries will cause an air lock anD prevent Draining.
Double water seals in se-
Pitch the drip piping in the direction of ow. There should be a minimum pitch of
1
/4in. perft (20mm per 1m).
Avoid long runs of drip piping. Long runs make it impossible to provide the pitch necessary for good drainage.
Prevent drip pipes from freezing sweating or freezing:
A. Do NOT install drip pipes in contact
with uninsulated suction lines. Suction lines should be insulated with a non-absorbent insulation material.
B. Where drip pipes are located in dead air
spaces, such as between merchandisers or between a merchandiser and a store wall, provide means to prevent drip pipe from sweating. External ventilation fans may be required to prevent sweating.
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
Page 46
7-2 Service
Do NOT use Thread Sealer on Drain Fitting!
(Drain Fitting)
Factory Installed (four turns)
Approx.
1
/
2
in. Clearance to Floor
1. Tee is factory-installed. If adjustment is necessary,
tighten factory-installed tee no more than ¼ turn. Do not overtighten threads, or the drain tting or tee may become damaged.
2. Do NOT use thread sealer on ABS drain tting.
If sealer is used the ABS drain tting may crack or leak! (If a tee needs to be installed it should be
hand tightened) Do not overtighten threads.
2. Dry t the supplied water seal / trap to en­sure approximately
1
/2 in. of clearance from the bottom of the trap to the oor as shown.
Merchandiser
Bottom
Factory-Installed
Tee Fitting
NOTE: It may be necessary to rotate water seal (trap) inside the tee a few degrees to en­sure clearance at two locations. There must be clearance 1) between the bottom of the water seal and the oor, and 2) between the top of the water seal outlet and the bottom of the merchandiser. Do not over-rotate or gravity seal may be compromised. Always rotate trap bot­tom toward merchandiser support rail.
Front of
Merchandiser
Waste Outlet
Maintain Clearance
to Bottom of Case
Field-Installed
Water Seal
Floor
Rotate Water Seal towards back of Merchandiser if required
1/2-in. Clearance to Floor
P/N 0520677_J U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM
Page 47
P/N 0520677_J 7-3
3. Install remaining PVC drain parts using recommended PVC cleaner, primer and cement per manufacturer’s recommendations.
4. Thread plug into the adapter until snug but not to exceed four full rotations.
It is the installing contractor’s responsibility
to consult local agencies for
local code requirements.
5. Installed drip piping may require additional support depending on the number and lo­cation of the hub oor drains. The installer should always provide adequate support to all drip piping arrangements to prevent ex­cess stress on all drip piping components. The installer must provide additional support when “evac” type waste water systems are applied.
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. Freedom Line Reach-in
Page 48
7-4 Service
The instructions on the following pages detail the installation and operation of the Electronic Unit Controller. These instructions are re­printed with permission from: Emerson Climate Technologies, Inc.
Notes:
P/N 0520677_J U.S. & Canada 1-800-922-1919 • Mexico 1-800-890-2900 • WWW.HUSSMANN.COM
Page 49
Application Engineering
BULLETIN
Application Engineering
BULLETIN
AE8-1376 R2
AE8-1376 R2
September 2013
Electronic Unit Controller
TABLE OF CONTENTS
Section Page Section Page
Safety
Safety Instructions ....................................................2
Safety Icon Explanation ...........................................2
Instructions Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons ..........................................3
Safety Statements ....................................................3
1. Introduction and Features .....................................4
1.1 Technical Specifi cations ..................................5
1.2 Pressure Probe Error Bypass .........................5
1.3 Bump Start ......................................................5
2. Installation and Controller Operation Instructions
2.1 Condensing Unit Installation Instructions ........5
2.2 Controller Display ............................................5
2.3 Button Descriptions and Key Combinations ....6
2.4 Viewing the Set Points ....................................7
2.5 Changing a Parameter Value ..........................7
2.6 Entering the Advanced Options Menu .............7
2.6.1 Moving Parameters Between the Programming Menu and the Advanced
Options Menu .............................................. 7
2.7 Locking the Keypad ....................................... 7
2.8 Unlocking the Keypad ................................... 7
2.9 Resetting the Alarm and Runtime Counters .. 8
3. Alarm Menu ............................................................8
4. Service Menu .........................................................8
5. Parameter List........................................................9
6. Controller Wiring ..................................................10
6.1 Additional Controller Inputs ...........................10
7. Alarms/Noti cations .............................................11
7.1 Discharge Line Temperature Protection ........12
7.2 UL High Pressure Safety Control ..................12
8. Thermister Temperature Resistance Values ... 13-14
9. Troubleshooting Guide .....................................15-16
© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.
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Application Engineering
BULLETIN
Safety Instructions Copeland
Safety Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained below and safety instructions applicable to the products in this bulletin are grouped on Page 3. These instructions should be retained throughout the lifetime of the compessor. You are strongly advised to follow these safety instructions.
brand products are manufactured according to the latest U.S. and European
Safety Icon Explanation
DANGER
WARNING
CAUTION
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
CAUTION
NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices
not related to personal injury.
© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.
2
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Application Engineering
BULLETIN
Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
AE8-1376 R2
WARNING
WARNING
WARNING
CAUTION
ELECTRICAL SHOCK HAZARD
• Disconnect and lock out power before servicing.
• Allow drive components to electrically discharge for a minimum of two minutes before servicing.
• Use compressor with grounded system only.
• Molded electrical plug must be used in all applications.
• Refer to original equipment wiring diagrams.
• Failure to follow these warnings could result in serious personal injury.
PRESSURIZED SYSTEM HAZARD
• System contains refrigerant and oil under pressure.
• Remove refrigerant from both the high and low compressor side before removing compressor.
• Never install a system and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system.
• Use only approved refrigerants and refrigeration oils.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in serious personal injury.
BURN HAZARD
• Do not touch the compressor until it has cooled down.
• Ensure that materials and wiring do not touch high temperature areas of the compressor.
• Use caution when brazing system components.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in serious personal injury or property damage.
COMPRESSOR HANDLING
• Use the appropriate lifting devices to move compressors.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in personal injury or property damage.
Safety Statements
• Refrigerant compressors must be employed only for their intended use.
• install, commission and maintain this equipment.
• All valid standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment must be observed.
© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.
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Application Engineering
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1. Introduction and Features
The introduction of the Electronic Unit Controller to Copeland
brand condensing units will provide many
benefi ts to the contractor and end-user. It has been designed specifi cally for demanding refrigeration applications to ensure precision in installation and operation. While the Electronic Unit Controller will replace existing adjustable low pressure controls, fan cycle switches and other relays, it also has additional features. These features include bump start (where applicable), data storage and short cycling protection (See Figure 3). This controller does NOT replace the xed high pressure control required by UL.
The Electronic Unit Controller can be used on any condensing unit application with the appropriate sensors and relays that will be factory installed on the condensing unit. This document will explain how Electronic Unit Controllers affects your installation process and how it can also assist in troubleshooting if the need arises.
Controllers will be preprogrammed with the proper settings, resulting in little to no setup time. The unit will come with an attached label showing how to adjust the low pressure cut-in and cut out (See Figure 1). There will also be an additional label on the inside of the enclosure which will also list all of the factory default settings for the controller, including those that are not adjustable (See Figure 2). The inside label will also include a basic wiring diagram for the controller, basic
Hold 3 Seconds to Enter Menu
(PSI Light Will Flash)
Cycle Through Menu Options
Select Function
Adjust Value
Store Function
Exit Menu
Alarm Description
PoF Key pad locked Pon Keypad unlocked
P1 Suction probe failure P2 Condenser probe failure
P3 DLT probe failure dLt DLT temperature alarm dLL DLT lock al arm
EE Module Failure
Note: After 15 seconds of inactivity the controller will revert to the default display
08/12
Figure 1
Figure 2
+
+
Alarm Description
HP High pressure trip alarm
High condenser
HA
temperature alarm High pressure trip
HPL
lock-out alarm
Functions
Low Pressure
Cut-In
Low Pressure
Cut-Out
More infor mation
inside panel
Scan for Electronic Unit Controller Alarm Code and Service Information
052-7269-01
AE8-1376 R2
Features Today Dixell
Low Pressure
Control
High Pressure UL
Safety Control
Adjustable Mechanical Switch Suction Pressure Transducer
Adjustable or Fixed
Mechanical Switch
Fixed Mechanical Switch
Fan Cycling 2 Mechanical Switches Mid Coil Temperature Sensor
Time Delay Timing module Built In
Discharge Line
Protection
Mechanical Thermostat T emperature Sensor
Bump Start Timing Module Built In
Multi-Refrigerant
Approval
2 Adjustable Mechanical
Pressure Switches
Utilize Mid Coil
T emperatur e Sensors
Data Storage Performance Alert* Built In
Short Cycle
Protection
Performance Alert* Built In
Figure 3
*Copeland PerformanceAlert is not replaced by the Electronic Pressure Control. The PerformanceAlert module includes
many features not included in the Electronic Pressure Control, such as locked rotor protection, loss of phase, etc. The Electronic Pressure Control is able to interface with PerformanceAlert to display error codes in an easy-to-read format.
© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.
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descriptions of what the buttons on the controller does, the controller part number and the part number for the pre-loaded program. A phone number to contact and a website for more information will be available on the inside label as well.
1.1 Technical Specifi cations
Mounting: Panel mounting in a 71x29mm panel cut-out Controller IP Rating: IP20 Front Panel IP rating: IP65 Power supply: 208/230Vac ±10%, 50/60Hz 110Vac ±10%, 50/60Hz Power absorption: 3VA max Relay outputs: Compressor Relay: 250VAC, 16A FLA, 96A LRA Fan Relay 1: 250VAC, 4.9 FLA, 29.4 LRA Fan Relay 2: 250VAC, 1.9 FLA. 11.4 LRA
Special Note: EUC fan cycling relays are not approved for use with ECM motors
Data storage: Non-volatile memory (EEPROM). Rated impulsive voltage: 2500V; Overvoltage Category: II Factory Installed Operating Range: -40 – 120°F Ambient Non-Factory Installed Operating Range: -4 to 120°F Ambient
1.2 Pressure Probe Error Bypass
The pressure probe bypass is in place to allow the controller to run proper during pull down if a system has been off for a period of time and the suction pressure is greater than the maximum value the suction transducer can read (In most cases, 135 PSIG). If this occurs, the controller will fl ash the maximum value of the transducer for 15 minutes or until the suction pressure is pulled down below the maximum transducer value. The compressor will run continuously during this time unless the thermostat input or high pressure input are opened, or if there is a discharge line temperature trip. If the 15 minutes expires the pressure probe error P1
is signaled and the compressor is switched on and off cyclically with  (default 5 minutes) and  (default 5 minutes) period.
1.3 Bump Start
Bump start is an optional feature which can provide additional fl ooded start protection. The compressor is turned on for 2 seconds, then turned off for 5 seconds 3 times before the compressor runs normally. This allows for refrigerant to exit the compressor without the oil being removed as well.
Bump start is enabled on all transport units, without the ability to be turned off. On most stationary units, it is turned off by default, but can be turned on in the Advanced Options Menu as by changing to Yes. (See section 2.6).
2. Installation and Controller Operation Instructions
2.1 Condensing Unit Installation Instructions
A condensing unit with an Electronic Unit Controller will be installed exactly the same as a condensing unit with mechanical controls. Customer connections will not change, and in a vast majority of cases, wiring to the unit will not change as well. See section 6 for more information. The key difference with an Electronic Unit Controller is that setpoints are set electronically rather than mechanically. See section 2.5 for further details.
If the unit keeps shutting down during charging, the low pressure cut out can be lowered to allow it to run. Be sure to adjust it back to the proper setting after charging.
2.2 Controller Display
The controller display is shown in Figure 4 below. Table 1 provides a description of each of the labeled lights. The controller is defaulted to display the current suction pressure to three signifi cant digits in pounds per square inch gage (psig).
Compressor
Alarm History
Module Restart, push to reset the HPL, DLL lock out faults (cycle power)
© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.
Fan Motor 1
ServiceActive Alarm
Fan Motor 2
Figure 4
5
Units
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Application Engineering
BULLETIN
Table 1 – LED Descriptions
LED MODE FUNCTION
ON Compressor On
Flashing Anti-short cycle delay enabled 1 2
PSI PSI
2.3 Button Descriptions and Key Combinations Table 2 lists the different buttons on the controller (as shown in Figure 4) as well as their
functions. Table 3 lists the different key combinations that are available and their functions.
ON Fan1 On ON Fan 2 On
ON Pressures displayed in PSIG
Flashing Programming mode
ON Browsing the service menu
Flashing New alarm indication
ON You’re browsing the alarm menu ON An alarm is occurring
AE8-1376 R2
Table 2 – Button Descriptions
BUTTON DESCRIPTION
Displays set point In programming mode it confirms an operation.
1) To override the cut-in value push the start function button (see Figure 4) for 3 seconds. Compressor will then start.
START
(UP)
(DOWN)
SERVICE
Alarm menu
2) If a DLL or HPL lock out condition occurs, to reset depress the start button (see Figure 4) for 3 seconds two consecutive times to reset the lock out condition. (If the temperatures or pressures are exceeding the cut out trip point values, pushing the start button will not clear the fault)
In programming mode it browses the parameter codes or increases the displayed value. In programming mode it browses the parameter codes or decreases the displayed value.
To enter the service menu. (See Section 4) To enter the Alarm menu. (See Section 3)
Table 3 – Key Combinations
KEY COMBINATIONS:
To lock & unlock the keyboard interface
+ +
To enter into programming mode. To return to the suction pressure display.
© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.
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2.4 Viewing the Set Points:
1. Push and immediately release the key: the display will show the “Cin ” message.
2. Press to see the value;
3. Push and immediately rele ase the key: the displa y will show the “ message.
4. Press to see the value.
2.5 Changing a parameter value:
To change the parameter’s value, operate as follows:
1. Hold do wn the + keys for 3 seconds or until the “PSI” LED starts blink ing to enter the module’s programming menu.
2. Use or to select the required parameter. Press the key to display its value.
3. Use or to change its value.
4. Press to store the new value.
TO EXIT: Press + or wait 15 seconds without pressing a key. NOTE: the set value is stored even when the procedure is exited by waiting for the time-out to expire.
2.6 Entering the Advanced Options Menu:
The advanced options m enu will be locked 5 m inutes af ter the controller is po wered. If you need to access this menu after this time, cycle power to the controller.
1. Enter th e Programming mode by pressing the + keys for 3 seconds (the PSI LED starts blinking).
2. Release the k eys, then push again the + keys for at least 7 sec onds. The Pr2 label will be displayed immediately followed from the
NOW YOU ARE IN THE ADVANCE OPTIONS MENU.
3. Use or to select the required parameter.
4. Press the key to display its value.
5. Use or to change its value.
6. Press to store the new value.
TO EXIT: Press + or wa it 15 seconds without pressing a key. NOTE1: if no parameter is present in Pr1, after 3 seconds the “noP” message is displayed.
Keep the keys pushed until the Pr2 message is displayed. NOTE2: the set value is stored even when the procedure is exited by waiting for the time-out to expire.
Ci.n parameter.
Cou
2.6.1 Moving Parameters between the Programming Menu and the Advanced Options Menu While in the advanced options menu, certain parameters will have a (. period) in between the 2
rd
and 3
character, for example
the Advanced Options Menu. To add or remove a parameter from the programming menu, press the SET + keys
together while the parameter name is on the display in the advanced options menu. The (.
period) between the 2
To Exit: Press SET + or wait 15 seconds without pressing the keys.
2.7 Locking the Keypad
1. Keep pressed for more than 3 seconds the + keys.
2. The “PO F” message will be dis played and the keyboard will be lock ed. At this point it will be
possible only to see the set points.
3. If a key is pressed more than 3 seconds the “POF” message will be displayed.
2.8 Unlocking the Keypad
Keep pressed together for more than 3 seconds the + keys, until the “Pon” message is displayed.
© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.
nd
and 3rd parameter will either be added or removed.
Ci.n
. These parameters are in the Programming Menu as well as
7
nd
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Application Engineering
BULLETIN
rSA
DLT
Loc rCA rCH rFH
n
HP
dLt
LOC
HP
dLt
Loc
StH
StL
StH
StL
CHH
CHL
CHH
CHL
F1H
F1L
F2H
F2L
2.9 Resetting the Alarm and Runtime Counters
See sections 3 and 4 for more information on the Alarm and Service Menus. The advanced options m enu will be lock ed 5 minutes af ter the controller is power ed. If you need to reset counters after this time, cycle power to the controller.
1. Enter the Programm ing mode by pressing the + keys for 3 seconds (the PSI LED starts blinking).
2. Release the k eys, then push again the + keys for more than 7 seconds. T he Pr2 label will be displayed immediately followed from the “
NOW YOU ARE IN THE ADVANCE OPTIONS MENU.
3. Use or to select the required parameter listed below.
r
4. Press the key to display its value.
5. Use Change the
6. Press to store the new value and reset the counter
7. Repeat steps 3 to 6 to reset any additional counters
3. Alarm Menu
The controller records in the Alarm menu the total number of activations of the following alarms.
- High Pressure Trips ( up to 999) -
- High DLT temperature alarm ( up to 999) -
- Total number of manual restarts (HPL and dLL) up to 255 -
To see the alarm counters:
– Reset Alarm Counters (HP, – Reset Compressor Starts Counters – Reset Compressor Run Hours Counters – Reset Fan Run Hours Counters
to y.
1. Push and release the
2. The controller shows the
3. Push the key to see the number of high pressure trips.
4. The controller shows the
5. Push the key to see the number of DLT Trips.
6. The controller shows the
7. Push the key to see the number of manual resets.
key.
.
label.
label.
label.
, and
.
)
Cin
parameter.
.
4. Service Menu In the SERVICE menu the following values are stored:
Number of compressor starts:
Example: If
Compressor Run Hours:
Example: If
Fan Motor 1 Run Hours:
Fan Motor 2 Run Hours:
To see the Service Counters:
1. Push and hold the
2. See the above list for the counter names and meanings.
© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.
=12
= 8 and
= 500: the total number of compressor starts = 12,500
= 500, the total number of compressor run hours is 8,500
key for 3 seconds
(0-999 resolution 1000);
( 0-65; res. 1000)
(0-65; res. 1000) (0-65; res. 1000)
8
( 0- 999; res. 1);
(0-999; res. 1) (0-999; res. 1);
(0-999 resolution 1)
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5. Parameter List
All of the parameters are listed below, along with their descriptions and default values. Depending on the condensing unit model, some of these values may be different or not applicable.
Table 4 – Parameters
Label Description Default Range
Default Display Value
Current Suction Pressure (PSIG)
Adjustable In Programming Menu
Compressor cut in (PSIG)
Cin
Compressor cut out (PSIG)
CoU
Adjustable From Advanced Options Menu
Outputs delay at start up (seconds) (Only adjustable on single phase scroll units)
odS
Anti-short cycle delay (Minimum time between compressor off then on) (seconds)
AC
Compressor ON time with faulty probe (minutes)
Con
Compressor OFF time with faulty probe (minutes)
CoF
Suction Pressure Transducer Offset (PSI)
P1F
Bump start enabled
b P
Number of activation of DLT alarm in a hour to lock compressor (Units with discharge
nPS
line temperature protection only) UL safety digital input activation before compressor lock (Units with fixed high
HPn
pressure controls only) Fan 1 Cut Out (°F) (Fan Cycling Units Only)
SF1
Fan 1 differential (°F) (Fan Cycling Units Only)
HF1
Fan 2 Cut Out (°F) (Fan Cycling Units Only)
SF2
Fan 2 differential (°F) (Fan Cycling Units Only)
HF2
Reset Alarm Counters (HP, DLT, and Loc)
rSA
Reset Compressor Starts Counters
rCA
Reset Compressor Run Hours Counters
rCH
Reset Fan Run Hours Counters (Fan Cycling Units Only)
rFH
Factory Set Definitions
Minimum set point (PSIG)
LS
Maximum set point (PSIG)
US
Minimum time between two compressor starts (minutes)
ono
Number of fans on during probe fault
nFA
Measurement unit for pressure: PSIG, bar, kPA
Unt
Measurement unit for temperature
CF
Bump Start Compressor on time (seconds)
on
Bump Start Compressor off time (seconds)
oFF
Number of cycle during bump start
nub
Compressor stop time for next bump start (hours)
bEn
DLT alarm temperature to stop compressor (°F)
doF
DLT temperature for compressor restart (°F)
don
DLT Stop compressor delay (seconds)
ALd
Minimum time of compressor off with dLL alarm (minutes)
dLF
Cut In for Condenser Temperature/Pressure alarm (°F)
AU2
Cut Out for high Condenser Temperature/Pressure alarm (°F)
AH2
High condenser temperature alarm delay (minutes)
Ad2
Minimum off time after a High Pressure Trip (minutes)
HPF
oU – US
25 15
C
S - Cin
L
2 or 4 2 - 255
6 6 - 900 5 0-255 5 0-255 0 -120 -120
No no - YES
0
4
5
-15; 0 = always
automatic restart
0
-15; 0 = always
automatic restart
70 -40 -ÒSF2 10 1 -100 85 SF1 - 230 15 1 - 100
-7 or 5 -7 - US 135 LS -135
0 0 -15 2 0 - 2
PSI PSI, bar, kPA
F ∞C or∞F 2 1 - 15 5 1 - 15 3 1 - 15
4.0 1.0 - 23.5 220 don - 302 170 -58 - doF
0 0 - 255
0 0 - 15 150 AH2 - 230 140 -40 - AU2
0 0 - 255
0 - 15
© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.
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6. Controller Wiring
WARNING
Always disconnect and lockout the power supply before beginning electrical installations or troubleshooting.
Copeland PerformanceAlert (CPA)
High Voltage
DLT Sensor
Line
Comm. Port
AE8-1376 R2
Electronic Unit Controller
Figure 5 – Wiring Schematic Example for the Electronic Unit Controller with Copeland PerformanceAlert
Suction Pressure Transducer: Use terminal 9 (+5V) for supply, terminal 1 1 for ground and terminal 12 for signal Condenser Temperature Sensor: Connect the probe to terminal 11 (ground) and 10 Thermostat input: use terminals 14-17 UL HP input: use terminals 15-17 DLT Sensor: Connect the probe to terminals 16-17 Copeland Performance Alert (CPA) connection: Connect the CPA as shown in the wiring diagram. For more information on PerformanceAlert, see Application Engineering Bulletin AE8-1347. Power supply: use terminals 4-5 Compressor: use terminals 1-3 FAN 1: use terminals 6-7 FAN 2: use terminals 1-2
6.1 Additional Controller Inputs
If any other devices are used to control the condensing unit, such as a thermostat or other type device, it will need to be a dry contact (no voltage) and will need to be connected to terminals 14 and 17. These terminals are located on the hotkey cable. These two terminals will be connected together by push-on type connectors allowing for ease of performing the fi nal connection. See Figure 5 for wiring details.
NOTE: If using a controller such as a thermostat with another device such as a pump down solenoid, no connections to the controller are required.
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PoF
Pon
dLt
dLL
HPL
CPA
C01
C02
C03
C04
C05
C06
C07
C08
C09
C10
C11
7. Alarms/Notifi cations
In the event of an issue, the below codes will fl ash to indicate the alarm condition. See Section 9, Troubleshooting Guide, for further instruction.
Table 5 – Alarms And Notifications
Code Description
AE8-1376 R2
P P
PP1 PP2 PP3
HHA d d
HHP H C
EEE
If a Copeland PerformanceAlert is installed in the unit, any error codes from the PerformanceAlert will be displayed on the screen of the Dixell controller. This eliminates the need to count light flashed on the PerformanceAlert itself. For more information on PerformanceAlert, see AE8-
1347.
Code Three Phase Recip Three Phase Scroll Single Phase
C C C C C C
Discharge Temperature Trip Discharge Temperature Trip Discharge Temperature Trip
System Trip System Trip System Trip Short Cycling Short Cycling Short C yclin g Locked Rotor Locked Rotor Locked Rotor
Open Circuit Open Circuit Open Circuit
Missing Phase Missing Phase Open Run
C C C C C
Welded Contactor Welded Contactor Welded Contactor
Low Voltage Low Voltage Lo w Voltag e
Lost communications Lost communications Lost communications
DLT Sensor Failure DLT Sensor Failure DLT Sensor Failure
Keypad locked Keypad unlocked Suction probe failure Condenser probe failure DLT probe failure High condenser temperature alarm DLT temperature alarm DLT lock alarm High pressure trip alarm High pressure trip lock-out alarm Copeland PerformanceAlert not connected properly Module Failure
Table 6 – Copeland PerformanceAlert Error Codes
NA Reverse Phase Open Start
© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.
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Application Engineering
BULLETIN
7.1 Discharge Line Temperature Protection
Discharge line temperature protection has traditionally been handled by a mechanical thermostat, which was always an automatic reset, and other than the system not running, gave no indication that a trip had occurred or is occurring. The Electronic Unit Controller uses a temperature sensor, which allows for more fl exibility in what the controller can do. If the unit trips, the unit will display an error code and log that an error has occurred. In addition, the controller will allow an automatic reset up to 4 times per hour. On the fourth trip, the controller will require a manual reset. The parameter  can be changed in the Advanced Options Menu (see section
2.6) to adjust the total number of trips allowed in an hour before a lockout. If an always automatic reset is needed, then  can be set to 0. The default value for the discharge line cut-out is 220°F and the cut-in is 170°F.
7.2 UL High Pressure Safety Control
High pressure control is a UL safety device. As such, Emerson Climate Technologies condensing units equipped with the Electronic Unit Controller still come with the high pressure mechanical control installed on the unit. The high pressure controls will all be fi xed to work with the control, and the value of the cut-out will be determined by the working pressure of the high side of the condensing unit. This should have no affect on a customer’s UL requirements.
The high pressure control will break power to the compressor output relay, which will shut down the compressor regardless of the program state. This change will also allow the controller to read the high pressure control state, and display the appropriate error codes as needed. In addition, the controller will allow an automatic reset up to 4 times per hour. On the fi fth trip, the controller will require a manual reset. The parameter Options Menu (See section 2.6) to adjust the total number of trips allowed in an hour before a lockout. If an always automatic reset is needed, then  should be set to 0.
 can be changed in the Advanced
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8. Thermister Temperature/Resistance Values for Condenser Temperature Sensor
AE8-1376 R2
Deg C Deg F
-50 -58 329.5
-49 -56 310.9
-48 -54 293.5
-47 -53 277.2
-46 -51 262
-45 -49 247.7
-44 -47 234.3
-43 -45 221.7
-42 -44 209.9
-41 -42 198.9
-40 -40 188.5
-39 -38 178.5
-38 -36 169
-37 -35 160.2
-36 -33 151.9
-35 -31 144.1
-34 -29 136.7
-33 -27 129.8
-32 -26 123.3
-31 -24 117.1
-30 -22 111.3
-29 -20 105.7
-28 -18 100.5
-27 -17 95.52
-26 -15 90.84
-25 -13 86.43
-24 -11 82.26
-23 -9 78.33
-22 -8 74.61
-21 -6 71.1
-20 -4 67.77
-19 -2 64.57
-18 0 61.54
-17 1 58.68
-16 3 55.97
-15 5 53.41
-14 7 50.98
-13 9 48.68
-12 10 46.5
-11 12 44.43
-10 14 42.47
-9 16 40.57
Resistance (kOhms)
Deg C Deg F
-8 18 38.77
-7 19 37.06
-6 21 35.44
-5 23 33.9
-4 25 32.44
-3 27 31.05
-2 28 29.73
-1 30 28.48 0 32 27.28 1 34 26.13 2 36 25.03 3 37 23.99 43923 5 41 22.05 6 43 21.15 7 45 20.3 8 46 19.48 9 48 18.7 10 50 17.96 11 52 17.24 12 54 16.56 13 55 15.9 14 57 15.28 15 59 14.69 16 61 14.12 17 63 13.58 18 64 13.06 19 66 12.56 20 68 12.09 21 70 11.63 22 72 11.2 23 73 10.78 24 75 10.38 25 77 10 26 79 9.632 27 81 9.281 28 82 8.944 29 84 8.622 30 86 8.313 31 88 8.014 32 90 7.728 33 91 7.454
Resistance (kOhms)
Deg C Deg F
34 93 7.192 35 95 6.94 36 97 6.699 37 99 6.467 38 100 6.245 39 102 6.032 40 104 5.827 41 106 5.629 42 108 5.438 43 109 5.255 44 111 5.08 45 113 4.911 46 115 4.749 47 117 4.593 48 118 4.443 49 120 4.299 50 122 4.16 51 124 4.026 52 126 3.896 53 127 3.771 54 129 3.651 55 131 3.536 56 133 3.425 57 135 3.318 58 136 3.215 59 138 3.116 60 140 3.02 61 142 2.927 62 144 2.838 63 145 2.751 64 147 2.668 65 149 2.588 66 151 2.511 67 153 2.436 68 154 2.364 69 156 2.295 70 158 2.228 71 160 2.163 72 162 2.1 73 163 2.039 74 165 1.98 75 167 1.924
Resistance (kOhms)
Deg C Deg F
76 169 1.869 77 171 1.816 78 172 1.765 79 174 1.716 80 176 1.668 81 178 1.621 82 180 1.577 83 181 1.533 84 183 1.491 85 185 1.451 86 187 1.411 87 189 1.373 88 190 1.336 89 192 1.3 90 194 1.266 91 196 1.232 92 198 1.2 93 199 1.168 94 201 1.137 95 203 1.108 96 205 1.079 97 207 1.051 98 208 1.024 99 210 0.9984 100 212 0.9731 101 214 0.9489 102 216 0.9246 103 217 0.9014 104 219 0.8789 105 221 0.8572 106 223 0.836 107 225 0.8155 108 226 0.7956 109 228 0.7763 110 230 0.7576
Resistance (kOhms)
© 2013 Emerson Climate Technologies, Inc. Printed in the U.S.A.
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8.1 Thermister Temperature/Resistance Values for Discharge Temperature Sensor
AE8-1376 R2
Deg C Deg F
-40 -40 2889.60
-35 -31 2087.22
-30 -22 1522.20
-25 -13 1121.44
-20 -4 834.72
-15 5 627.28
-10 14 475.74
-5 23 363.99 0 32 280.82 5 41 218.41 10 50 171.17 15 59 135.14 20 68 107.44 25 77 86.00 30 86 69.28 35 95 56.16 40 104 45.81 45 113 37.58 50 122 30.99 55 131 25.68 60 140 21.40 65 149 17.91
Resistance (kOhms)
Deg C Deg F
70 158 15.07 75 167 12.73 80 176 10.79 85 185 9.20 90 194 7.87 95 203 6.77 100 212 5.85 105 221 5.09 110 230 4.45 115 239 3.87 120 248 3.35 125 257 2.92 130 266 2.58 135 275 2.28 140 284 2.02 145 293 1.80 150 302 1.59 155 311 1.39 160 320 1.25 165 329 1.12 170 338 1.01 175 347 0.92 180 356 0.83
Resistance (kOhms)
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AE8-1376 R2
Application Engineering
BULLETIN
9. Troubleshooting Guide
Display Likely Causes Other Possible Causes
Controller display remains blank after applying power
Controller displays correctly, but the green compressor light is off and the compressor is not running
Controller displays correctly and the green compressor light is on and the compressor is not running
Controller fl ashes “135” or “P1”
• Unit power not properly applied - check for proper applied voltage
• Power cable harness not plugged in properly or securely into the back of the controller – check connections
• Jumper cable not plugged in properly or securely into the back of the controller – check connections
• Controller is currently above the cut-in setting – check cut-in and cut-out settings
• Power cable harness not plugged in properly or securely into the back of the controller – check connections
• Current system pressure is above 135 PSIG – wait for system to pull down
• Green harness not plugged in properly or securely into the back of the controller – check connections
• Cable not connected properly with the pressure transducer – check connections
• Power cable miswired – inspect cable, replace if needed
• Electrical assembly miswired – trace wiring diagrams
• Jumper cable miswired – inspect cable, replace if needed
• Power cable not wired to the contactor or compressor correctly, check wiring
• Power cable miswired – inspect cable, replace if needed
• Transducer cable miswired – inspect cable, replace if needed
• Damaged transducer – inspect transducer, replace if needed
Controller fl ashes “P2” on a unit with fan cycling
Controller fl ashes “P2” on a unit without fan cycling after replacing a controller
Controller fl ashes “P3” on a unit with DLT
Controller fl ashes “P3” on a unit without DLT after replacing a controller
• Green harness not plugged in properly or securely into the back of the controller – check connections
• Controller not programmed properly – check parameters in the advanced menu
• Jumper cable not plugged in properly or securely into the back of the controller – check connections
• Controller not programmed properly – check parameters in the advanced menu
• Transducer cable miswired – inspect cable, replace if needed
• Check condenser temperature sensor resistance values against table in Section 8.
• Jumper cable miswired – inspect cable, replace if needed
• Faulty DLT temperature sensor – check the discharge line temperature sensor resistance values against table in Section 8.
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Troubleshooting Guide (continued)
Display Likely Causes Other Possible Causes
Fans not running on a fan cycling unit and the fan lights are not on
Fans not running on a fan cycling unit and the fan lights are on
Controller fl ashes “HP” at power-up
Controller fl ashes “HP” or “HPL”
• Condensing temperature is currently below the fan cut-in
• Condensing temperature sensor not properly installed – check installation
• Power cable harness not plugged in properly or securely into the back of the controller – check connections
• Jumper cable not plugged in properly or securely into the back of the controller – check connections
• High pressure switch is seeing above the cut-out pressure
• For a replacing an -00 controller, ensure that the jumper cable is the latest revision. It should have a blue wire in the harness. See replacement instructions for more details.
• System operation causing high discharge pressures, check system operations
• Transducer cable miswired – inspect cable, replace if needed
• Faulty temperature sensor ­check condenser temperature sensor resistance values against table in Section 8.
• Power cable miswired – inspect cable, replace if needed
• Electrical assembly miswired – trace wiring diagrams
• Jumper cable miswired – inspect cable, replace if needed
• Faulty fi xed Hp switch – inspect switch, replace if needed
• Bad high pressure switch, verify system pressure when the pressure switch trips.
• See Section 7.2 for more details.
Controller fl ashes “DLT” or “DLL”
• System operation causing high discharge line temperatures, check system operations
• Faulty temperature sensor ­check DLT sensor values against table in section 8.
• See Section 7.1 for more details
Controller fl ashing “HPL” or “DLL”
• System operation causing high discharge pressures (HPL) or high discharge line temperatures (DLL) repeatedly, check system operations
• To clear an “HPL” or “DLL” lockout, you can hold the Restart button for 3 seconds twice, or cycle power to the unit. If using the reset button, the alarm condition will have to clear (DLT temperature drops or Hp switch resets), and any minimum off time will need to complete (5 minutes for the fi xed Hp switch)
The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. Emerson Climate Technologies, Inc. and/or its affi liates (collectively "Emerson"), as applicable, reserve the right to modify the design or specifi cations of such products at any time without notice. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson product remains solely with the purchaser or end user.
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