Hussmann USL-2 Guide rapide

January 2006

HUSSMANN - GLOVERSVILLE

INSTALLATION & SERVICE

INSTRUCTIONS

FOR

USL LOW TEMPERATURE

Solid Door Reach-In

for

Ice Cream and Frozen Foods

P/N OII – USL

January 2006

First Call for help (US and Canada):

1-800-922-1919

Soporte Tècnico y Asistencia (Mèxico):

01-800-522-1900

For a Service Network Locator and other

Information visit us at

www.hussmann.com

select Worldwide Locations

Page 1

TABLE OF CONTENTS

Page

Introduction, Inspection, Location, and Clearance 2

Installation and Start-Up 2

Skid, Leg Installation, and Top Decorative Panel Removal 2

CabinetDrain 3

Shelves 3

Air Distribution and Rear Flue Spacer 3

Electrical Connections 3

Serial Plate Information 3

Startupprocedure 4

Specifications, Dimensions, Electrical and BTU Capacities 4

General Upkeep, Care and Cleaning Routine Maintenance 4

Power Switches, Temperature Control 5

Thermometer, Electrical Enclosure 5

DefrostTimeClock 6

Defrost Heater Thermostat and Replacement 6

Lighting 7

Frame Heaters and Replacement 7

Expansion Valve Adjustment 7

Refrigeration, Leak Testing, and Evacuation 7 – 8

Operational Data, Compressor and Receiver 8

Crankcase Pressure Regulator 9

Trouble Shooting Charts 10 – 12

Electrical Components List 12

Warranty and Parts Information 12

Ordering Replacement Parts, and Compressor Replacement 12 – 13

Page 2

INTRODUCTION -

Hussmann USL models are self-

contained, low temperature, vertical solid

door reach-ins for the storage of ice cream

and frozen foods. Design features include

automatic defrost, efficient foamed in place

non-CFC insulation, and balanced refrigera-

tion systems for energy saving performance.

INSPECTION –

Upon receipt of the cabinet, carefully

examine the crating for damage. If the crate

is damaged, make a note on the delivery

ticket before signing. Carefully remove ship-

ping crate and examine cabinet for

“concealed damage. If damage is found, con-

tact the delivery carrier immediately and

have his agent prepare an inspection report

for the purpose of filing a claim. THIS IS

YOUR RESPONSIBILITY.

LOCATION –

The USL low temperature, storage,

self contained reach-ins are designed for

back room storage applications of ice cream

and frozen food products. Location where

drafts from air conditioning grille, fans and

open doors that would blow into the case

should be avoided.

CLEARANCE –

Because the condensing unit is located

at the top of the cabinet, at least 12 inches of

clearance should be allowed at the rear of the

cabinet and at the top of the case. This clear-

ance is necessary to provide free air move-

ment to and from the condenser for maxi-

mum operating efficiency.

INSTALLATION and START-UP –

SKID –

The skid should be left on the cabinet

until it is near the final location. The skid pro-

vides protection for both the case and floor.

The skid is removed by raising one end of the

case approximately six inches. BLOCK SE-

CURELY and remove the two skid bolts on the

raised end. This procedure is repeated on the

opposite end. When the skid bolts are re-

moved, the case may be slid off the skid.

LEG INSTALLATION –

After the case is near its final location

and the skid has been removed, the NSF ap-

proved legs should be installed. The legs are

packaged inside the cabinet. To install the

legs, replace the tape and door blocks. Raise

one end of the cabinet approximately 8 inches,

BLOCK SECURELY, and install two legs.

The leg mounting plates are factory installed

and contain a 1/2 x 13 tapped hole to match

with the leg assembly. The procedure is re-

peated on the opposite end. With the cabinet

legs installed, the cabinet should be positioned

in its final location and leveled.

The cabinet is leveled by turning the

bottom section of each leg. The self closing

doors require the cabinet to be properly lev-

eled. End to end leveling will make the doors

close with uniform speed and tightness. A

slight pitch from front to rear is desirable.

THE CABINET BACK SHOULD NEVER BE

HIGHER THAN THE FRONT.

TOP DECORATIVE PANEL REMOVAL –

The top decorative panel is removed by

sliding the panel up into the upper aluminum

Page 3

trim and pulling it forward until it clears the

bottom aluminum trim.

CABINET DRAIN –

A vinyl drain tube is provided for con-

nection to the condensate pan which is

mounted to the bottom of the cabinet. The

drain must be trapped to guard against the

drain line freezing, to prevent warm air from

going up into the back of the case, and for

good sanitation practice. A copper tube trap

is supplied for this purpose.

The condensate pan is electrically

heated. A separate 115 volt supply with a

ground rated at 10 amps should be provided

for this heater. The heater is supplied with a

115 volt supply cord with a grounding prong.

DO NOT REMOVE the grounding prong un-

der any circumstances.

The cabinet power switch does not

shut off the power to this pan. If the heater in

the pan should need replacing, be sure to dis-

connect the power source to the pan.

SHELVES –

Each cabinet is provided with 3 canti-

lever shelves per door that are adjustable on 1

inch increments & tiltable. Each cabinet also

has one bottom shelf per door. These shelves

have one inch legs to allow proper air flow in

the cabinet. Behind the shelves are wire flue

spacers which also allow for proper air flow.

All shelves and flue spacers are white, epoxy

coated for durability and ease of cleaning.

Care should be taken when loading the

shelves with product. Product on the highest

level of shelves, should not touch the evapora-

tor drain pan. This pan gets warm during the

defrost cycle, and some melting of the product

may occur if it is touching the pan/

AIR DISTRIBUTION and REAR

FLUE SPACER

Air is drawn through the evaporator

from front to rear and is discharged down the

back wall, returning up the face of the door to

the return air grill. NOTE: Rear wire grid

must be in place as this forms a discharge air

flue at the back of the cabinet

ELECTRICAL CONNECTIONS –

The USL-2 is supplied with a power

supply cord with a grounding prong. Do not

remove the grounding prong under any cir-

cumstances.

It is very important for safety to you

and your customers to have the cabinet prop-

erly grounded. The electrical installation

should be done by a qualified electrician in

accordance with the National Electrical Code

and/or local codes.

Note: Connecting this unit to

any electrical supply other

than specified on the serial

plate will void the warranty

and may result in serious

damage to the case. The cabi-

net should be supplied with its

own service.

SERIAL PLATE INFORMATION –

The serial plate is located in the upper

left hand corner of the case interior. It has all

the pertinent information needed for proper

electrical installation. The serial plate should

not be removed for any reason.

Page 4

START UP PROCEDURE –

1. After the wiring has been completed, set the

defrost timer for the correct time of day,

making sure the defrost pins are secure in

the face of the clock. USL cabinets are fac-

tory set for 1 defrost period in 24 hours. (12

a.m.)

2. Cut the band holding the compressor in

place during shipping.

3. Check the cabinet thoroughly for loose nuts

and bolts and electrical connections. In-

spect the refrigeration lines for any visible

damage or chafing.

4. Replace the electrical box cover.

5. Start the cabinet and allow to pull down to

operating temperature before loading.

SPECIFICATIONS –

DIMENSIONS –

Cu.

Ft. Exterior

Model Cap Drs L W+ H

USL-2 43.7 2 52” 34 1/4” 84 1/4”

Interior

47 13/16” 25 11/16” 62 3/4”

+ Exclusive of Door Handles

ELECTRICAL –

Unit

H.P. Hz/Ph Volts

USL-2 3/4 60/1 115

Run Fuse Ship

Amps Size Wt.

USL-2 15.0 20 amp 875

BTU CAPACITIES –

RatingTempsºF

BTU/HR Evap Cond. Amb

USL-2 2280 -20 110 90

During June ‘95, R404A refrigerant was

phased into use on the USL-2. The refriger-

ant charge is 46 oz. of R404A.

GENERAL UPKEEP

CARE and CLEANING –

To insure good sanitation, appear-

ance, and minimum maintenance, the cabinet

should be cleaned and washed regularly as

use demands. Clean with mild detergent and

warm water. DO NOT USE AN ABRASIVE

CLEANER OR STEEL WOOL AS THEY

WILL MAR THE FINISH.

ROUTINE MAINTENANCE –

Under normal conditions, after the

cabinet is installed and running, very little

maintenance should be required. However,

the following list of housekeeping practices

will assure trouble-free operation.

1. Check operation of condenser fan motors.

Fan blades must turn freely.

2. Check drain pan and heater to prevent

accidental overflow.

3. Make sure doors are closing properly and

that the gaskets seal.

4. Make sure all evaporator fan motors are

running. These can be seen through grill

inside cabinet.

Page 5

5. Clean the cabinet with a mild detergent.

This will insure good sanitation, and mini-

mize maintenance. Never use an abrasive

as this could mar the finish.

OPERATION and MAINTENANCE

POWER SWITCHES –

The power switch is located at the

electrical box which is behind the top decora-

tive panel. The switch will shut off all power.

TEMPERATURE CONTROL –

The temperature control is located in

the electrical box on the top of the case. The

temperature control does not have an ‘OFF’

position. Adjustments may be made by the use

of a screwdriver in the slot provided in the

face of the control. Turning it clockwise will

give warmer temperatures while counter-

clockwise will give colder temperatures. There

is also an adjustable temperature differential

( the difference between the cut-in temperature

and the cut-out temperature) located next to

the dial face.

The control has a range of –30ºF to

+50ºF with a differential of 5º to 20º. It is fac-

tory set for approximately –15ºF with an 8º

differential. The temperature should be

checked with a thermometer other than the

case thermometer after it is running to insure

that the case is running at the proper

temperature for the product.

THERMOMETER –

The thermometer is located in the

center of the top header. The thermometer

will probably need resetting to reflect the

proper case temperature. Using a separate

thermometer located on a shelf in the case,

compare this temperature to that on the case

thermometer. If the case thermometer needs to

be adjusted, remove the clear protective cover

by popping it off with a small screwdriver and

turning the small adjustment screw on the face

of the thermometer.

The thermometer is used to indicate

proper operating temperatures. For the USL

the proper operating temperature is –10ºF

to –15ºF.

The thermometer will also warm up

rather rapidly when the case door is held open

for a time such as when the case is being re-

stocked or a shopper is making a decision on a

product. After the door is closed it will take

some time for the thermometer to pull back

down to the case temperature.

The thermometer can be replaced by re-

moving the three screws securing it to the cabi-

net. Open the doors and remove the evaporator

drain pan be removing the screws along the

edges. Remove the evaporator fan grill. The

thermometer sensing element is secured to the

evaporator fan plenum.

Loosen the screw securing the element.

Remove the element and thermometer. Insert

new element and retighten screw. Finish as-

sembly in reverse order. Be sure to run the

sensing element of the new thermometer

through the hole I the cabinet face prior to se-

curing it to the evaporator fan plenum.

ELECTRICAL ENCLOSURE –

The electrical enclosure contains the de-

frost time clock and terminal

Page 6

boards. For servicing convenience, access is

gained by removing the top decorative panel

and electrical box cover. THE CABINET

SUPPLY BREAKERS SHOULD BE DIS-

CONNECTED BEFORE REMOVING THE

ENCLOSURE COVER.

The cabinet electrical supply breakers

should be disconnected before removing the

enclosure cover, and before service work ore

maintenance of any kind is performed.

DEFROST TIME CLOCK –

The timer is factory pre-set for one de-

frost cycle per day at 12:00 a.m., with a 40

minute failsafe. The timer must be adjusted

to the proper time of day when the cabinet is

started. The timer is adjusted by turning the

knurled adjustment knob in the center of the

dial face counter-clockwise until the time indi-

cator corresponds with the correct time of

day.

The defrost pins should be checked for

tightness. The timer will require re-adjusting

after a power failure of the cabinet supply or

if it is turned off for extended periods of time.

If an additional defrost is required due to am-

bient or cabinet usage conditions, do not put a

defrost during the middle of the day.

Put any additional defrost during the

night or at a time when the cabinet has the

lowest usage.

Defrost is time initiated and tempera-

ture terminated. If the thermostat should fail,

the timer is equipped with a failsafe set at 40

minutes that will allow defrost to terminate on

time.

DEFROST HEATER THERMOSTAT –

The defrost heater thermostat is

clamped to the evaporator outlet tube. It

is a bi-metal thermostat that is tied in se-

ries with the evaporator fans for a delay

and with defrost time clock solenoid to

end defrost when the temperature has

been satisfied. The evaporator fans will

not come on until the thermostat senses

32ºF and defrost will terminate when the

stat senses 58ºF.

DEFROST HEATER REPLACEMENT

–

The defrost heaters are firmly em-

bedded in the evaporator and held in

place with spring clips. To remove the

heater, first remove all the spring clips

and pull the defective heater out of the

slots in the evaporator, starting at the

wire supply lead.

The replacement heater should be

firmly seated in the slots by using a small

block of wood and a mallet. After the

new heater is in place, replace all of the

spring retaining clips to assure heater re-

tention. One lead of the defective heater

may be used to pull the new leads

through the cabinet to the respective ter-

minals as marked on each lead.

NOTE: Care must be taken to

make sure the drain stub is

correctly inserted in the cabinet

drain tube for proper drainage.

Page 7

LIGHTING –

Interior lighting is provided by incan-

descent lamps. The lamps have protective

shields which can be removed for bulb re-

placement. The lights are equipped with

switches mounted in the upper left hand cor-

ner of the door opening, that allow the lights

to come on when the door is opened. The

switches are connected in series.

FRAME HEATERS –

The cabinet is equipped with frame

heaters around each door. These are ther-

mostatically controlled and will not come on

until the cabinet is at operating temperature.

FRAME HEATER REPLACEMENT –

To replace the cabinet frame heater

wires, first remove the vinyl breaker strips

by pulling the outer edge away from the cabi-

net. Replace wires exactly as removed, pull-

ing the leads through the plastic conduit. Af-

ter connections have been made, check the

heaters for operation. Replace the plastic

breakers by reversing the removal proce-

dure.

EXPANSION VALVE ADJUSTMENT –

Expansion valve must be adjusted to

fully feed the evaporator. Before attempting

to adjust the valve make sure the evaporator

is either clean or only lightly covered with

frost, and that the cabinet is within 10º of its

expected operation temperature. Adjust the

expansion valve as follows:

1. Attach two sensing probes to the evapora-

tor, one under the clamp holding the ex-

pansion valve sensing bulb and the other

securely taped to one of the return bends

two thirds of the way through the evapo-

rator circuit. Some “hunting” of the ex-

pansion valve is normal

2. The valve should be adjusted so that dur-

ing the hunting the greatest difference

between the two probes is 3º to 5º F.

3. Remove valve stem cover and turn valve

stem counter-clockwise to decrease tem-

perature difference between the probes.

4. To increase temperature difference of

probes, turn the valve stem clockwise.

With this adjustment, during a portion of

the hunting the temperature differences

between the two probes may be less than

3º F, or at times as low as 0º F.

5. Make adjustments of no more than one

half turn of the valve stem at a time and

wait for at least fifteen minutes before

rechecking probe temperature and mak-

ing further adjustments. Replace and

tighten cover of the valve stem.

REFRIGERATION –

As stated previously, this case is a self-

contained system featuring semi-hermetic

compressor and thermostatic expansion

valve. The condenser is of a bare tube con-

struction and SHOULD BE PERIODI-

CALLY CLEANED TO MAINTAIN EFFI-

CIENT OPERATION

If it should become necessary to leak

test the system, please adhere to the following

notice:

Page 8

Because of the CFC atmospheric considerations

being taken today, we ask that leak testing be

done with refrigerant 22 mixed with nitrogen. If

the condensing unit nameplate designates a re-

frigerant other than R-22, remove all R-22 from

the immediate area to avoid confusion after leak

testing and evacuating the unit. Recharge the

unit with proper refrigerant.

LEAK TESTING –

The test gas cylinder must be equipped

with a pressure gauge and regulator so that sys-

tem test pressures do not exceed maximum allow-

able limits. Do not ever use anything other than a

R-22/Nitrogen mixture for leak testing.

Attach a refrigerant test gas cylinder to

your service manifold and connect the manifold

to the charging port on the liquid line valve.

Charge an R-22/Nitrogen mixture into the sys-

tem, raising the pressure to the unit’s nameplate

for the low side and high side pressures. Using an

electronic detector, carefully check the entire sys-

tem for leaks. Take special care to inspect all

brazed and flare connections.

EVACUATION –

After the system is proven leak tight, thor-

oughly evacuated the system according to the fol-

lowing procedure:

1. Discharge the refrigerant-nitrogen mixture,

allowing it to blow from the system as rapidly

as possible, into an empty cylinder. Be sure

that all service valves and solenoid valves are

open to allow all of the mixture to be dis-

charged.

2. Connect a deep-drain vacuum pump to

both the high and low side of the sys-

tem. Pull a vacuum on the system to at

least 1500 microns.

3. Break the vacuum by adding refriger-

ant into the system until the pressure is

above 0 PSIG. Always charge the re-

frigerant line into the system through a

new drier in the charging manifold line.

A 16 cubic inch drier is sufficient for

this purpose.

4. Repeat steps 2 and 3 two more times,

the third time evacuating the system to

500 microns.

OPERATING DATA –

The following is typical data for

USL models based on lab tests, and may

vary under field operating conditions.

Ambient Temperature 75ºF

Head Pressure 225 psi

Suction Pressure 3-5 psi

Discharge Air -25ºF

Return Air -10ºF

COMPRESSOR –

The compressor is mounted on

springs and banded for shipping purposes

and this band needs to be cut upon installa-

tion. DO NOT LOOSEN THE COM-

PRESSOR MOUNTING BOLTS AS

THESE ARE FACTORY PRE-SET FOR

PROPER RIDING ON THE SPRINGS.

RECEIVER –

The receiver should not be confused

for a filter-drier or muffler. The receiver is

Page 9

in the liquid line after the condenser and just

ahead of the filter-drier. It has sweat connec-

tions, and is in a horizontal position. The

manufacturer may label the receiver as a muf-

fler or a drier but it is, in fact, an empty shell.

CRANKCASE PRESSURE REGULATOR -

The USL-2 with R404a refrigerant em-

ploys a crankcase pressure regulator in the

suction line. The CPR is set for 12 psi. The

purpose of the valve is to maintain a low suc-

tion pressure on start-up so that the compres-

sor will start properly. On start-up, the valve

will hold the suction pressure at the desired

setting until the suction pressure has dropped

below the setting, then the valve will open.

If it becomes necessary to check or reset

the setting, the case must be warm such as af-

ter a defrost cycle or from an initial warm

case condition. Put a suction compound gauge

on the compressor suction valve, start the com-

pressor. If the pressure needs to be reduced

turn the adjustment screw clockwise or, coun-

terclockwise to raise the pressure. DO NOT

SET THE VALVE BASED ON THE NAME-

PLATE AMPERAGE RATING AS THE

PRESSURE SETTING WILL BE TOO HIGH

AND THE COMPRESSOR WILL NOT

START PROPERLY.

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