DELI MODELS: PMNUM, PMFNUM, PMN2UM, PMFN2UM INSTALLATION & OPERATION HANDBOOK. Featuring. Technology P902077H. Rev 4 1/07 COMPONENT

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1 DELI C A S E S MODELS: PMNUM, PMFNUM, PMN2UM, PMFN2UM INSTALLATION & OPERATION HANDBOOK Featuring Technology COMPONENT P902077H Rev 4 1/07

2 WARNING MORE THAN ONE SOURCE OF ELECTRICAL SUPPLY. DISCONNECT ALL SOURCES BEFORE SERVICING. WARNING DISCONNECT POWER SUPPLY BEFORE SERVICING. AVERTISSEMENT PLUS D UNE SOURCED ALIMENTATION. AVANT LE DÉPANNAGE, COUPER TOUTES LES SOURCES D ALIMENTATION. AVERTISSEMENT COUPER L ALIMENTATION AVANT L ENTRETIEN ET LE DÉPANNAGE. WARNING HOT PARTS. DO NOT OPERATE UNIT WITH ACCESS PANEL REMOVED. AVERTISSEMENT PIÈCES CHAUDES. N ACTIONNEZ PAS L UNITÉ LE PANNEAU D ACCESS ÉTANT COUPÉ. CAUTION USE SUPPLY WIRES SUITABLE FOR AT LEAST 194 o F (90 o C). ATTENTION EMPLOYER DES FILS D ALIMENTATION À 90 o C (194 o F).

3 Welcome to the Prestige display case family. We re very pleased you joined us. This installation and operation handbook has been especially prepared for everyone involved with Prestige display cases owners, managers, installers and maintenance personnel. You ll find this book different than traditional manuals. The most dramatic difference is the use of many more illustrated instructions to make it easier to read and to help you get the most from this innovative new design. When you follow the instructions you should expect remarkable performance, attractive fits and finish, and long case life. We are interested in your suggestions for improvement both in case design and in this handbook. Please call/write to: Hill PHOENIX Marketing Services Department 1925 Ruffin Mill Road Colonial Heights, VA Tel: Fax: or visit our web site at We wish you the very best in outstanding food merchandising and a long trouble-free operation.

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5 TABLE OF CONTENTS GENERAL INFORMATION PAGES 2-6 General information, first step recommendations and case dimensional drawings. THE USE OF CASTERS PAGE 7 Cases roll on casters general use and caster removal. LINE-UP PAGES 8-9 A ten step procedure for initial case lineup with illustrations. TRIM-OUT PAGES An eleven step procedure for trimming out cases with illustrations. REFRIGERATION - PAGE 12 Diagrams show coil outlet CASE PIPING - PAGE Diagrams show case piping options PIPING DIAGRAMS - PAGE Detail piping diagrams for each configuration. SYSTEM CHARGING PAGE Instructions on charging and testing the system. PLUMBING PAGE 19 Information on drain connections. ELECTRICAL HOOKUP AND WIRING DIAGRAMS PAGES Complete information on electrical connections. CASE OPERATION PAGES Recommended settings for all case controls. DEFROST AND TEMPERATURE CONTROL PAGE Defrost data. Sensor bulb locations. DIXELL CONTROLS PAGE Information on setting the Dixell control units. AIR FLOW AND PRODUCT LOADING PAGE 40 Air flow and load limits. USE AND MAINTENANCE PAGES Cleaning and fan information. GLASS CLEANING - PAGES Detailed cleaning instructions for non-glare glass. PARTS ORDERING PAGES 45 Replacement parts identification. APPENDIX A - DIXELL INSTALLING AND OPERATING INSTRUCTIONS - PAGE 46 APPENDIX B - SMS OPERATING INSTRUCTIONS - PAGE 53 APPENDIX C - STEP MOTOR EXPANSION VALVES INSTALLATION INSTRUCTIONS - PAGE 61 APPENDIX D - WATER SHED INSTALLATION DETAIL - PAGE 66 PRODUCT WARRANTY - Inside Back Cover 1

6 GENERAL INFORMATION DESCRIPTION OF CASES: The cases described in this handbook are part of the Hill PHOENIX, Prestige design series. Specifically covered in this manual is the PMNUM, PMFNUM, PMN2UM and PMFN2UM refrigerated service dome and self-service front display cases. STORE CONDITIONS: Hill PHOENIX cases are designed to operate in an air conditioned store with a system that can maintain 75 F (24 C) store temperature and 55 percent (maximum) relative humidity (CRMA conditions). RECEIVING CASES: Examine fixtures carefully for shipping damage and shortages. For information on shortages contact the Service Parts Department at APPARENT DAMAGE: A claim for obvious damage must be noted on the freight bill or express receipt and signed by the carriers agent, otherwise the carrier may refuse the claim. CONCEALED DAMAGE: If damage is not apparent until after the equipment is unpacked, retain all packing materials and submit a written request to the carrier for inspection within 15 days of receipt of equipment. LOST ITEMS: This equipment has been carefully inspected to insure the highest level of quality. Any claim for lost items must be made to Hill PHOENIX within 48 hours of receipt of equipment. TECHNICAL SUPPORT: If any technical questions arise regarding a refrigerated display case contact our Customer Service Department in Colonial Heights, VA at For any questions regarding our refrigeration systems or electrical distribution centers contact our Customer Service Department in Conyers at CONTACTING FACTORY: Should you need to contact Hill PHOENIX regarding a specific fixture, be sure to know the case model number and serial number. This information is on the serial plate located on the rear panel of the case (see next page for details). Ask for a Service Parts Representative at PRESSURE TESTING: Standard practice for pressure testing secondary systems is to pressurize the system to 100psi. This case must be limited to 70 psi or damage to the deck pans may occur. GYLCOL: Glycols used in Hill Phoenix secondary coolant cases should NEVER be mixed between different manufacturers. Each manufacturer may have different additives or inhibitors that will congeal when mixed with other manufacturers materials. For more detailed information, refer to the Second Nature manual located on our website at 2

7 REAR SLIDING DOORS 12 1/4 in [31.1 cm] Amp Plate & Serial Plate Location COIL 14 1/2 in [36.8 cm] 12 1/4 in [31.1 cm] 25 in [63.5 cm] COOLGENIX DISPLAY PANS 54 7/16 in [138.2 cm] 34 7/8 in [88.6 cm] 20 13/16 in [52.9 cm] 14" 24 3/16 in [61.4 cm] 15 3/4 in [40.1 cm] FLAT FRONT POLYMER BUMPER FRONT ALUMINUM BUMPER FRONT 12 3/4 in [32.4 cm] COIL PLENUM 15 7/16 in [39.1 cm] 15 3/4 in [40.0 cm] 16 5/16 in [41.5 cm] 5 in [12.7 cm] 4 1/4 in [10.7 cm] 6 3/16 in [15.7 cm]* 13 3/4 in [34.9 cm] 11 9/16 in [29.4 cm] 11 1/2 in [29.2 cm] 39 7/16 in [100.1 cm] 46 13/16 in [118.9 cm] 50 1/16 in [127.1 cm] {Flat Front} 51 13/16 in [131.6 cm] {Polymer Bumper Front} 51 11/16 in [131.3 cm] {Aluminum Bumper Front} MODEL PMNUM REAR REFRIGERATION 4 1/8 in [10.5 cm] 4 1/4 in [10.8 cm] 50 1/16 in [127.2 cm] or 51 13/16 in [131.6 cm] or 51 11/16 in [131.3 cm] 40 9/16 in [103.0 cm] 42 1/2 in [107.9 cm] ** 13 3/4 in [34.9 cm] 38 1/2 in [97.8 cm] 42 3/16 in [107.2 cm] 46 13/16 in [118.9 cm] ELECTRICAL 39 7/16 in [100.2 cm] REFRIGERATION WIRING-TO-RACEWAY (STANDARD) 8 1/8 in [20.6 cm] 10 5/8 in [27.0 cm] 1 1/2" PVC DRAIN CONNECTION C L 7/8 in [2.2 cm] {END} 6 5/8 in [16.8 cm] FRONT OF CASE NOTES: 48 in [121.9 cm] {4' case} 72 in [182.9 cm] {6' case} 96 in [243.8 cm] {8' case} 144 in [365.8 cm] {12' case} * STUB-UP AREA ** RECOMMENDED STUB-UP CENTERLINE FOR ELECTRICAL AND HUB DRAINS ENDS ADD APPROXIMATELY 1" TO CASE HEIGHT SUCTION LINE - 7/8", LIQUID LINE - 1/2" AVAILABLE SHELF SIZES: 10", 12", 14" & 16" PRODUCT ON TOP SHELF SHOULD BE 3" BELOW DISCHARGE RECOMMENDED SHELF CONFIGURATION IS ROWS: 1-14" 3

8 GENERAL INFORMATION REAR SLIDING DOORS 12 1/4 in [31.1 cm] Amp Plate & Serial Plate Location COIL 14 1/2 in [36.8 cm] 12 1/4 in [31.1 cm] 25 in [63.5 cm] COOLGENIX DISPLAY PANS 54 7/16 in [138.2 cm] 34 7/8 in [88.6 cm] 5 in [12.7 cm] 12 3/4 in [32.4 cm] 20 13/16 in [52.9 cm] 4 1/4 in [10.7 cm] COIL 14" 24 3/16 in [61.4 cm] 39 7/16 in [100.1 cm] 46 13/16 in [118.9 cm] PLENUM 6 3/16 in [15.7 cm]* 15 3/4 in [40.1 cm] 50 1/16 in [127.1 cm] {Flat Front} 51 13/16 in [131.6 cm] {Polymer Bumper Front} 51 11/16 in [131.3 cm] {Aluminum Bumper Front} FLAT FRONT 13 3/4 in [34.9 cm] 15 7/16 in [39.1 cm] POLYMER BUMPER FRONT 11 9/16 in [29.4 cm] 15 3/4 in [40.0 cm] ALUMINUM BUMPER FRONT 11 1/2 in [29.2 cm] 16 5/16 in [41.5 cm] MODEL PMFNUM REAR REFRIGERATION 4 1/8 in [10.5 cm] 4 1/4 in [10.8 cm] 50 1/16 in [127.2 cm] or 51 13/16 in [131.6 cm] or 51 11/16 in [131.3 cm] 40 9/16 in [103.0 cm] 42 1/2 in [107.9 cm] ** 13 3/4 in [34.9 cm] 38 1/2 in [97.8 cm] 42 3/16 in [107.2 cm] 46 13/16 in [118.9 cm] ELECTRICAL 39 7/16 in [100.2 cm] REFRIGERATION WIRING-TO-RACEWAY (STANDARD) 8 1/8 in [20.6 cm] 10 5/8 in [27.0 cm] 1 1/2" PVC DRAIN CONNECTION C L 7/8 in [2.2 cm] {END} 6 5/8 in [16.8 cm] FRONT OF CASE NOTES: 48 in [121.9 cm] {4' case} 72 in [182.9 cm] {6' case} 96 in [243.8 cm] {8' case} 144 in [365.8 cm] {12' case} * STUB-UP AREA ** RECOMMENDED STUB-UP CENTERLINE FOR ELECTRICAL AND HUB DRAINS ENDS ADD APPROXIMATELY 1" TO CASE HEIGHT SUCTION LINE - 7/8", LIQUID LINE - 1/2" AVAILABLE SHELF SIZES: 10", 12", 14" & 16" PRODUCT ON TOP SHELF SHOULD BE 3" BELOW DISCHARGE RECOMMENDED SHELF CONFIGURATION IS ROWS: 1-14" 4

9 REAR SLIDING DOORS 12 1/4 in [31.1 cm] COIL Amp Plate & Serial Plate Location 14 1/2 in [36.8 cm] 12 1/4 in [31.1 cm] 25 in [63.5 cm] COOLGENIX DISPLAY PANS 60 7/16 in [153.5 cm] 40 15/16 in [103.9 cm] 5 in [12.7 cm] 12 3/4 in [32.4 cm] 26 7/8 in [68.2 cm] 4 1/4 in [10.7 cm] 24 3/16 in [61.4 cm] COIL 14" 16" 39 7/16 in [100.1 cm] 46 13/16 in [118.9 cm] PLENUM 6 3/16 in [15.7 cm]* 21 13/16 in [55.4 cm] 50 1/16 in [127.1 cm] {Flat Front} 51 13/16 in [131.6 cm] {Polymer Bumper Front} 51 11/16 in [131.3 cm] {Aluminum Bumper Front} FLAT FRONT 13 3/4 in [34.9 cm] 15 7/16 in [39.1 cm] POLYMER BUMPER FRONT 11 9/16 in [29.4 cm] 15 3/4 in [40.0 cm] ALUMINUM BUMPER FRONT 11 1/2 in [29.2 cm] 16 5/16 in [41.5 cm] MODEL PMN2UM REAR REFRIGERATION 4 1/8 in [10.5 cm] 4 1/4 in [10.8 cm] 50 1/16 in [127.2 cm] or 51 13/16 in [131.6 cm] or 51 11/16 in [131.3 cm] 40 9/16 in [103.0 cm] 42 1/2 in [107.9 cm] ** 13 3/4 in [34.9 cm] 38 1/2 in [97.8 cm] 42 3/16 in [107.2 cm] 46 13/16 in [118.9 cm] ELECTRICAL 39 7/16 in [100.2 cm] REFRIGERATION WIRING-TO-RACEWAY (STANDARD) 8 1/8 in [20.6 cm] 10 5/8 in [27.0 cm] 1 1/2" PVC DRAIN CONNECTION C L 7/8 in [2.2 cm] {END} 6 5/8 in [16.8 cm] FRONT OF CASE NOTES: 48 in [121.9 cm] {4' case} 72 in [182.9 cm] {6' case} 96 in [243.8 cm] {8' case} 144 in [365.8 cm] {12' case} * STUB-UP AREA ** RECOMMENDED STUB-UP CENTERLINE FOR ELECTRICAL AND HUB DRAINS ENDS ADD APPROXIMATELY 1" TO CASE HEIGHT SUCTION LINE - 7/8", LIQUID LINE - 1/2" AVAILABLE SHELF SIZES: 10", 12", 14" & 16" PRODUCT ON TOP SHELF SHOULD BE 3" BELOW DISCHARGE RECOMMENDED SHELF CONFIGURATION IS ROWS: 1-14" & 1-16" 5

10 GENERAL INFORMATION REAR SLIDING DOORS 12 1/4 in [31.1 cm] Amp Plate & Serial Plate Location COIL 14 1/2 in [36.8 cm] 12 1/4 in [31.1 cm] 25 in [63.5 cm] COOLGENIX DISPLAY PANS 60 7/16 in [153.5 cm] 40 15/16 in [103.9 cm] 5 in [12.7 cm] 12 3/4 in [32.4 cm] 26 7/8 in [68.2 cm] 4 1/4 in [10.7 cm] 24 3/16 in [61.4 cm] COIL 14" 16" 39 7/16 in [100.1 cm] 46 13/16 in [118.9 cm] PLENUM 6 3/16 in [15.7 cm]* 21 13/16 in [55.4 cm] 50 1/16 in [127.1 cm] {Flat Front} 51 13/16 in [131.6 cm] {Polymer Bumper Front} 51 11/16 in [131.3 cm] {Aluminum Bumper Front} FLAT FRONT 13 3/4 in [34.9 cm] 15 7/16 in [39.1 cm] POLYMER BUMPER FRONT 11 9/16 in [29.4 cm] 15 3/4 in [40.0 cm] ALUMINUM BUMPER FRONT 11 1/2 in [29.2 cm] 16 5/16 in [41.5 cm] MODEL PMFN2UM REAR REFRIGERATION 4 1/8 in [10.5 cm] 4 1/4 in [10.8 cm] 50 1/16 in [127.2 cm] or 51 13/16 in [131.6 cm] or 51 11/16 in [131.3 cm] 40 9/16 in [103.0 cm] 42 1/2 in [107.9 cm] ** 13 3/4 in [34.9 cm] 38 1/2 in [97.8 cm] 42 3/16 in [107.2 cm] 46 13/16 in [118.9 cm] ELECTRICAL 39 7/16 in [100.2 cm] REFRIGERATION WIRING-TO-RACEWAY (STANDARD) 8 1/8 in [20.6 cm] 10 5/8 in [27.0 cm] 1 1/2" PVC DRAIN CONNECTION C L 7/8 in [2.2 cm] {END} 6 5/8 in [16.8 cm] FRONT OF CASE NOTES: 48 in [121.9 cm] {4' case} 72 in [182.9 cm] {6' case} 96 in [243.8 cm] {8' case} 144 in [365.8 cm] {12' case} * STUB-UP AREA ** RECOMMENDED STUB-UP CENTERLINE FOR ELECTRICAL AND HUB DRAINS ENDS ADD APPROXIMATELY 1" TO CASE HEIGHT SUCTION LINE - 7/8", LIQUID LINE - 1/2" AVAILABLE SHELF SIZES: 10", 12", 14" & 16" PRODUCT ON TOP SHELF SHOULD BE 3" BELOW DISCHARGE RECOMMENDED SHELF CONFIGURATION IS ROWS: 1-14" & 1-16" 6

11 CASES MOVE ON CASTERS FOR EASIER INSTALLATION Prestige cases are manufactured and shipped to stores with casters installed on the base frame to make the job of moving cases easier for everyone involved with the manufacturing, shipping and installation process. Casters not only speed up the process, but they also reduce the chance of damage from raising and lowering cases with J bars to place them on dollies, skates or rollers. In most situations, one or two persons can move the case with ease. ROLL OUT OF TRUCK. 1When there is a truck - level delivery dock, cases may be rolled directly from the truck to the store floor. [CAUTION] If skid boards are required to unload cases, casters should be removed prior to sliding them down the skid; after which they can ROLL TO LINE UP POSITION. Casters may remain in place to move the cases to staging areas around the store, prior to final installation. When ready for final line-up, roll the case to set position, then remove the 2 casters. be reinstalled on case. REMOVE COTTER PIN. 3Removing the casters is easy. Simply remove the pins holding the casters then lift the case with J bar, and pull the casters out. [CAUTION] Make certain hands are out of the way. 7 CASTERS MAY BE DISCARDED. 4

12 LINE UP COIL BASE RAIL COIL PLENUM BASE RAIL Consult With General Contractor Snap Chalk Lines Snap Lines On Base Rail Locations Snap lines where base rails are positioned, not the front or back edges of the cases. See case cross-section drawing, pages 3-6, for rail location dimensions Ask the general contractor if there have been changes in the building dimensions since the print you are using was issued. Also, ask the points of reference from which you should take dimensions to locate the cases. Mark floor where cases are to be located for the entire lineup. CASTER COTTER PIN LOCATION Level Floor. Use Laser Transit 4 Leveling is necessary to assure proper case alignment. Locate highest point on chalk line as reference for determining height of shim-pack levelers. A laser transit is recommended for precision and requires just one person. Set Shims On Basehorse Locations 5 Locate basehorse positions along chalk lines. Spot shim packs at each basehorse location. Position First Case In Lineup, Remove Casters, 6Level Roll first case into position. Raise case from end under cross support using J bar. Remove the pins holding the casters and pull the casters out of the baseframe. [CAUTION! Keep hands from under case]. 8

13 COIL CAULK COIL PLENUM BUMPER JOINT MASTER BUMPER BUMPER SCREWS Position Next Case In Line Up Remove Shipping Accessories From 7 Case. Add Sealant. 8 Roll case approximately 6 from adjoining case. Remove casters on the end interfere with case joining (eg. shipping Remove anything from case that may nearest to the next case. Allow casters braces). Run a bead of sealant around to remain on opposite end to assist in entire end before pushing cases tightly pushing cases together - then remove together. them. OPTIONAL FRONT - Loosen Bumper 9 Loosen screws on master bumper. Move bumper joint to a position for sliding between adjoining case bumper. COIL COIL PLENUM 6 5 Bolt Cases Together Using Bolt Holes Provided 10 Push cases tightly together. Bolt cases together through the holes provided. Tighten until all margins are equal; do not over tighten. Ask about our case installation video available by request through your local Hill PHOENIX Sales or Field Service Representative. 9

14 TRIM OUT Now that cases have been positioned and leveled, you may proceed to trim-out case lineup. Trim parts have been designed to be applied easily with only a small number of fasteners required. Most external parts are adjustable to achieve almost invisible, snug-fitting joints and a high level of excellence in fit and finish. MASTER BUMPER Tighten all joint 1bolts. Draw up tightly, but do not over tighten. Bolts are intended to hold the line-up in place not for pulling OPTIONAL MASTER BUMPER BUMPER JOINT LOCATION OPTIONAL ORIGIN 2FRONT - Adjust polymer master bumper joints, if required. First loosen bumper screws. Then slide cases together. sub-surface joint band to center of joint. Use screw driver in hole provided. END Close seam where 3bumper joins case end. Bumper joint closes seam that may develop if master bumper is moved away from end to close case-to-case joint seam. *OPTIONAL FRONT* See page 3 for other options. ACRYLIC TAPE CASE TO CASE WATERSHED Seal joints along 4pipe chase seam with the caulk provided. PIPE CHASE Apply acrylic tape 5over pipe chase seam for the self-service portion of the case. Tape is found with the ship loose items and acts as a watershed preventing water from settling in case joint. Apply water shed 6over pipe chase seam for the service dome portion of the case. The water shed is found with the ship loose items and acts as a barrier preventing water from settling in case joint. For more details see Appendix D on page

15 LONGITUDINAL RAIL KICKPLATE BRACKET KICKPLATE RETAINER LOWER REAR PANEL Install lower rear 7panel. Slide lower rear panel underneath the rear storage box then down onto the longitudinal rail. Install j-rail. The 8j-rail simply screws to the kickplate bracket with the fasteners provided. J-RAIL KICKPLATE BRACKET Attach kickplate 9retainer. The kickplate retainer screws to the kickplate bracket just above the j-rail. END KICKPLATE RETAINER END KICKPLATE KICKPLATE J-RAIL DUAL LOCK BASEFRAME Install kickplate. 10 Fit the kickplate up, behind the kickplate retainer and then down onto the j-rail. Attach end 11 kickplate. Screw the kickplate to the baseframe, both at the front and rear, using the screws provided. Seal the end kickplate to the floor by running a bead of caulk along the edge where it meets the floor. OPTIONAL 12 ORIGIN FRONT - Insert nose bumper into master bumper channel. Roll nose bumper into channel along entire lineup (up to 96 ). We recommend that the nose bumper be left in the store 24 hours before installing. DO NOT STRETCH the bumper during installation as it will shrink to its original length and leave a gap. 11

16 REFRIGERATION Refrigeration components and the coil outlet hole are located to provide the best access for installation and maintenance. As the diagram below indicates, the front coil outlet hole is positioned forward on the right hand side of the case. An alternate penetration location is at the right hand side of the rear box. The case piping can be run independently to the self service front and the full service dome, or the 2 circuits can be piped together and routed through either of the 2 locations. When piped together additional control components for defrost and temperature control are required for the front section. The expansion valve and other controls are located on the left hand side of the case in the self-service section. If it becomes necessary to penetrate the case bottom for any reason, make certain it is sealed afterward with canned-foam sealant and white RTV. REAR REFRIGERATION 4 1/8 in [10.5 cm] 4 1/4 in [10.8 cm] 50 1/16 in [127.2 cm] or 51 13/16 in [131.6 cm] or 51 11/16 in [131.3 cm] 46 13/16 in [118.9 cm] 42 1/2 in [107.9 cm] ** 13 3/4 in [34.9 cm] 38 1/2 in [97.8 cm] 39 7/16 in [100.2 cm] REFRIGERATION 7/8 in [2.2 cm] {END} C L 6 5/8 in [16.8 cm] FRONT OF CASE NOTES: 48 in [121.9 cm] {4' case} 72 in [182.9 cm] {6' case} 96 in [243.8 cm] {8' case} 144 in [365.8 cm] {12' case} ** RECOMMENDED STUB-UP CENTERLINE FOR ELECTRICAL AND HUB DRAINS SUCTION LINE - 7/8", LIQUID LINE - 1/2" 12

17 CASE PIPING - SSC TOP AND FRONT PIPED SEPERATELY COOLGENIX PAN TOP COIL COOLGENIX PAN COOLGENIX PAN COOLGENIX PAN FRONT COIL SUCTION LINE LIQUID LINE TOP COIL COOLGENIX PAN COOLGENIX PAN CHILLER SUCTION LINE LIQUID LINE Separate piping allows the top and the front of the case to be supplied from different suction groups. The top requires a 15 F saturated evaporator temperature while the front will work with either a 20 F saturated evaporator temperature or a 15 F evaporator temperature. If a 15 F saturated evaporator temperature is supplied to the front, the case has to be controlled as temperature cycled. Separate piping is also the only way to get hot gas defrost for the front coil. The top can not be subjected to any defrost from compressor system. TOP AND FRONT PIPED TOGETHER COOLGENIX PAN TOP COIL COOLGENIX PAN COOLGENIX PAN COOLGENIX PAN FRONT COIL SUCTION LINE LIQUID LINE TOP COIL COOLGENIX PAN COOLGENIX PAN SOLENOID CHILLER SUCTION LINE LIQUID LINE This will require an additional liquid line solenoid to be orderded with the refrigeration package. The liquid line solenoid can be controlled as a temperature cycled case from the rack controller; or controlled at the case. Defrost can be controlled from the rack controller or at the case as a time off defrost or electric defrost. See SSC defrost note below for more details. Refrigeration can only be stopped by using the liquid solenoid in the case, thus leaving the top refrigeration feed on to the top of the case. SSC Defrost Note: A rack controller can be used to control the front of the case by cycling off the solenoid for time off defrost, or to cycle off the solenoid and energize the electric defrost heaters. Otherwise, a DiXell case controller will be supplied to control the fronts defrost. If electric defrost is ordered a defrost termination sensor is required for rack control. If a DiXell case controller is used, all required components are included. Top case defrost is controlled by either the rack controller or a separate factory installed DiXell 460 controller. When a rack controller is used, the top case has to be setup as if it were 2 separate temperature cycled cases. It requires 2 sensor inputs that independently control 2 digital outputs. If a DiXell case controller is used, all required components are included. 13

18 CASE PIPING - REMOTE TOP AND FRONT PIPED SEPERATELY COOLGENIX PAN TOP COIL COOLGENIX PAN COOLGENIX PAN COOLGENIX PAN FRONT COIL RETURN LINE SUPPLY LINE TOP COIL COOLGENIX PAN COOLGENIX PAN BALANCING VALVE VALVE STATION RETURN LINE SUPPLY LINE The standard for separate piping has the top connections located in the right side of the rear storage box, while the front piping is inside the right side of the front case. Both sections require a 20 F supply. Separate piping is also the only way to get warm fluid defrost for the front section. The top can not be subjected to the same defrost as the front of the case. Temperature sensors for the top coil, and Coolgenix pans are required for any remote case. They have to be the same make as the rack controller. The required sensors independently control 2 digital outputs. The front section should be controlled like a standard open case. Optionally, the top supply and return can be run to the inside right of the front case. The tops of all remote cases have to be controlled as 2 separate temperature cycled cases. This requires 2 sensor inputs that independently control 2 digital outputs. There are pan supply and coil supply solenoids for the top of each case with the standard being a 120 volt normally closed valve. Normally open valves are an option as well as 208 volt and 24 volt solenoid coils. The front section should be controlled like a standard open case. TOP AND FRONT PIPED TOGETHER COOLGENIX PAN TOP COIL COOLGENIX PAN COOLGENIX PAN COOLGENIX PAN FRONT COIL RETURN LINE TOP COIL COOLGENIX PAN COOLGENIX PAN VALVE STATION RETURN LINE SUPPLY LINE When both sections of the case piping are tied together, the case has to be controlled as 3 separate temperature cycled cases. This requires 3 sensor inputs that independently control 3 digital outputs. The solenoid type, normally open or normally closed, and voltage, 120, 208 or 24 volts, have to be determined. This is based on how the case will be controlled. See remote defrost note below for more details. SUPPLY LINE SOLENOID VALVE BALANCING VALVE Remote Defrost Note: The preferred method is to have defrost controlled by the system controller. The front defrost will be time-off based on the case operation information. The top coil and coolgenix pans defrost will be time-off based on the case operation information. Neither warm fluid nor electric defrost is available for either section of the case when piped as a single circuit. 14

19 PIPING DIAGRAM- SEMI-SELF-CONTAINED 15

20 PIPING DIAGRAM- REMOTE 16

21 DOME SYSTEM CHARGING Sevice Dome s System Charging Charging the system is important to insure that air is eliminated from the system for maximized performance and that the pump is flooded to prevent damage caused by cavitation. Excessive air in the system can reduce the heat transfer capacity and even block the flow to one or more of the heat transfer components (a Coolgenix Pans or section of the top coils). The Hill Phoenix SSC (Semi-Self- Contained) cases use an open loop secondary system supplying independent circuits to the Coolgenix pans and the gravity top coils. Both circuits return to a common reservoir tank that is at atmospheric pressure. All cases are tested and shipped with a 35% mixture of Dowfrost propyleneglycol. Staring a newly delivered SSC case Unless specified otherwise, all Hill Phoenix SSC cases are charged and run at the factory. Much of the fluid is drained out of the reservoir before shipping to keep it from sloshing out during shipment and handling. Before starting the case, the DX (direct expansion) side of the chiller must be connected to the appropriate refrigerant lines and the power connected to the case. Starting the case consist of topping up the reservoir tank, insuring that all hand valves are open and applying power by switching the main control switch and the pump switch to the on position. This requires access to the chiller and the electrical box. They are located at the rear of the case on the right hand side below the top dome. A removable panel containing the light switches and level indicator lights identifies this section. A filling tube initiating at the top of the reservoir tank is assessable once the panel is removed. There are 2 indicator lamps located at the rear of the control box. One is red and the other blue. The red lamp indicates that the fluid level in the reservoir is low and should be topped up. The blue lamp indicates that the reservoir is full and no more glycol should be added or it will spill onto the floor. If neither lamp is on the fluid level is in the operating range. To top up the reservoir remove the filling tube from its holding position and extend it to insure there are no kinks or obstructions in it. Remove the charging cap and pour propyleneglycol (use only 35% Dowfrost) in until the blue lamp lights, indicating that the reservoir tank is full. Replace the charging cap and return the hose to its holding position. CHILLER PACKAGE 17

22 DOME SYSTEM CHARGING Recharging a System That Has Been Drained There may be circumstances where a system has to be drained, flushed and recharged. This would usually be due to contaminants being added to the approved propyleneglycol. Charging and air purging should be done with the hand valve on the primary side of the chiller closed. Field charging the chiller system requires bumping the pump. The pump is capable of emptying the reservoir faster than fluid can be poured into it. When the system is empty the reservoir must be filled until the blue light is illuminated, the pump should then be bumped on using the pump switch until the red light comes on. The reservoir has to be refilled and the process repeated until the red light no longer comes on. The pump can then be left on. Each circuit in the system may be cycled by adjusting the set point above ambient to stop flow and below fluid temperature to force flow. This will help force any entrapped air out of the pans and top coils. The flow through the system is never perfectly silent; however if an obvious gurgling sound is heard in any of the pans or at the outlet of a top coil, this indicates air movement at that location. Increased flow can be forced by restricting the flow to the other components in the circuit. For pans with quick connects, this can be done by disconnecting one of the hoses to the non-problem pans. For pans without quick connects, the flow can be restricted by pinching the blue feed hoses on the non-problem components. Do not use any kind of clamp that could cut or tear the hoses. There are also Schrader fittings in the return headers of each of the top coils. Entrapped air may be bled off by depressing the core of the fitting or removing it until a solid fluid stream is present. While purging air pay attention to the red indicator lamp, do not allow the reservoir to empty. Once the majority of the air is purged and the case is performing acceptably, top-up the reservoir until the blue lamp is on, open the primary side hand valve and close up the case. Any incidental air in the system will be removed during the normal operation of the case. 18

23 PLUMBING The drain outlet is located front and center of the cases for convenient access and is especially molded out of PVC material. The P trap, furnished with the case, is constructed of molded PVC pipe. Care should be given to assure that all connections are water tight and sealed with the appropriate PVC cement. The kickplate is shipped loose with the case for field installation, therefore you should have open access to the drain line area. If the kickplate has been installed, you will find it very easy to remove. See instructions below, or the trim out section of this manual on page 11. The drain lines can be run left or right of the tee with the proper pitch to satisfy local drainage requirements. 4 1/4 in [10.8 cm] 50 1/16 in [127.2 cm] or 51 13/16 in [131.6 cm] or 51 11/16 in [131.3 cm] 46 13/16 in [118.9 cm] 42 1/2 in [107.9 cm] ** 39 7/16 in [100.2 cm] 42 3/16 in [107.2 cm] 1 1/2" PVC DRAIN CONNECTION C L 7/8 in [2.2 cm] {END} FRONT OF CASE NOTES: 48 in [121.9 cm] {4' case} 72 in [182.9 cm] {6' case} 96 in [243.8 cm] {8' case} 144 in [365.8 cm] {12' case} ** RECOMMENDED STUB-UP CENTERLINE FOR ELECTRICAL AND HUB DRAINS HOW TO REMOVE KICKPLATE KICKPLATE RETAINER KICKPLATE J-RAIL 1. Lift up kickplate from j-rail and pull out from behind kickplate retainer. 2. Unscrew kickplate retainer from kickplate bracket 19

24 ELECTRICAL HOOKUP Electrical hookups for the case are made in the front of the case in the continuous raceway. Each circuit will be labeled separately. Access is gained by removing the front kickplate and kickplate retainer. For case-to-case wiring the wires can be routed through the continuous raceway. 4 1/4 in [10.8 cm] CAUTION USE SUPPLY WIRES SUITABLE FOR AT LEAST 194 o F (90 o C). 50 1/16 in [127.2 cm] or 51 13/16 in [131.6 cm] or 51 11/16 in [131.3 cm] 40 9/16 in [103.0 cm] 42 1/2 in [107.9 cm] ** 39 7/16 in [100.2 cm] ATTENTION EMPLOYER DES FILS D ALIMENTATION À 90 o C (194 o F) /16 in [118.9 cm] ELECTRICAL Note: When re-installing any lamp (cornice, shelf, nose, etc.) be sure the lamp cap is seated completely on to the lamp holder. WIRING-TO-RACEWAY (STANDARD) 7/8 in [2.2 cm] {END} 8 1/8 in [20.6 cm] 10 5/8 in [27.0 cm] C L FRONT OF CASE NOTES: 48 in [121.9 cm] {4' case} 72 in [182.9 cm] {6' case} 96 in [243.8 cm] {8' case} 144 in [365.8 cm] {12' case} LAMP CAP LAMP HOLDER ** RECOMMENDED STUB-UP CENTERLINE FOR ELECTRICAL AND HUB DRAINS WIRING NUMBERS AND COLORS 20

25 DOME REMOTE WIRING NO-CONTROLLER 21

26 22 DIXELL CONNECTION DIAGRAM ALL CONTROLS AT CASE

27 DIXELL LADDER DIAGRAM ALL CONTROLS AT CASE 23

28 24 SMS CONNECTIONS

29 FAN AND LIGHT WIRING 25

30 26 DOME DIXELL LADDER DIAGRAM TEMP CONTROLLED AT CASE DEFROST CONTROLLED BY CUSTOMER

31 27 DIXELL SCHEMATIC TEMP CONTROLLED AT CASE DEFROST CONTROLLED BY CUSTOMER

32 28 CPC CONTROLS WIRING

33 Multi-Deck Curved Glass Dome Meat/Seafood Merchandiser PMNUM - 4, 6, 8 & 12 Electrical Data Model PMNUM Fans 1 per Case Standard Fans 120 Volts Amps Watts High Efficiency Fans 120 Volts Amps Watts Anti-Condensate Heaters 120 Volts Amps Watts Secondary 2 Coolant Pump 120 Volts Amps Watts Volts Amps Watts Defrost Heaters 240 Volts Amps Watts Applicable for self service portion of PMNUM case only. 2 Secondary coolant pump is only applicable for the semi-self-contained version of the service dome. Lighting Data Model PMNUM Bulbs per Row Bulb Length Typical per Light Row 120 Volts Amps Watts Maximum Lighting 120 Volts Amps Watts Guidelines & Control Settings - Semi-Self-Contained Cut in / Cut Out Pans Top Coil ASHRAE Conditions 3 Cut Out Cut in Temp. ( F) Temp. ( F) Suggested Meat Prep. Settings 4 Cut Out Temp. ( F) Cut in Temp. ( F) These temperatures are based on cases running at ASHRAE conditions. 4 These specifications should be considered a guide and may need to be adjusted based on store conditions. Because these cases are often installed in stores near a meat preparation area where standard ASHRAE conditions may not apply; the following suggested meat prep. setting may prove useful. Model PMNUM - Self Service BTUH/ft Evaporator ( F) 17 Superheat Set Bulb ( F) 6-8 Discharge Air ( F) Return Air ( F) Discharge Air Velocity 6 (FPM) Model BTUH/ft 5 Supply Temp. ( F) Chiller Temp. ( F) Flow Rate 7 GPM/ft Charge 8 GAL/ft Max. Working Max. Static Pressure (PSIG) Pressure (PSIG) PMNUM - Dome BTUHs/ft listed are for parallel operation. Conventional ratings may be approximated by multiplying listed rating by Average discharge air velocity at peak of defrost. 7 Minimum flow rate. 8 For semi-self-contained cases add 2.75 gallon of fluid for the chiller to the total charge. 9 The dome portion of the PMNUM case operates using our patented secondary coolant Coolgenix technology. Guidelines & Control Settings - Remote Secondary Model BTUH/ft Supply Temp. ( F) Flow Rate GPM/ft Charge GAL/ft PMNUM - Self Service PMNUM - Dome Defrost Controls Model PMNUM - Self Service Defrosts Per Day 6 Run-Off Time (min) 6-8 Electric Defrost Fail-safe (min) 30 Termination Temp. ( F) 47 Timed Off Defrost Fail-safe (min) 30 Termination Temp. ( F) 47 Fail-safe (min) Warm Fluid Termination Temp. ( F) Reverse Air Defrost Fail-safe (min) Termination Temp. ( F) PMNUM - Dome NOTE: not an option on this case model. 11 This option only available on the remote secondary version. All measurements are taken per ARI specifications. COMPONENT 29

34 Multi-Deck Flat Glass Dome Meat/Seafood Merchandiser PMFNUM - 4, 6, 8 & 12 Electrical Data Model PMFNUM Fans 1 per Case Standard Fans 120 Volts Amps Watts High Efficiency Fans 120 Volts Amps Watts Anti-Condensate Heaters 120 Volts Amps Watts Secondary 2 Coolant Pump 120 Volts Amps Watts Volts Amps Watts Defrost Heaters 240 Volts Amps Watts Applicable for self service portion of PMFNUM case only. 2 Secondary coolant pump is only applicable for the semi-self-contained version of the service dome. Lighting Data Model PMFNUM Bulbs per Row Bulb Length Typical per Light Row 120 Volts Amps Watts Maximum Lighting 120 Volts Amps Watts Guidelines & Control Settings - Semi-Self-Contained Cut in / Cut Out Pans Top Coil ASHRAE Conditions 3 Cut Out Cut in Temp. ( F) Temp. ( F) Suggested Meat Prep. Settings 4 Cut Out Temp. ( F) Cut in Temp. ( F) These temperatures are based on cases running at ASHRAE conditions. 4 These specifications should be considered a guide and may need to be adjusted based on store conditions. Because these cases are often installed in stores near a meat preparation area where standard ASHRAE conditions may not apply; the following suggested meat prep. setting may prove useful. Model PMFNUM - Self Service BTUH/ft Evaporator ( F) 17 Superheat Set Bulb ( F) 6-8 Discharge Air ( F) Return Air ( F) Discharge Air Velocity 6 (FPM) Model BTUH/ft 5 Supply Temp. ( F) Chiller Temp. ( F) Flow Rate 7 GPM/ft Charge 8 GAL/ft Max. Working Max. Static Pressure (PSIG) Pressure (PSIG) PMFNUM - Dome BTUHs/ft listed are for parallel operation. Conventional ratings may be approximated by multiplying listed rating by Average discharge air velocity at peak of defrost. 7 Minimum flow rate. 8 For semi-self-contained cases add 2.75 gallon of fluid for the chiller to the total charge. 9 The dome portion of the PMFNUM case operates using our patented secondary coolant Coolgenix technology. Guidelines & Control Settings - Remote Secondary Model BTUH/ft Supply Temp. ( F) Flow Rate GPM/ft Charge GAL/ft PMFNUM - Self Service PMFNUM - Dome Defrost Controls Model PMFNUM - Self Service Defrosts Per Day 6 Run-Off Time (min) 6-8 Electric Defrost Fail-safe (min) 30 Termination Temp. ( F) 47 Timed Off Defrost Fail-safe (min) 30 Termination Temp. ( F) 47 Fail-safe (min) Warm Fluid Termination Temp. ( F) Reverse Air Defrost Fail-safe (min) Termination Temp. ( F) PMFNUM - Dome NOTE: not an option on this case model. 11 This option only available on the remote secondary version. All measurements are taken per ARI specifications. COMPONENT 30

35 Multi-Deck Curved Glass Dome Meat/Seafood Merchandiser PMN2UM - 4, 6, 8 & 12 Electrical Data Model PMN2UM Fans 1 per Case Standard Fans 120 Volts Amps Watts High Efficiency Fans 120 Volts Amps Watts Anti-Condensate Heaters 120 Volts Amps Watts Secondary 2 Coolant Pump 120 Volts Amps Watts Volts Amps Watts Defrost Heaters 240 Volts Amps Watts Applicable for self service portion of PMN2UM case only. 2 Secondary coolant pump is only applicable for the semi-self-contained version of the service dome. Lighting Data Model PMN2UM Bulbs per Row Bulb Length Typical per Light Row 120 Volts Amps Watts Maximum Lighting 120 Volts Amps Watts Cut in / Cut Out Pans Top Coil ASHRAE Conditions 3 Cut Out Cut in Temp. ( F) Temp. ( F) Suggested Meat Prep. Settings 4 Cut Out Temp. ( F) Cut in Temp. ( F) These temperatures are based on cases running at ASHRAE conditions. 4 These specifications should be considered a guide and may need to be adjusted based on store conditions. Because these cases are often installed in stores near a meat preparation area where standard ASHRAE conditions may not apply; the following suggested meat prep. setting may prove useful. Guidelines & Control Settings - Semi-Self-Contained Model PMN2UM - Self Service BTUH/ft Evaporator ( F) 17 Superheat Set Bulb ( F) 6-8 Discharge Air ( F) Return Air ( F) Discharge Air Velocity 6 (FPM) Model BTUH/ft 5 Supply Temp. ( F) Chiller Temp. ( F) Flow Rate 7 GPM/ft Charge 8 GAL/ft Max. Working Max. Static Pressure (PSIG) Pressure (PSIG) PMN2UM - Dome BTUHs/ft listed are for parallel operation. Conventional ratings may be approximated by multiplying listed rating by Average discharge air velocity at peak of defrost. 7 Minimum flow rate. 8 For semi-self-contained cases add 2.75 gallon of fluid for the chiller to the total charge. 9 The dome portion of the PMN2UM case operates using our patented secondary coolant Coolgenix technology. Defrost Controls Model PMN2UM - Self Service Defrosts Per Day 6 Run-Off Time (min) 6-8 Electric Defrost Fail-safe (min) 30 Termination Temp. ( F) 47 Timed Off Defrost Fail-safe (min) 30 Termination Temp. ( F) 47 Fail-safe (min) Warm Fluid Termination Temp. ( F) Reverse Air Defrost Fail-safe (min) Termination Temp. ( F) PMN2UM - Dome NOTE: not an option on this case model. All measurements are taken per ARI specifications. COMPONENT 31

36 Multi-Deck Flat Glass Dome Meat/Seafood Merchandiser PMFN2UM - 4, 6, 8 & 12 Electrical Data Model PMFN2UM Fans 1 per Case Standard Fans 120 Volts Amps Watts High Efficiency Fans 120 Volts Amps Watts Anti-Condensate Heaters 120 Volts Amps Watts Secondary 2 Coolant Pump 120 Volts Amps Watts Volts Amps Watts Defrost Heaters 240 Volts Amps Watts Applicable for self service portion of PMFN2UM case only. 2 Secondary coolant pump is only applicable for the semi-self-contained version of the service dome. Lighting Data Model PMFN2UM Bulbs per Row Bulb Length Typical per Light Row 120 Volts Amps Watts Maximum Lighting 120 Volts Amps Watts Cut in / Cut Out Pans Top Coil ASHRAE Conditions 3 Cut Out Cut in Temp. ( F) Temp. ( F) Suggested Meat Prep. Settings 4 Cut Out Temp. ( F) Cut in Temp. ( F) These temperatures are based on cases running at ASHRAE conditions. 4 These specifications should be considered a guide and may need to be adjusted based on store conditions. Because these cases are often installed in stores near a meat preparation area where standard ASHRAE conditions may not apply; the following suggested meat prep. setting may prove useful. Guidelines & Control Settings - Semi-Self-Contained Model PMFN2UM - Self Service BTUH/ft Evaporator ( F) 17 Superheat Set Bulb ( F) 6-8 Discharge Air ( F) Return Air ( F) Discharge Air Velocity 6 (FPM) Model BTUH/ft 5 Supply Temp. ( F) Chiller Temp. ( F) Flow Rate 7 GPM/ft Charge 8 GAL/ft Max. Working Max. Static Pressure (PSIG) Pressure (PSIG) PMFN2UM - Dome BTUHs/ft listed are for parallel operation. Conventional ratings may be approximated by multiplying listed rating by Average discharge air velocity at peak of defrost. 7 Minimum flow rate. 8 For semi-self-contained cases add 2.75 gallon of fluid for the chiller to the total charge. 9 The dome portion of the PMFN2UM case operates using our patented secondary coolant Coolgenix technology. Defrost Controls Model PMFN2UM - Self Service Defrosts Per Day 6 Run-Off Time (min) 6-8 Electric Defrost Fail-safe (min) 30 Termination Temp. ( F) 47 Timed Off Defrost Fail-safe (min) 30 Termination Temp. ( F) 47 Fail-safe (min) Warm Fluid Termination Temp. ( F) Reverse Air Defrost Fail-safe (min) Termination Temp. ( F) PMFN2UM - Dome NOTE: not an option on this case model. All measurements are taken per ARI specifications. COMPONENT 32

37 DEFROST AND TEMP CONTROL The Coolgenix dome portion of the case is available with the defrost and temperature controls completely mounted at the case, or with these controls being initiated by the rack controller. When the controls are mounted at the case the single time-off defrost is initiated by the Dixell 460 controller mounted in the rear mechanical area. During defrost the relay logic stops refrigeration by closing the DX liquid line solenoid, it stops glycol flow to the Coolgenix Pans and forces flow through the top coil via the 2 return solenoids. When in refrigeration the glycol flow to the top coil and the Coolgenix pans is independently controlled by the Dixell controller. If neither coils or pans require flow, a bypass solenoid dumps the flow into the glycol reservoir. When defrost and temperature are controlled from the rack, the time-off defrost is controlled by a set of normally open contacts at the rack controller. When in refrigeration, the top coils and the Coolgenix pans are controlled as 2 separate temperature controlled cases, independent of each other. Relay logic at the case still dumps the flow to the reservoir when neither circuit demands flow. Whether the controls are totally contained at the case or initiated by the rack controller, the case and product temperatures are maintained by having the top coils and the Coolgenix deck pans cycle through their individual dead band range. The flow of the chilled fluid to the Coolgenix pans and top coil circuit is controlled by comparing the temperature reading of the appropriate temperature sensor against the CUT-IN and DEAD BAND control settings. These two settings indicate the CUT-OUT temperature, which is the CUT-IN minus the DEAD BAND. For example, the factory setting for pan CUT-IN is 31 F with a 5 F DEAD BAND which yields a CUT-OUT setting of 26 F. When the sensor on the pan senses a temperature of 31 F, fluid is pumped through the pans until the sensor reads a temperature of 26 F. Once this temperature is reached, fluid flow ceases and the temperature slowly creeps through the dead band until it reaches 31 F and the process begins again. The factory settings should be considered a guide and may need to be adjusted based on store conditions. Because these cases are often installed in stores near a meat preparation area where standard ASHRAE conditions may not apply different settings may be required for optimal operation CUT IN DEAD BAND CUT OUT The defrost schedule is listed on the case operations page of this manual and it is important to consult the control setting guidelines shown on pages before setting defrost times. Further adjustment may be required depending on store conditions. Cut in / Cut Out Pans Top Coil ASHRAE Conditions 1 Cut Out Cut in Temp. ( F) Temp. ( F) Suggested Meat Prep. Settings 2 Cut Out Temp. ( F) Cut in Temp. ( F) These temperatures are based on cases running at ASHRAE conditions. 2 These specifications should be considered a guide and may need to be adjusted based on store conditions. Because these cases are often installed in stores near a meat preparation area where standard ASHRAE conditions may not apply; the following suggested meat prep. setting may prove useful. 33

38 DEFROST AND TEMP CONTROL The self-service portion of the case is independant from the dome. The dome section, the front case defrost and temperature can be controlled by the rack controller or completely at the case. There are 2 different piping arrangements that affect how these are controlled. The preferred piping is for the dome section and the front self service section to be run as 2 separate refrigeration circuits. When piped separately the front section can be controlled by the rack controller and is treated like any other open medium temperature case, with defrost and temperature controlled at the rack. When the dome section and the front self service section are piped together as the same refrigeration circuit, it is still possible to control the front section from the rack but not at the rack. When both sections are dependent on the same circuit the refrigeration feed from the rack can not be interrupted before it splits to feed the 2 sections. In this condition the defrost are limited to Timed Off and Electric Defrost. Hot Gas Defrost is not an option. During defrost, the refrigeration must be shut off by the rack controller using a liquid line solenoid position in the case after the tee that splits the dome section and front section refrigerant feed. The same solenoid will be used to maintain the lower case discharge air temperature. Optionally, the case temperature and defrost can be controlled at the case by a second DiXell controller. When used with electric defrost, the termination sensor is included with the controller. It is important to consult the control setting guidelines shown on pages before setting defrost times. Further adjustments may be required depending on store conditions. TOP COIL TEMPERATURE SENSOR LOCATION PAN TEMPERATURE SENSOR LOCATION -DISCHARGE AIR TEMPEATURE SENSOR LOCATION -ELECTRIC DEFROST TERMINATION SENSOR LOCATION -TIMED-OFF DEFROST TERMINATION SENSOR LOCATION 34

39 DIXELL CONTROLLER DIXELL XR460C DUAL TEMPERATURE CONTROLLER The PMNUM Case family can use up to two independent Dixell XR460C controllers depending on the options selected and the case configuration. In general, these configurations include: Dome Control using three independent temperature probes to control top coil and deck pans. Front Case control using separate temperature probes for temperature control and defrost control (time-off or active). DIXELL CONNECTIONS FOR DOME SECTION DIXELL CONNECTIONS FOR FRONT SECTION 35

40 DIXELL CONTROLLER The following describes the terminals used on the Dixell XR460C controller: TERMINAL DESCRIPTION 16 Input for DECK PAN temperature. Dome Control Only 19 Input for TOP COIL temperature probe. Input for Front Case TEMPERATURE CONTROL when configured for front case control. 17 Input for DEFROST TERMINATION temperature probe. Used with DONE and FRONT CASE control configurations. 18 Common terminal for following inputs: 16, 17, and 19. Used with DOME and FRONT CASE control configurations. 5 Output for TOP COIL temperature probe. [Dome Control] Relay (N.O.) output based on Terminal 16 temperature input. Rated at 8 A (resistive) and 3 A (inductive). 7 Output for DECK PAN temperature probe. [Dome Control] Output for Temperature Control when configured for front case temperature control. Relay (N.O) output based on Terminal 19 temperature input. Rated at 8 A (resistive) and 3 A (inductive). Refer to the wiring diagram for terminal connections. SPECIFICATIONS: Model Number... XR460C-100F0 Power Supply...24V AC/DC Power Draw... 3VA Maximum Operating Temperature F Operating Humidity % Non-Condensing Relay Output... 8A (Resistive Load) and 3A (Inductive Load) Temperature Probe...NTC (Negative Temperature Coefficient) Type Thermistor PROGRAMMING THE DIXELL CONTROLLER The Dixell controller is used as an elapsed time refrigeration control. In addition to controlling internal case temperature, the control will cause defrost to occur at regular time intervals. The default setting is one defrost every 24 hours for the dome and one defrost every 4 to 6 hours for the front case. The timer begins a programmed defrost countdown to defrost when the case is powered up or when a manual defrost is initiated. 36

41 HOW TO CHANGE A PARAMETER VALUE: Note: SET 1/2 indicates either Parameter Set 1 (Top Coil Parameter Set - SET 1) or parameter set 2 (Deck Pan Parameter Set - SET 2). 1. Press and hold + SET 1/2 for 3 seconds. Two LEDS will begin blinking on the display 2. Use and to move to the desired parameter. 3. Press SET 1/2. The current value for the parameter will be displayed. 4. Press and keys to change the parameter value. 5. Press SET 1/2 to store the new parameter value and move to the next parameter value. 6. To exit the menu, press + SET 1/2 or wait 15 seconds without pressing a key. HOW TO VIEW THE TEMPERATURE SET POINTS: 1. Press and immediately release SET 1/2. The display will show the set point value. 2. Press and immediately release SET 1/2 or wait for 5 seconds to display the probe value again. HOW TO CHANGE THE TEMPERATURE SET POINTS: 1. Press SET 1/2 for more than 2 seconds. 2. The value of the temperature set point will be displayed and the * LED starts blinking 3. Press the or to raise or lower the temperature set point. 4. Press SET 1/2 again, or wait 10 seconds and the new value will be stored. HOW TO START MANUAL DEFROST: 1. To start a defrost for SET 1: Press for 3 seconds. 2. To start a defrost for SET 2: Press for 3 seconds. 37

42 DIXELL CONTROLLER DOME CONTROL USING THE DIXELL XR460C The Dixell XR460X controller controls the temperature and defrost based on inputs from three independent temperature probes. These temperature probes are attached to two different components in the dome case: one probe is attached to the deck pans and the other two are attached to the top coil. When used in the Coolgenix application the Dixell XR460C uses these temperature probe inputs to independently control relay outputs. Simple relay logic is initiated based on the input temperatures. The controller cycles the solenoid valves to maintain the product and case interior temperature of the Coolgenix system. Also, the Dixell XR460C regulates the top coil defrost cycle based on timeoff. During a defrost cycle the chiller continues to pump the secondary coolant. Flow to the deck pans is terminated and flow to the top coil is forced. DOME PARAMETERS: SET 1 parameters are related to the TOP COIL. SET 2 parameters are related to the DECK PANS. Parameter Label Parameter Name Value Hy1 Top Coil Temperature Setpoint Differential 5 F Hy2 Deck Pan Temperature Setpoint Differential 5 F IdF1 Top Coil Defrost Interval 24 MdF1 Top Coil Defrost Duration 60 IdF2 Deck Pan Defrost Interval 24 MdF2 Deck Pan Defrost Duration 0 dp1 Top Coil Temperature Probe Value 26 F dp2 Deck Pan Temperature Probe Value 26 F dp3 Evaporator Probe Value 45 F Pr2 Protected Parameter Access Passcode Call Service 38

43 FRONT CASE CONTROL USING THE DIXELL XR460C When used as a front case option the Dixell XR460X controller is used for TEMPERATURE CONTROL and DEFROST CONTROL (active or time-off). The temperature probe for temperature control is placed in the discharge air stream and the temperature probe for defrost control is attached to the coil. The input from the temperature control probe is used by the Dixell XR460C to set the output for the liquid line solenoid valve. The input from the defrost termination probe is used to control the defrost heater (active defrost) and/or close the liquid line solenoid valve (time-off defrost). FRONT CASE PARAMETERS: SET 1 parameters are related to the FRONT CASE only. SET 2 parameters are not used when the Dixell XR460C is configured front case control. Parameter Label Parameter Name Value Hy2 Temperature Setpoint Differential 5 F dte2 Defrost Termination Temperature 45 F IdF2 Defrost Interval [hours] 4 to 6 MdF2 Defrost Duration [minutes] 40 dp1 Temperature Control Temperature Probe Value 29 F dp3 Defrost Termination Probe Value 45 F Pr2 Protected Parameter Access Passcode Call Service 39

44 AIR FLOW AND PRODUCT LOADING Cases have been designed to provide maximum product capacity within the refrigerated air envelope. It is important that you do not overload the food product display so that it impinges on the air flow pattern. Overloading will cause malfunction and the loss of proper temperature levels, particularly when discharge and return air sections are covered. Please keep products within the load limit line shown on the diagram below. DISCHARGE...1 LOAD LIMIT...2 COIL AIR FLOW...3 RETURN AIR...4 Coolgenix dome does not have airflow

45 USE AND MAINTENANCE CASE CLEANING Cases are designed to facilitate cleaning. All surfaces pitch to a deep-drawn drain trough that angles toward the front and center of the case where the waste outlet is located for easy access. COIL The coil is covered to keep food fluids from entering, but the cover lifts up easily when coil cleaning is desired. The single piece fan plenum lifts up for cleaning, exposing a major portion of the inside bottom of the tank. Make certain fan plenum is properly closed after cleaning to avoid air leaks. SINGLE PIECE FAN PLENUM SWINGS UP FOR EASY CLEANING COIL PLENUM OPTIONAL REMOVAL OF DECK PANS WITH QUICK CONNECTS POSITIVE DRAIN OFF SINGLE PIECE FAN PLENUM LIFT UP CLEANING PROCEDURES A periodic cleaning schedule should be established to maintain proper sanitation, insure maximum operating efficiency, and avoid the corrosive action of food fluids on metal parts that are left on for long periods of time. We recommend cleaning once a week. To avoid shock hazard, be sure all electrical power is turned off before cleaning. In some installations, more than one disconnect switch may have to be turned off to completely de-energize the case. Check waste outlet to insure it is not clogged before starting the cleaning process and avoid introducing water faster than the case drain can carry it away. Avoid spraying cleaning solutions directly on fans or electrical connections. Allow cases to be turned off long enough to clean any frost or ice from coil and flue areas. Clean the discharge air grill in the self-service section of case. You may need to use spray detergent and a soft, long bristle brush. Use mild detergent and warm water. When necessary, water and baking soda solution will help remove case odors. Avoid abrasive scouring powders or pads. When cleaning non-glare glass be sure to use a standard glass cleaner and not a multi-purpose cleanser or combination cleanser. A mixture of white vinegar and water or isopropyl alcohol straight from the bottle is very effective in cleaning build-up on non-glare glass. Under no circumstances should abrasive cleaning solutions such as scouring powders or steel wool be used to clean non-glare glass. When cleaning rear door tracks be sure to remove the rear doors and clean from the outside channel to the inside channel using the wipe-out groove machined into the track. Remove front panels and clean underneath the case with a broom and a long handled mop. Instructions for removing the front panels can be found on page 11 of this manual. Use warm water and a disinfecting cleaning solution when cleaning underneath the cases. When removing deck pans for cleaning, gently set the pans on the ground in a vertical position up against the front of the case. If equipped with the optional quick connects, disconnect the coolant lines from the pans for cleaning. WARNING MORE THAN ONE SOURCE OF ELECTRICAL SUPPLY. DISCONNECT ALL SOURCES BEFORE SERVICING. 41 AVERTISSEMENT PLUS D UNE SOURCED ALIMENTATION. AVANT LE DÉPANNAGE, COUPER TOUTES LES SOURCES D ALIMENTATION.

46 USE AND MAINTENANCE FANS The evaporator fans are equipped with 5 watt fan motors, 1550 RPM s. The motor has a counter clockwise rotation when viewed from the shaft end. The fan blades are 6 in diameter and the blades are pitched according to the charts below. It is important that the blade pitch be maintained as specified. Do not attempt a field modification by altering the blades. 2 Fan motors may be changed with an easy twostep process without lifting up the plenum, thereby avoiding the necessity to unload the entire product display to make a change: 1 1. Unplug the fan motor, easily accessible out side the plenum 2. Remove three fasteners, then lift out the entire fan basket Model No. Fans Blade Pitch PMNUM SERIES o 37 o 37 o 37 o CAUTION MOVING PARTS. DO NOT OPERATE UNIT WITH DISPLAY PANS REMOVED. ATTENTION PIÈCES MOBILES. N ACTIONNEZ PAS L UNITÉ DES CASSEROLES D AFFICHAGE ÉTANT COUPÉES. WARNING DISCONNECT POWER SUPPLY BEFORE SERVICING. AVERTISSEMENT COUPER L ALIMENTATION AVANT L ENTRETIEN ET LE DÉPANNAGE. 42

47 GLASS CLEANING SOVIS ULTRAVISION tempered glass specialized Anti- Reflective coatings on each surface of the glass. These coatings reduce the glare from lighting so that the products on display are more visible to your customers. While the Anti-Reflective coatings are durable, they are susceptible to scratching if abrasive materials are used for cleaning. Once the glass surfaces are scratched, it is impossible to restore the original finish. Special care must be taken to prevent damage when cleaning the glass. SOVIS recommends the following products for routine cleaning of ULTRAVISION Anti-Reflective glass: Cleaning Cloths - two products are recommended Scotch-Brite High Performance Cloth - manufactured by 3M and available in most grocery stores under the name Scotch-Brite Microfiber Cleaning Cloth in a 12 x 14 size. This cloth is washable and may be reused as long as it remains clean. Spontex Microfibre Cleaning Cloth - distributed by Spontex and available in most grocery stores under the same name in a x 12 size. This cloth is washable and may be reused as long as it remains clean. Cleaning Fluid - for more difficult cleaning jobs, these products are recommended Windex - standard product only (extra-strength or specialty products may not be suitable) Glass-Plus - standard product only (extra-strength or specialty products may not be suitable) Warm Water Note: equivalent store-brand glass cleaning products are normally acceptable substitutes to the brand name products listed above. The cleaning cloths named above will normally remove dust, grease, oil, and fingerprints without the need for cleaning fluids. A light spray of the cleaning fluids listed above will reduce the time required for cleaning. These materials have been tested and proven to clean ULTRAVISION glass without scratching or damaging the Anti-Reflective coatings. If you need assistance with obtaining these materials, please contact your display case supplier. Under no circumstances should the following types of materials be used for cleaning glass with ULTRAVISION Anti-Reflective coatings. Coarse Paper Towels Scouring Pads or Powders Steel Wool or Steel Fiber Materials Blades Acidic or highly Alkaline detergents Fluorine based detergents WARNING! DO NOT USE THESE MATERIALS 43

48 GLASS CLEANING RECOMMENDATIONS FOR CLEANING ULTRAVISION GLASS ULTRAVISION glass is more sensitive to scratches than regular float glass. Therefore, it is important to carefully follow the recommendations listed below regarding the materials and chemicals that may be used: Regular Cleaning Soft rags with water and soft detergent Chamois leather with water and soft detergent Soft sponge with water and soft detergent Rubber wiper with water and soft detergent A neutral chemical can also be used (WINDEX, GLASS PLUS, etc.) For More Difficult Cleaning Acetone Trichlorethylene Methlyated spirits Petroleum ether White spirit Never Use Acids High alkaline detergents Fluorine based detergents Scouring powders Scouring pads Blades Steel wool Steel fiber materials Note that the intrinsic structure of anti-glare coatings makes the surface roughness of ULTRAVISION glass rather high. However, after a few cleanings, the surface of the glass is smoother, and is therefore easier to clean. 44

49 PARTS ORDERING Procedure 1. Contact the Service Parts Department Hill PHOENIX 1925 Ruffin Mill Road Colonial Heights, VA Tel: Fax: Provide the following information about the part you are ordering: Model number and serial number of the case on which the part is used. Length of part, if applicable, I.E. 4, 6, 8 & 12. Color of part if painted, or color of polymer part. Whether part is for left hand or right hand application. Whether shelves are with or without lights. Quantity *Serial plate is located on top flue panel on the right hand side of the case (See illustrations on pages 3-6). 3. If parts are to be returned for credit, ask the Parts Department to furnish you with a Return Materials Authorization Number. 45

50 APPENDIX A DIXELL INSTALLING AND OPERATING INSTRUCTIONS 46

51 dixel Installing and Operating Instructions Contents XR460C DUAL TEMPERATURE CONTROLLER 1. GENERAL WARNING 1 2. GENERAL DESCRIPTION 1 3. TEMPERATURE CONTROL 1 4. DEFROST 1 5. CONTROL OF EVAPORATOR FANS (ONLY FOR SECTION 1) 1 6. THE DISPLAY 1 7. PARAMETER LIST 2 8. DIGITAL INPUT 4 9. INSTALLATION AND MOUNTING ELECTRICAL CONNECTIONS SERIAL LINE USE OF THE PROGRAMMING HOT KEY ALARM SIGNALS TECHNICAL DATA WIRING CONNECTIONS DEFAULT SETTING VALUES 5 1. GENERAL WARNING 1.1 PLEASE READ BEFORE USING THIS MANUAL This manual is part of the product and should be kept near the instrument for easy and quick reference. The instrument shall not be used for purposes different from those described hereunder. It cannot be used as a safety device. Check the application limits before proceeding. 1.2 SAFETY PRECAUTIONS Check the supply voltage is correct before connecting the instrument. Do not expose to water or moisture: use the controller only within the operating limits avoiding sudden temperature changes with high atmospheric humidity to prevent formation of condensation Warning: disconnect all electrical connections before any kind of maintenance. Fit the probe where it is not accessible by the End User. The instrument must not be opened. In case of failure or faulty operation send the instrument back to the distributor or to Dixell S.p.A. (see address) with a detailed description of the fault. Consider the maximum current which can be applied to each relay (see Technical Data). Ensure that the wires for probes, loads and the power supply are separated and far enough from each other, without crossing or intertwining. In case of applications in industrial environments, the use of mains filters (our mod. FT1) in parallel with inductive loads could be useful. 2. GENERAL DESCRIPTION Model XR460C, 32x74 mm format, is a microprocessor based controller, able to control 2 temperatures in an independent way. The first section is suitable for applications on medium or low temperature refrigerating units. It is provided with 3 relay outputs to control compressor, defrost - which can be either electrical or hot gas - and the evaporator fans. It is also provided with 2 NTC or PTC probe inputs, one for temperature control the other one to control the defrost end temperature of the evaporator. The second section is suitable for applications on medium or normal temperature refrigerating units, with timed defrost. It s provided with 1 relay output to control compressor. It is also provided with 1 NTC/PTC probe inputs, for temperature control. There are two digital inputs (free contact) completely configurable by parameter. The standard TTL output allows the user to connect, by means of a TTL/RS485 external module, a ModBUS-RTU compatible monitoring system and to programme the parameter list with the Hot Key. In case of fault in the thermostat probe the start and stop of the compressor are timed through parameters COn1(2) and COF1(2). 4. DEFROST 4.1 SECTION 1 For the section 1 two defrost modes are available through the tdf1 parameter: tdf1= re defrost with electrical heater tdf1= in or hot gas. The defrost interval is control by means of parameter EdF : rtc (only for instruments with RTC): beginning of defrost cycles is set by the L1d1 L1d6 parameters during the working days and S1d1 S1d6 during the holidays in the defrost is made every IdF time Sd the interval IdF is calculate through Smart Defrost algorithm (only when the compressor is ON) At the end of defrost the drip time is controlled through the Fdt parameter. 4.2 SECTION 2 For the section 2 the defrost interval is control by means of parameter EdF2 : with EdF=in the defrost is made every IdF2 time, with EdF2=Sd the interval IdF2 is calculate through Smart Defrost algorithm (only when the compressor 2 is ON). Defrost is performed through a simple stop of the compressor2. Parameter IdF2 controls the interval between defrost cycles, while its length is controlled by parameter MdF RELATION BETWEEN DEFROSTS Different kinds of defrosts are available for each section. The relation between defrosts is set by the dfs parameter: relation between defrosts. 4 relation between the 2 sections of the controller are available, to manage different kinds of applications: in = independent defrosts; StS = same defrost start, synchronised defrost end; St = same defrost start, independent defrost end; SE = sequential defrost; dfs= in - independent defrosts The defrosts of the 2 sections of controller are completely independent. First section: defrost interval is set by idf1 parameter. Second section: defrost interval is set by idf2 parameter. The defrost interval is control by means of parameter EdF1(2) : in the defrost is made every IdF time Sd the interval IdF is calculate through Smart Defrost algorithm (only when the compressor is ON) Manual defrost activation, by pushing the DOWN key (defrost 1) or UP key (defrost 2). By pushing the Down key or Up key for 3s, a defrost request is generated for section 1 or 2 respectively. The defrost interval is re-loaded dfs = StS Same defrost start, end defrost synchronised or dfs = St - Same defrost start, end defrost independent. The defrost of the 2 sections of controller starts at the same time. idf1 parameter sets the defrost interval for both the sections. The defrosts are performed at regular interval if EdF1 = in or according to the Smartdefrost algorithm if EdF1 = Sd. With dfs = StS regulation restarts only when defrost is finished for both the sections. The section that finishes the defrost before the other starts dripping time until also the other section has not finished its defrost. Manual defrost activation, by pushing the DOWN key (defrost 1) or UP key (defrost 2). By pushing the Down key or Up key for 3s, a defrost request is generated for both the sections 1 and 2. The defrost interval is re-loaded. With dfs = St each section restarts regulation as soon as its defrost is finished dfs = SE sequential defrost The defrost of 2 sections is synchronised. idf1 parameter sets the defrost interval for both the sections. Defrosts are performed at regular interval if EdF1 = in or according to the Smartdefrost algorithm if EdF1 = Sd. Section 1 does its defrost first, at the end of the defrost of section 1, section 2 starts its defrost.. Manual defrost activation, by pushing the DOWN key (defrost 1) or UP key (defrost 2). By pushing the Down key or Up key for 3s, a defrost request is generated for both the sections 1 and 2. The defrost interval is re-loaded. 3. TEMPERATURE CONTROL 3.1 THE COMPRESSOR 1 (2) For each section, the regulation is performed according to the temperature measured by its own thermostat probe with a positive differential from the set point. If the temperature increases and reaches set point1 (2) plus differential1 (2) the compressor is started and then turned off when the temperature reaches the set point value again. 5. CONTROL OF EVAPORATOR FANS (ONLY FOR SECTION 1) Section 1 has 1 relay to control evaporator fan. The fan control mode is selected by means of the FnC1 parameter: FnC1=C-n fans will switch ON and OFF with the compressor and not run during defrost:; FnC1= O-n fans will run continuously, but not during defrost After defrost, there is a timed fan delay allowing for drip time, set by means of the Fnd1 parameter. FnC1=C-y fans will switch ON and OFF with the compressor and run during defrost; FnC1=O-y fans will run continuously also during defrost An additional parameter FSt1 provides the setting of temperature, detected by the evaporator probe, above which the fans are always OFF. This can be used to make sure circulation of air only if his temperature is lower than set in FSt XR460C GB r doc XR460C 1/6

52 dixel Installing and Operating Instructions THE DISPLAY Select Pr2 PAS parameter and press the SET1 key. The flashing value is displayed. use o or n to input the security code and confirm the figure by pressing SET key. XR400 X----C Temperature2 The security code is 321. If the security code is correct the access to Pr2 is enabled by pressing SET1 on the last digit. Another possibility is the following: After switching ON the instrument, within 30 seconds, push SET1 + n keys together for 3s: the Pr2 menu will be entered. The display is divided in 2 parts: Upper left part: to see the temperature2 (upper display) Lower left part: to see the temperature1(lower display) 6.1 THE KEYBOARD SET1 To display and modify target set point1; in programming mode it selects a parameter or confirm an operation. To switch on/off the instrument: by holding it pressed for 5s the instrument is switched in stand by mode. SET2 To display and modify target set point2. o/ (UP/DEFROST 2) in programming mode it browses the parameter codes or increases the displayed value. By holding it pressed for 3s the defrost for section 2 is started. n/ (DOWN/DEFROST 1) in programming mode it browses the parameter codes or decreases the displayed value. By holding it pressed for 3s the defrost for section 1 is started o + n To lock and unlock the keyboard. SET + n To enter the programming mode. SET + o To exit the programming mode. 6.2 MEANING OF THE ICONS Temperatature1 6.7 HOW TO MOVE A PARAMETER FROM THE PR2 MENU TO PR1 AND VICE VERSA. Each parameter present in Pr2 MENU can be removed or put into Pr1, user level, by pressing SET1 + n. In Pr2 when a parameter is present in Pr1 the decimal point LE of the bottom display is on. 6.8 HOW TO CHANGE A PARAMETER To change a parameter value operates as follows: Enter the Programming mode Select the required parameter. Press the SET1 key and the value starts blinking. Use UP or DOWN to change its value. Press SET1 to store the new value and move to the following parameter. TO EXIT: Press SET1 + o or wait 15s without pressing a key. NOTE: the set value is stored even when the procedure is exited by waiting the time-out to expire. 6.9 HOW TO LOCK THE KEYBOARD Keep pressed for more than 3 s the o and n keys. The POF message will be displayed and the keyboard will be locked. At this point it will be possible only to see the set points. If a key is pressed more than 3s the POF message will be displayed TO UNLOCK THE KEYBOARD Keep pressed together for more than 3s the o and n keys, till the Pon message will be displayed I con FUNCTION Meaning ON Celsius degree ON Fahrenheit degree ON Compressor 1 on FLASHING Anti-short cycle delay enabled for compressor 1 ON Compressor 2 on FLASHING Anti-short cycle delay enabled for compressor 2 ON Defrost 1 in progress FLASHING Drip time in progress for section 1 ON Defrost 2 in progress ON Fan enabled FLASHING Drip time in progress ON ALARM signal 6.3 HOW TO SEE AND MODIFY THE SET-POINT Push and release the SET1 or SET2 key: the bottom display shows the label St1 or St2 the upper display shows the Set point value flashing To change the Set value push the o or n within 15s. To memorise the new set point value push the SET1 or SET2 key again or wait 15s. 6.4 HOW TO START A MANUAL DEFROST FOR THE SECTION 1 OR SECTION 2 To start a defrost for the section 1: push the DOWN key( ) for 3s. To start a defrost for the section 2: push the UP key( ) for 3s. 6.5 HOW TO ENTER THE PR1 PARAMETER LIST To change the parameter s value operate as follows: Enter the Programming mode by pressing the Set1 and DOWN key for 3s The controller will show the first parameter present in the Pr1 menu: Bottom menu: label Upper menu: value To exit: Press SET + UP or wait 15s without pressing a key. 6.6 HOW TO ENTER IN PARAMETERS LIST PR2 To access parameters in Pr2 : Enter the Pr1 level ON/OFF FUNCTION HOW TO SWITCH ON AND OFF THE CONTROLLER If the function is enabled (par. onf=yes), by pressing the SET1 key for more than 5s the controller is switched OFF. The stand-by function switches OFF all the relays and stops the regulation. During the stand by if a monitored unit is connected, it does not record the instrument data and alarms To switch the instrument on again press the SET1 key for 5s. NOTE1: When the instrument is under Stand-by, all the relays are under power supply. Don t connect any loads to the normal closed contact of the relays. NOTA2: With the instrument in stand-by, it s possible to see and modify the set points and enter the programming mode. 7. CLOCK FUNCTIONS 7.1 TO DISPLAY CURRENT HOUR AND DATE Enter parameter list Pr1 (press SET + n for some seconds) The controller displays the parameter rtc Press SET key, the controller displays the following labels Hur (hour) and the current hour Min (Minute) and the current minutes day (day) and the current day. Mon (Monday), Tue (Tuesday), Ued (Wednesday), thu (Thursday), Fri (Friday), Sat (Saturday), Sun (Sunday) Press n key or wait for 5 seconds to go back to normal temperature display. 7.2 TO PROGRAM HOUR, DATE AND HOLYDAY Enter parameter list Pr1 (press SET + n for some seconds) The controller displays the parameter rtc Press SET key, the controller displays hour and date. By pressing SET it will be possible to program the current hour, date and the 3 week end days Press n key or wait for 5 seconds to go back to normal temperature display. 8. PARAMETER LIST DIFFERENTIALS rtc To enter the RTC menu Hy1 Differential1: (0,1 25,5 C; 1 45 F): Intervention differential for set point1, always positive. Compressor1 Cut IN is Set Point Plus Differential1 (Hy1). Compressor1 Cut OUT is when the temperature reaches the set point1. Hy2 Differential2: (0,1 25,5 C; 1 45 F): Intervention differential for set point2, always positive. Compressor2 Cut IN is Set Point2 Plus Differential2 (Hy2). Compressor2 Cut OUT is when the temperature reaches the set point2. REGULATION SECTION XR460C GB r doc XR460C 2/6

53 dixel Installing and Operating Instructions LS1 Minimum set point1 limit: (-50,0 C SET1; -58 F SET1) Sets the minimum acceptable value for the set point1. US1 Maximum set point1 limit: (SET1 110 C; SET1 230 F) Set the maximum acceptable value for set point1. OdS1 Outputs activation delay of section 1 at start up: (0 255 min) This function is enabled at the initial start up of the instrument and inhibits any output activation of the section 1 for the period of time set in the parameter. (Light can work) AC1 Anti-short cycle delay for compressor1: (0 30 min) interval between the compressor1 stop and the following restart. Con1 Compressor1 ON time with faulty probe1: (0 255 min) time during which the compressor1 is active in case of faulty thermostat probe. With COn=0 compressor1 is always OFF. COF1 Compressor1 OFF time with faulty probe1: (0 255 min) time during which the compressor is off in case of faulty thermostat probe. With COF=0 compressor is always active. CH1 Kind of action for section 1: CL = cooling; Ht = heating REGULATION SECTION 2 LS2 Minimum set point2 limit: (-50,0 C SET2; -58 F SET2) Sets the minimum acceptable value for the set point2. US2 Maximum set point2 limit: (SET2 110 C; SET2 230 F) Set the maximum acceptable value for set point2. OdS2 Outputs activation delay of section 2 at start up: (0 255 min) This function is enabled at the initial start up of the instrument and inhibits any output activation of the section 1 for the period of time set in the parameter. AC2 Anti-short cycle delay for compressor2: (0 30 min) interval between the compressor2 stop and the following restart. Con2 Compressor2 ON time with faulty probe2: (0 255 min) time during which the compressor2 is active in case of faulty thermostat probe. With COn=0 compressor2 is always OFF. COF2 Compressor2 OFF time with faulty probe2: (0 255 min) time during which the compressor is off in case of faulty thermostat probe. With COF=0 compressor2 is always active. CH2 Kind of action for section 2: CL = cooling; Ht = heating DISPLAY CF Temperature measurement unit: C = Celsius; F = Fahrenheit. When the measurement unit is changed the SET point and the values of some parameters have to be modified. res Resolution (for C): (in = 1 C; de = 0,1 C) allows decimal point display. de = 0,1 C; in = 1 C Lod1 Bottom display visualization: select which probe is displayed by the instrument in the bottom display: P1 = Thermostat1 probe; P2 = Evaporator probe; P2 = Thermostat2 probe Lod2 Upper display visualization: select which probe is displayed by the instrument in the upper display: P1 = Thermostat1 probe; P2 = Evaporator probe; P2 = Thermostat2 probe DEFROST dfs relation between defrosts.4 relation between the 2 sections of the controller are available, to manage different kinds of applications: in = independent defrosts; StS = same defrost start, synchronised defrost end; St = same defrost start, independent defrost end; SE = sequential defrost; tdf1 Defrost type, section 1: re = electrical heater (Compressor OFF); in = hot gas (Compressor and defrost relays ON) EdF1 Defrost mode, section 1: rtc = The defrost is done according to the rtc parameters in = interval mode. The defrost starts when the time IdF1 is expired. Sd = Smartdefrost mode. The time IdF (interval between defrosts) is increased only when the compressor is running (even non consecutively). SdF1 Set point for SMARTDEFROST, section 1: ( C/ F) evaporator temperature which allows the IdF counting (interval between defrosts) in SMARTDEFROST mode. dte1 Defrost termination temperature, section 1: (-50,0 110,0 C; F) (Enabled only when the evaporator probe is present) sets the temperature measured by the evaporator probe which causes the end of defrost. IdF1 Interval between defrosts, section 1: (1 120h) Determines the time interval between the beginning of two defrost cycles. MdF1 (Maximum) duration of defrost, section 1: (0 255 min) When P2P = no, no evaporator probe, it sets the defrost duration, when P2P = yes, defrost end based on temperature, it sets the maximum length for defrost. tpf1 Pre-defrost time: (0 30min) The compressor is activated for this time before a hot gas defrost. Fdt1 Drain down time, section 1: (0 60 min.) time interval between reaching defrost termination temperature and the restoring of the control s normal operation. This time allows the evaporator to eliminate water drops that might have formed due to defrost. dpo1 First defrost after start-up, section 1: y = Immediately; n = after the IdF time EdF2 Defrost mode, section 2: rtc = The defrost is done according to the rtc parameters in = interval mode. The defrost starts when the time IdF2 is expired. Sd = Smartdefrost mode. The time IdF (interval between defrosts) is increased only when the compressor is running (even non consecutively). IdF2 Interval between defrosts, section 2: (1 120h) Determines the time interval between the beginning of two defrost cycles. MdF2 (Maximum) duration of defrost, section 2: (0 255 min) it sets the defrost duration. dfd Display during defrost: rt = real temperature; it = temperature reading at the defrost start; Set = set point; def = def label; deg = deg label; dad Defrost display time out: (0 255 min) Sets the maximum time between the end of defrost and the restarting of the real room temperature display. dsd Start defrost delay : ( 0 99min) This is useful when different defrost start times are necessary to avoid overloading the plant. FANS FnC1 Fan operating mode, section 1: C-n = running with the compressor1, OFF during the defrost; C-y = running with the compressor1, ON during the defrost; O-n = continuous mode, OFF during the defrost; O-y = continuous mode, ON during the defrost; Fnd1 Fan delay after defrost, section 1: (0 255 min) The time interval between the defrost end and evaporator fans start. FSt1 Fan stop temperature, section 1: ( C; F) setting of temperature, detected by evaporator probe, above which the fan is always OFF. FAP1 Probe selection for fans management, section 1: np = no probe: fan follows the setting of FnC1 parameter; P1 = thermostat 1 probe; P2 = thermostat 2 probe; P3 = evaporator probe; ALARMS ALc1 Temperature alarms configuration, section 1: it determines if alarms are relative to set point 1 or referred to absolute values: re relative to set point; Ab absolute temperature ALL1 Minimum alarm, section 1: with ALc1=rE: relative to set point1, (0 50 C) this value is subtracted from the set point1. The alarm signal is enabled when the probe values goes below the SET1-ALL value. with ALc1=Ab absolute value, minimum alarm is enabled when the probe values goes below the ALL1 value. ALU1 Maximum alarm, section 1: with ALc1=rE: alarm relative to set point1, (0 50 C) Maximum alarm is enabled when the probe values exceeds the SET1+ALU value. with ALc1=Ab: absolute alarm, (Set1 Full Sc.) Maximum alarm is enabled when the probe values exceeds the ALU value. ALd1 Temperature alarm delay, section 1: (0 255 min) time interval between the detection of an alarm condition and the corresponding alarm signalling. dao1 Delay of temperature alarm at start-up, section 1: (0min 23h 50min) time interval between the detection of the temperature alarm condition in section after the instrument power on and the alarm signalling. ALc2 Temperature alarms configuration, section 2: it determines if alarms are relative to set point 2 or referred to absolute values: re relative to set point; Ab absolute temperature ALL2 Minimum alarm, section 2: with ALc2=rE: relative to set point1, (0 50 C) this value is subtracted from the set point2. The alarm signal is enabled when the probe values goes below the SET2-ALL value. with ALc2=Ab absolute value, minimum alarm is enabled when the probe values goes below the ALL2 value. ALU2 Maximum alarm, section 2: with ALc2=rE: alarm relative to set point1, (0 50 C) Maximum alarm is enabled when the probe values exceeds the SET2+ALU value. with ALc2=Ab: absolute alarm, (Set2 Full Sc.) Maximum alarm is enabled when the probe values exceeds the ALU value. ALd2 Temperature alarm delay, section 2: (0 255 min) time interval between the detection of an alarm condition and the corresponding alarm signalling. dao2 Delay of temperature alarm at start-up, section 2: (0min 23h 50min) time interval between the detection of the temperature alarm condition in section after the instrument power on and the alarm signalling. AFH Temperature alarm and fan differential: (0,1 25,5 C; 1 45 F) Intervention differential for temperature alarm set point and fan regulation set point, always positive. EdA Alarm delay at the end of defrost: (0 255 min) Time interval between the detection of the temperature alarm condition at the end of defrost and the alarm signalling. dot Delay of temperature alarm after closing the door : (0 255 min) Time delay to signal the temperature alarm condition after closing the door. doa Open door alarm delay:(0 255 min) delay between the detection of the open door condition and its alarm signalling: the flashing message da is displayed. PROBE INPUTS Pbc Kind of probe: Ptc = PTC; ntc = NTC ofs1 Thermostat1 probe calibration: ( C/ F) allows to adjust possible offset of the thermostat1 probe. ofs2 Thermostat2 probe calibration: ( C/ F) allows to adjust possible offset of the thermostat2 probe. ofs3 Evaporator probe calibration: ( C/ F) allows to adjust possible offsets of the evaporator probe. P2P Thermostat2 probe presence : no= not present; yes= present. P3P Evaporator probe presence: : no= not present: the defrost stops only by time; yes= present: the defrost stops by temperature and time. DIGITAL INPUTS i1p Digital input 1 polarity (14-15): CL : the digital input is activated by closing the contact; OP : the digital input is activated by opening the contact. i1f Digital input 1 operating mode(14-15): configure the digital input function: MP1 = door switch 1; MP2 = door switch 2, MP: door switch (it s used by both the sections); EA1 = generic alarm section 1; EA2 = generic alarm section 2; EAL = generic alarm (it s used by both the sections); ba1 = serious alarm mode section 1; ba2 = serious alarm mode section 2;, bal = serious alarm mode section (it s used by both the sections); df1 = Start defrost, section 1; df2 = Start defrost, section 2; def = Start defrost (it s used by both the sections); of1 = remote on/ off, section1; of2 = remote on/ off, section 2; off = = remote on/ off (it s used by both the sections); ES = Energy Saving i2p Digital input 2 polarity(13-14): CL : the digital input is activated by closing the contact; OP : the digital input is activated by opening the contact. i2f Digital input 2 operating mode(13-14): configure the digital input function: MP1 = door switch 1; MP2 = door switch 2, MP: door switch (it s used by both the sections); EA1 = generic alarm section 1; EA2 = generic alarm section 2; EAL = generic alarm (it s used by both the sections); ba1 = serious alarm mode section 1; ba2 = serious alarm mode section 2;, bal = serious alarm mode section (it s used by both the sections); df1 = Start defrost, section 1; df2 = Start defrost, section 2; def = Start defrost (it s used by both the sections); of1 = remote on/ off, section1; of2 = remote on/ off, section 2; off = = remote on/ off (it s used by both the sections); ES = Energy Saving odc1 Compressor and fan status when open door, section 1: no = normal; Fan = Fan OFF; CPr = Compressor OFF; F_C = Compressor and fan OFF. rrd1 Outputs restart after door open alarm, section 1: n = status of outputs according to odc1; Y= outputs restart working XR460C GB r doc XR460C 3/6

54 dixel Installing and Operating Instructions did1 Time interval delay for digital input alarm, section 1:(0 255 min.) With i1f or i2f = EAL1 or bal1 (external alarms), did parameter defines the time delay between the detection and the successive signalling of the alarm. odc2 Compressor status when open door, section 2: no,fan = normal; CPr, F_C = Compressor OFF. rrd2 Outputs restart after door open alarm, section 2: n = status of outputs according to odc2; Y= outputs restart working. did2 Time interval delay for digital input alarm, section 2:(0 255 min.) With i1f or i2f = EAL1 or bal1 (external alarms), did parameter defines the time delay between the detection and the successive signalling of the alarm. ENERGY SAVING SETTING HES1 Temperature increase during the Energy Saving cycle, section 1: ( C / F) sets the increasing value of the set point1 during the Energy Saving cycle. HES2 Temperature increase during the Energy Saving cycle, section 2: ( C / F) sets the increasing value of the set point2 during the Energy Saving cycle. to set current time and weekly holidays Hur Current hour (0 23 h) Min Current minute (0 59min) day Current day (Sun SAt) Hd1 First weekly holiday (Sun nu) Set the first day of the week which follows the holiday times. Hd2 Second weekly holiday (Sun nu) Set the second day of the week which follows the holiday times. Hd3 Third weekly holiday (Sun nu) Set the third day of the week which follows the holiday times. N.B. Hd1,Hd2,Hd3 can be set also as nu value (Not Used). TO SET ENERGY SAVING TIMES ILE Energy Saving cycle start during workdays: (0 23h 50 min.) During the Energy Saving cycle the set point is increased by the value in HES so that the operation set point is SET + HES. dle Energy Saving cycle length during workdays: (0 24h 00 min.) Sets the duration of the Energy Saving cycle on workdays. ISE Energy Saving cycle start on holidays. (0 23h 50 min.) dse Energy Saving cycle length on holidays (0 24h 00 min.) TO SET DEFROST TIMES SECTION 1 L1d1 L1d6 Workday defrost start section 1 (0 23h 50 min.) These parameters set the beginning of the eight programmable defrost cycles during workdays. Ex. When Ld2 = 12.4 the second defrost starts at during workdays. S1d1 S1d6 Holiday defrost start section 1 (0 23h 50 min.) These parameters set the beginning of the eight programmable defrost cycles on holidays. Ex. When Sd2 = 3.4 the second defrost starts at 3.40 on holidays.. N.B. : To disable a defrost cycle set it to nu (not used). Ex. If Ld6=nu ; the sixth defrost cycle is disabled TO SET DEFROST TIMES SECTION 2 L2d1 L2d6 Workday defrost start section 2 (0 23h 50 min.) These parameters set the beginning of the eight programmable defrost cycles during workdays. Ex. When Ld2 = 12.4 the second defrost starts at during workdays. S2d1 S2d6 Holiday defrost start section 2 (0 23h 50 min.) These parameters set the beginning of the eight programmable defrost cycles on holidays. Ex. When Sd2 = 3.4 the second defrost starts at 3.40 on holidays.. N.B. : To disable a defrost cycle set it to nu (not used). Ex. If Ld6=nu ; the sixth defrost cycle is disabled OTHER Adr1 RS485 serial address, section 1 (1 247): Identifies section 1 address when connected to a ModBUS compatible monitoring system. Adr2 RS485 serial address, section 2 (1 247): Identifies section 2 address when connected to a ModBUS compatible monitoring system. If Adr1 = Adr2 dp1 First probe display dp2 Second probe display dp3 Third probe display OnF Stand-by function: n = Stand-by function not enabled; y = Stand-by function enabled (under SET key control). rel Release software: (read only) Software version of the microprocessor. Ptb Parameter table: (read only) it shows the original code of the dixel parameter map. Pr2 Access to the protected parameter list (read only). 9. DIGITAL INPUT The instrument can support up to 2 free contact digital inputs. Both of them can be configured as One is always configured as door switch, the second is programmable in seven different configurations by the I2F parameter. 9.1 DOOR SWITCH INPUT (MP1, MP2, MP) It signals the door status to the controller: MP1: door open for section 1; MP2: door open for section 2; MP door open for both the sections. When the door is open the status of compressor (and fans) depends on the odc1 and odc2 parameters: no = normal (no changes); Fan = Fan OFF (if fan is present); CPr = Compressor OFF; F_C = Compressor and fan OFF. Since the door is opened, after the delay time set through parameter doa, the alarm output is enabled and the display shows the message da. The alarm stops as soon as the external digital input is disabled again. During this time and then for the delay dot after closing the door, the high and low temperature alarms are disabled. EAL: generic alarm it counts for both the sections. As soon as the digital input is activated the unit will wait for did1 time for section 1 and did2 time for section 2 delay before signalling the EAL alarm message. The outputs status don t change. The alarm stops just after the digital input is de-activated. 9.3 CONFIGURABLE INPUT - SERIOUS ALARM MODE (BA1, BA2, BAL) It signals to the controller: ba1: serious alarm section 1; ba2: serious alarm section 2; bal: serious alarm it counts for both the sections. As soon as the digital input is activated the unit will wait for did1 time for section 1 and did2 time for section 2 delay before signalling the bal alarm message. The relay outputs are switched OFF. The alarm will stop as soon as the digital input is de-activated. 9.4 CONFIGURABLE INPUT - START DEFROST (DF1, DF2, DEF) It executes a defrost if there are the right conditions, respectively for: df1: section 1; df2: section 2; def: both the sections. After the defrost is finished, the normal regulation will restart only if the digital input is disabled otherwise the instrument will wait until the Mdf1 and MdF2 safety time is expired. 9.5 CONFIGURABLE INPUT - REMOTE ON/OFF (OF1, OF2, ONF) This function allows to switch ON and OFF a sections of the instrument or the whole instrument according to the following setting:. of1: section 1; of2: section 2; onf: it counts for both the sections. When the digital input is de-activated, the corresponding section restarts working. 9.6 CONFIGURABLE INPUT - ENERGY SAVING (ES) The Energy Saving function allows to change the set point value as the result of the SET1+HES1 for section and SET2 + HES2 fro section 2. This function is enabled until the digital input is activated. 9.7 DIGITAL INPUTS POLARITY The digital inputs polarity depends on I1P and I2P parameters. CL : the digital input is activated by closing the contact. OP : the digital input is activated by opening the contact 10. INSTALLATION AND MOUNTING Instruments shall be mounted on panel, in a 29x71 mm hole, and fixed using the special brackets supplied. To obtain an IP65 protection grade use the front panel rubber gasket (mod. RG-C) as shown in figure. The temperature range allowed for correct operation is 0 60 C. Avoid places subject to strong vibrations, corrosive gases, excessive dirt or humidity. The same recommendations apply to probes. Let air circulate by the cooling holes. 11. ELECTRICAL CONNECTIONS The instrument are provided with screw terminal block to connect cables with a cross section up to 2,5 mm 2. Heat-resistant cables have to be used. Before connecting cables make sure the power supply complies with the instrument s requirements. Separate the probe cables from the power supply cables, from the outputs and the power connections. Do not exceed the maximum current allowed on each relay, in case of heavier loads use a suitable external relay PROBE CONNECTION The probes shall be mounted with the bulb upwards to prevent damages due to casual liquid infiltration. It is recommended to place probe away from air streams to correctly measure the average room temperature. 12. SERIAL LINE The serial output allows the unit to connect to a network line ModBUS-RTU compatible as the dixel monitoring system such as XJ500 or X-XWEB. 9.2 CONFIGURABLE INPUT - GENERIC ALARM (EA1, EA2, EAL) It signals to the controller: EA1: generic alarm section 1; EA2: generic alarm section 2; 13. USE OF THE PROGRAMMING HOT KEY The unit can UPLOAD or DOWNLOAD the parameter list from its own E2 internal memory to the Hot Key and vice-versa XR460C GB r doc XR460C 4/6

55 dixel Installing and Operating Instructions DOWNLOAD (FROM THE HOT KEY TO THE INSTRUMENT) Turn OFF the instrument, insert the Hot Key and then turn the instrument ON. Automatically the parameter list of the Hot Key is downloaded into the memory, the dol message is blinking. After 10 seconds the instrument will restart working with the new parameters. Turn OFF the instrument remove the Hot Key, plug in the TTL serial cable, then turn it ON again. At the end of the data transfer phase the instrument displays the following messages: end for right programming. The instrument starts regularly with the new programming. err for failed programming. In this case turn the unit off and then on if you want to restart the download again or remove the Hot key to abort the operation UPLOAD (FROM THE INSTRUMENT TO THE HOT KEY ) When the unit is ON, insert the Hot key and push è key; the "upl" message appears. Push SET key to start the UPLOAD; the upl message is blinking. Turn OFF the instrument remove the Hot Key, plug in the TTL serial cable, then turn it ON again. At the end of the data transfer phase the instrument displays the following messages: end for right programming. err for failed programming. In this case push SET key if you want to restart the programming again or remove the not programmed Hot key. 14. ALARM SIGNALS Message Cause Outputs P1 Thermostat1 probe failure Alarm output ON; Compressor1 output according to parameters COn1 and COF1 P2 Thermostat2 probe failure Alarm output ON; Compressor2 output according to parameters COn2 and COF2 P3 Evaporator probe failure Alarm output ON; Other outputs unchanged HA High temperature alarm Outputs unchanged LA Low temperature alarm Outputs unchanged EE Some memory problems Alarm output ON; Other outputs OFF da Door switch alarm Outputs unchanged EAL External alarm Outputs unchanged bal Serious external alarm Regulation outputs deactivated POF Keyboard locked Outputs unchanged POn Keyboard unlocked Outputs unchanged rtc Real time clock alarm Alarm output ON; Other outputs unchanged; Defrosts according to par. IdF1 and IdF2 rtf Real time clock failure Alarm output ON; Other outputs unchanged; Defrosts according to par. IdF1 and IdF2 The alarm message is displayed until the alarm condition is recovery. All the alarm messages are showed alternating with the room temperature except for the P1 which is flashing. To reset the EE alarm and restart the normal functioning press any key, the rst message is displayed for about 3s SILENCING BUZZER Once the alarm signal is detected the buzzer can be silenced by pressing any key EE ALARM The dixel instruments are provided with an internal check for the data integrity. Alarm EE flashes when a failure in the memory data occurs. In such cases the alarm output is enabled ALARM RECOVERY Probe alarms : P1 (probe1 faulty), P2 and P3 ; they automatically stop 10s after the probe restarts normal operation. Check connections before replacing the probe. Door switch alarm da stop as soon as the door is closed. External alarms EAL, bal stop as soon as the external digital input is disabled. rtc alarm disappears when the time is set. rtf alarm signals that the internal RTC is faulty. The instrument has to be replace. The alarm message is displayed until the alarm condition is recovery. All the alarm messages are showed alternating with the room temperature except for the P1 which is flashing. 15. TECHNICAL DATA Housing: self extinguishing ABS. Case: frontal 32x74 mm; depth 60mm; Mounting: panel mounting in a 71x29mm panel cut-out Protection: IP20. Frontal protection: IP65 with frontal gasket RG-C (optional). Connections: Screw terminal block 2,5 mm 2 heat-resistant wiring. Power supply: 12Vac/dc (opt.24vac/dc), ±10% Power absorption: 5VA max. Inputs: 3 NTC or PTC probes Relay outputs compressor1: SPST relay 8(3) A, 250Vac or compressor 2: relay SPDT 8(3) A, 250Vac defrost: relay SPDT 8(3) A, 250Vac fans: relay SPST 8(3) A, 250Vac Other output: Alarm buzzer Kind of action: 1B.; Pollution grade: normal; Software class: A. Data storing: on the non-volatile memory (EEPROM). Operating temperature: 0 60 C. Storage temperature: C. Relative humidity: 20 85% (no condensing) Measuring and regulation range: C ( F) Resolution: 0,1 C or 1 C or 1 F (selectable). Accuracy (ambient temp. 25 C): range C ( F): ±0,5 C ±1 digit 16. WIRING CONNECTIONS 8(3)A250 V~ Line Def N.C. Fan Comp XR460C GB r doc XR460C 5/6 Config.2 Max 16A Config.1 Ro om2 8(3)A Def. 8(3)A Room (3)A Line Comp2 N.C. Supply 12V= 17. DEFAULT SETTING VALUES Label Nome Range Default level REGULATION Set1 Set point 1 LS1 US1-5 Pr1 Set2 Set point 2 LS2 US2 3 Pr1 Hy1 Differential 1 0,1 25,5 C / 1 45 F 2.0 Pr1 Hy2 Differential 2 0,1 25,5 C / 1 45 F 2.0 Pr1 REGULATION SECTION 1 LS1 Minimum set point1 limit -50,0 C SET1 / -58 F SET Pr2 US1 Maximum set point1 limit SET1 150 C / SET1 302 F 110 Pr2 ods1 Outputs activation delay of sect. 1 at start up min. 0 Pr2 Ac1 Anti-short cycle delay for compressor min. 1 Pr1 con1 Compressor1 ON time with faulty probe min. 15 Pr2 cof1 Compressor1 OFF time with faulty probe min. 15 Pr2 ch1 Kind of action for section 1 cl / Ht cl Pr2 REGULATION SECTION 2 LS2 Minimum set point2 limit -50,0 C SET2 / -58 F SET Pr2 US2 Maximum set point2 limit SET2 150 C / SET2 302 F 110 Pr2 ods2 Outputs activation delay of sect. 2 at start up min. 0 Pr2 Ac2 Anti-short cycle delay for compressor min. 1 Pr1 con2 Compressor2 ON time with faulty probe min. 15 Pr2 cof2 Compressor2 OFF time with faulty probe min. 15 Pr2 ch2 Kind of action for section 2 cl / Ht cl Pr2 DISPLAY cf Temperature measurement unit C / F C Pr2 res Resolution (for C in de de Pr1 Lod1 Bottom display visualization P1 P4 P1 Pr2 Lod2 Upper display visualization P1 P4 P2 Pr2 DEFROST dfs Relation between defrosts ind; StS; Sti, SE ind Pr2 tdf1 Kind of defrost section 1 re, in re Pr2 EdF1 Defrost mode, section 1 In, Sd,RTC in Pr2 SdF1 Set point for Smart Defrost section C / F 0 Pr2 dte1 End defrost temperature section 1-50,0 110 C/ F 6.0 Pr2 idf1 Interval between defrosts, section ore 6 Pr1 MdF1 Maximum duration of defrost, section min. 20 Pr1 tpf1 Pre-defrost compressor on time 0 30 min. 0 Pr2 Fdt1 Dripping time section min. 0 Pr2 dpo1 Defrost at power on section. 1 n y n Pr2 EdF2 Defrost mode, section 2: In, Sd, RTC in Pr2 idf2 Interval between defrosts, section ore 8 Pr1 MdF2 (Maximum) duration of defrost, section min. 20 Pr1 dfd Display during defrost rt, it, SEt, def, deg it Pr2 dad Defrost display time out min. 20 Pr2 dsd Defrost delay min. 0 Pr2 FANS FnC1 Fans operating mode, section 1 C-n, C-y, O-n, O-y O-n Pr2 Fnd1 Fans delay after defrost, section min. 10 Pr2 FSt1 Fans stop temperature, section 1-50,0 110 C/ F 2.0 Pr2 FAP1 Probe for fans P1 P3 P3 Pr2 ALARM ALc1 Temperature alarms configuration, section 1 re / Ab Ab Pr2 ALu1 Maximum alarm, section 1-50,0 150 C/ F 110 Pr1 ALL1 Minimum alarm, section 1-50,0 150 C/ F Pr1 ALd1 Temperature alarm delay, section min. 15 Pr2 dao1 Delay of temp. alarm at start-up, section h 50 min. 1.3 Pr2 ALc2 Temp. alarms configuration, section 2 re Ab Ab Pr2 ALu2 Maximum alarm, section 2-50,0 150 C/ F 110 Pr1 ALL2 Minimum alarm, section 2-50,0 150 C/ F Pr1 ALd2 Temperature alarm delay, section min. 15 Pr2 dao2 Delay of temp. alarm at start-up, section h 50 min. 1.3 Pr2 AFH Temperature alarm and fan differential 0,1 25,5 C / 1 45 F 1.0 Pr2 EdA Alarm delay at the end of defrost min. 20 Pr2 dot Delay of temp. alarm after closing the door min. 20 Pr2 Hot Key

56 dixel Installing and Operating Instructions Label Nome Range Default level doa Open door alarm delay min., nu 15 Pr2 Pbc Kind of probe PTC/ntc ntc Pr2 ANALOGUE INPUTS ofs1 Thermostat1 probe calibration -12,0 12,0 C / F 0.0 Pr2 ofs2 Thermostat2 probe calibration -12,0 12,0 C / F 0.0 Pr2 ofs3 Evaporator probe calibration -12,0 12,0 C / F 0.0 Pr2 P2P Thermostat2 probe presence n / y Y Pr2 P3P Evaporator probe presence n y Y Pr2 DIGITAL INPUTS i1p Digital input 1 polarity cl OP cl Pr2 i1f Digital input 1 operating mode MP1; MP2, MP; EA1; EA2; EAL; ba1; ba2;, bal; df1; MP1 Pr2 df2; def; of1; of2; off; ES i2p Digital input 2 polarity cl OP cl Pr2 i2f Digital input 2 operating mode MP1; MP2, MP; EA1; EA2; EAL; ba1; ba2;, bal; df1; df2; def; of1; of2; off; ES MP2 Pr2 odc1 Comp. and fan status when open door, sect no, Fan, CPr, F_C 1 FAn Pr2 rrd1 Outputs restart after door open alarm, sect. 1 n, y Y Pr2 did1 Time interval delay for digital input alarm, min. sect Pr2 odc2 Comp. status when open door, section 2: no, Fan, CPr, F_C no Pr2 rrd2 Outputs restart after door open alarm, sect. 2 n, y Y Pr2 did2 Time interval delay for digital input alarm, min. sect. 2 5 Pr2 ENERGY SAVING HES1 Temp. increase during the Energy Saving C / F 0 Pr2 cycle, sect. 1 HES2 Temp. increase during the Energy Saving C / F 0 Pr2 cycle, section 2 time and weekly holidays Hur Current hour Pr2 Min Current minute Pr2 day Current day Sun SAt Sun Pr2 Hd1 First weekly holiday Sun SAt nu nu Pr2 Hd2 Second weekly holiday Sun SAt nu nu Pr2 Hd3 Third weekly holiday Sun SAt nu nu Pr2 ENERGY SAVING TIMES ILE Energy Saving cycle start during workdays 0 23h 50 min. 0 Pr2 dle Energy Saving cycle length during workdays 0 24h 00 min. 0 Pr2 ISE Energy Saving cycle start on holidays 0 23h 50 min. 0 Pr2 dse Energy Saving cycle length on holidays 0 24h 00 min. 0 Pr2 defrost TIMES L1d1 1 st workdays defrost start section h 50 min. - nu 6.0 Pr2 L1d2 2 nd workdays defrost start section h 50 min. - nu 13.0 Pr2 L1d3 3 rd workdays defrost start section h 50 min. - nu 21.0 Pr2 L1d4 4 th workdays defrost start section h 50 min. - nu nu Pr2 L1d5 5 th workdays defrost start section h 50 min. - nu nu Pr2 L1d6 6 th workdays defrost start section h 50 min. - nu nu Pr2 S1d1 1 st holiday defrost start section h 50 min. - nu 6.0 Pr2 S1d2 2 nd holiday defrost start section h 50 min. - nu 13.0 Pr2 S1d3 3 rd holiday defrost start section h 50 min. - nu 21.0 Pr2 S1d4 4 th holiday defrost start section h 50 min. - nu nu Pr2 S1d5 5 th holiday defrost start section h 50 min. - nu nu Pr2 S1d6 6 th holiday defrost start section h 50 min. - nu nu Pr2 L2d1 1 st workdays defrost start section h 50 min. - nu 6.0 Pr2 L2d2 2 nd workdays defrost start section h 50 min. - nu 13.0 Pr2 L2d3 3 rd workdays defrost start section h 50 min. - nu 21.0 Pr2 L2d4 4 th workdays defrost start section h 50 min. - nu nu Pr2 L2d5 5 th workdays defrost start section h 50 min. - nu nu Pr2 L2d6 6 th workdays defrost start section h 50 min. - nu nu Pr2 S2d1 1 st holiday defrost start section h 50 min. - nu 6.0 Pr2 S2d2 2 nd holiday defrost start section h 50 min. - nu 13.0 Pr2 S2d3 3 rd holiday defrost start section h 50 min. - nu 21.0 Pr2 S2d4 4 th holiday defrost start section h 50 min. - nu nu Pr2 S2d5 5 th holiday defrost start section h 50 min. - nu nu Pr2 S2d6 6 th holiday defrost start section h 50 min. - nu nu Pr2 OTHER Adr1 RS485 serial address, section Pr2 Adr2 RS485 serial address, section Pr2 dp1 Thermostat 1 probe value Pr1 dp2 Thermostat 2 probe value Pr1 dp3 Evaporator probe value Pr1 onf Stand-by function y, n Pr2 rel Release software Pr2 Ptb Parameter table Pr2 Pr2 Access to the protected parameter list Pr1 Dixell s.r.l. Z.I. Via dell Industria, Pieve d Alpago (BL) ITALY tel fax dixell@dixell.com XR460C GB r doc XR460C 6/6

57 APPENDIX B SUPERHEAT MANAGEMENT SYSTEM (SMS) OPERATING INSTRUCTIONS 53

58 Superheat Management System Operation Manual Introduction The Superheat Management System (SMS) is a stand alone system designed to regulate the superheat in a refrigerated fixture. It performs the same basic function as a typical mechanical thermostatic expansion valve, however, it automatically adjusts the superheat to pre-determined target values based on the application (i.e. low temperature or medium temperature operation). In addition, the SMS does not require periodic adjustments as it automatically regulates in response to changing ambient conditions, system parameter changes, and case load changes. Components The components of the SMS include: control module, power supply, refrigeration valve with stator, pressure transducer, and temperature sensor. The picture below depicts the SMS components: Pressure Transducer Control Module Stator Refrigeration Valve Temperature Sensor A 24 volt AC transformer is also required to power the system. A 3 wire power cable is used to connect the transformer to the control module. Installation Refrigeration Valve The refrigeration valve should be oriented and installed with the stator slightly higher than the outlet of the refrigeration valve to prevent debris from blocking the orifice and needle assembly. The inlet and outlet of the refrigeration valve are depicted in the picture below. Inlet Outlet 01/15/07 Superheat Management System Operation Manual, Rev Page 2 of 8

59 Superheat Management System Operation Manual When brazing, the refrigeration valve must be wrapped with a wet rag to prevent damage to internal components. There are two refrigeration valves currently in use today, a 3 ton and a 5 ton valve. The valves are rated as a 3 ton or 5 ton based on R22 flow capacity. The two valves can be distinguished by an engraving on the top of the valve. 18B indicates a 3 ton valve and 24B indicates a 5 ton valve. The valves can also be distinguished by rings engraved around the bottom housing of the valve. One ring indicates a 3 ton valve and 2 rings indicate a 5 ton valve as shown below. 2 Rings = 5 Ton 1 Ring = 3 Ton Stator The stator is connected to the refrigeration valve by lining up the tabs on the stator with the notches on the valve and then turning ¼ turn to lock the stator in place. The stator is connected to the control module via the cable provided. The stator cable has been designed to only fit one connector attached to the module. Control Module with Power Cord The control module is an over-molded electronics board with a 4 connector pigtail. The mounting holes in the module are utilized to attach the module to a fixed surface, i.e. tank surface or mounting plate, etc. Each of the connectors on the 4 connector pigtail are unique and should only be plugged into its matching connector from the temperature sensor, pressure transducer, power input, and stator. No attempts should be made to jump or cross wire the connectors. These actions could lead to damage to the control module or components. The power cord is connected to the control module via the matching connector. The pigtail end of the power cord is hardwired to the transformer. The power cord should not be connected directly to the pressure transducer as damage to the transducer could occur. 01/15/07 Superheat Management System Operation Manual, Rev Page 3 of 8

60 Superheat Management System Operation Manual Each connector should be fastened together until a slight click is heard or visually checked to ensure the locking tab on the side of the connector is engaged. Pressure Transducer The pressure transducer is connected to the control module via a snap-in cable. The transducer cable should never be plugged directly into the power supply as damage to the transducer could result. To attach the transducer to the schraeder fitting on the suction line, clean the flare fitting mating surface with a scotch bright pad prior to transducer installation. Apply a thin layer of oil around the mating surface and install the transducer. The transducer must be torqued to 120 in-lbs. The transducer is sensitive to heat and should be removed if brazing or soldering is being done to the suction line within 2 feet of the transducer. The transducer can be left installed while a vacuum is applied to the system. Temperature Sensor Transformer The temperature sensor is connected to the control module via a connector at the end of the sensor wires. The temperature sensor must be attached to the suction line in the same fashion as a capillary tube utilized on a mechanical valve. The sensor should be firmly attached longitudinally along the suction line in the 4 or 8 o clock position for 7/8 lines or larger and on the top portion of the pipe between 3 and 9 o clock for pipe sizes below 7/8. The temperature sensor must be removed if brazing or soldering is being done to the suction line within 2 feet of the sensor. The required transformer is a 24VAC transformer with a minimum rating of 20 VA. The transformer must also be grounded. The ground wire must be utilized with the line voltage. The ground wire leading to the control module must be utilized. A maximum transformer rating of 50 VA can be utilized to energize the SMS. Operation, Error Codes & Failsafe Operation The SMS is equipped with 3 LED lights that are capable of steady-on or blinking operation. Upon voltage being applied to the system, the control module will begin its startup and verify LED operation by cycling through all the lights. The amber light will then turn on indicating the module is working correctly and all the sensors have been checked. If a sensor failure is found a corresponding error code will be displayed via the lights. The error codes are contained below. 01/15/07 Superheat Management System Operation Manual, Rev Page 4 of 8

61 Superheat Management System Operation Manual Lights Display Error Description Superheat within target range Controller functioning, superheat not within target range Superheat too high for over 2 hours Superheat too low for over 2 hours B B Valve Connection Problem B Transducer Connection Problem B Temperature Probe - Connection Problem Solid B Blinking If a sensor failure is detected, the first response should be to check all connections and wiring points and to visually inspect sensors for cracks in the wiring, excessive heat, etc. If the problem still persists, the sensor should be replaced and the power cycled to reset the control module. If no sensor failures are indicated, the module will open the refrigeration valve and attempt to reach the superheat target. Upon reaching the target value, the amber light will be turned off and the green light displayed to indicate proper superheat has been achieved. If the superheat target can not be achieved, the module will indicate the error. If an error code is displayed, the control module will default to a safe mode based on previous case performance. The system will continue to operate in this safe mode until the condition is corrected and then will return to normal operation. In the event of errors related to the superheat target not being achieved (not sensor failures), the system will default to its safe mode and attempt to reach its target superheat every 45 minutes. If the superheat is not reached within 15 minutes, the system will default back to safe mode. In some rare circumstances, 15 minutes might not be long enough for the system to reach its target superheat. It may be necessary to cycle the power to reset the system immediately and provide an additional 15 minutes to reach superheat. It may be necessary to cycle the power to the unit several times to achieve proper performance if the system has been turned on without refrigeration, etc. If the superheat can not be achieved and accurately maintained, the SMS will continue to default into its safe mode. Further trouble shooting should be done to ensure a full column of liquid refrigerant is at the refrigeration valve, the system is performing adequately, and all SMS sensors are attached correctly and reading accurately. 01/15/07 Superheat Management System Operation Manual, Rev Page 5 of 8

62 Superheat Management System Operation Manual The safe mode is determined by historical data collected by the SMS during normal case operation. The average valve capacity over a 24 hour period is collected and is stored under a signature value for the case. This value is specific to the case and application. When the SMS operates in a safe mode, the signature value is utilized to provide a safe level of refrigeration until maintenance can be completed. It is important to note that a safe level of refrigeration is based on historical performance of the case and that maintenance should be completed as soon as possible. Communication The SMS can communicate externally via infrared (IR) technology. The control module has an onboard emitter and receiver located as in the picture below. IR Device Line of Sight IR Components An IR device, as shown above, is required to connect the control module with a PC through a USB port. IR requires the module and IR device to be in line of sight of one another and from 3 inches to 2 feet apart. The picture above also demonstrates the correct orientation of the components for communication. The SMS software must be loaded on the PC and the drivers for the IR device installed. Refrigerant Selection The SMS is able to handle a wide variety of refrigerants and has the capability of selecting or changing the refrigerant through an IR device and a PC. The software must be obtained through Hill PHOENIX and expires on a semi-annual basis to ensure use by only authorized personnel. Upon installing and launching the SMS software, a Quick Start interface screen will appear as shown below on the left. 01/15/07 Superheat Management System Operation Manual, Rev Page 6 of 8

63 Superheat Management System Operation Manual The circle next to the desired refrigerant should be selected and then the Send Settings to Controller button should be pressed. The software will monitor the change in parameters and display if the change was successful or not as shown above in the picture on the right. If the settings were not successfully sent, the connection to the IR device should be checked and the orientation of the IR device and control module should be examined to ensure there is nothing blocking the line of sight between the IR device and the module. The signature value of the controller can also be reset by checking the box next to Clear valve signature value and then selecting the desired refrigerant and then pushing the Send Settings to Controller box. It may be necessary to reset this value if switching a controller to a different case or if a refrigerant change is made, etc. Diagnostics/View Status The SMS is also capable of displaying in-depth information pertaining to the performance of the system. Normal operation does not warrant the use of these functions but could aid in diagnosing system performance. To utilize this functionality, the IR device is used as detailed above in the refrigerant selection. When the software is initialized and the Quick Start screen is displayed, the View Status heading (circled in red on the figure below) at the top of the SMS screen must be selected. 01/15/07 Superheat Management System Operation Manual, Rev Page 7 of 8

64 Superheat Management System Operation Manual When the status screen is displayed, the Connect to Controller button should be pressed. The buttons marked Rx and Tx should blink from green to red and a status summary will be displayed at the bottom of the SMS screen. The software should indicate that the connection was successful and the current settings and the readings of the SMS sensors will be displayed in real time. A graph will record the readings as measured by the SMS and display them. The control module does not store data so data can not be pulled from the module. The graph can be started and then viewed later to look at system performance. Values to be displayed on the graph are listed on the right of the graph. The checked boxes indicate the value is to be displayed. The following is a list of displayed readings and parameters: Suction Pressure Displays the suction pressure as recorded by the SMS pressure transducer. Coil Inlet Temp. Displays the saturated suction temperature converted from the pressure recorded by the SMS transducer and based on the refrigerant selected. Superheat Displays the calculated superheat based on the SMS temperature sensor and the coil inlet temperature. Coil Outlet Temp. Displays the coil outlet temperature as recorded by the SMS temperature sensor. Refrigeration Valve Capacity Displays the percentage of full capacity the valve is currently operating at. Refrigerant Displays refrigerant selected in the software. System Temp Not used at this time. Questions If there are any questions or concerns, please contact Hill PHOENIX at (804) /15/07 Superheat Management System Operation Manual, Rev Page 8 of 8

65 APPENDIX C STEP MOTOR EXPANSION VALVES INSTALLTION INSTRUCTIONS 61

66 Step Motor Expansion Valves Installation Instructions Operation The ESX valves are step motor operated electric expansion valves. Step motors are designed to provide discrete segments of angular motion, or rotation, in response to an electronically generated signal. The advantages of step motors in valve applications are high resolution, repeatability and reliability with low hysteresis. Feedback loops are not required, simplifying controller design and circuitry. The step motor used in the ESX valve is a 12-volt DC, four phase, unipolar, permanent magnet rotor type. Each step creates a 3.75 rotation of the rotor. Final rotation is converted to linear motion by the use of a threaded shaft. Forward motion of the motor extends the pin, which moves the valve to the closed position. Backward rotation of the motor retracts the pin, modulating the valve in the opening direction. Full forward or backward travel is limited by the valve seat in the closed position or an upper stop in the open direction. A slight clicking sound may be heard at either of these two positions and does no harm to the valve or drive mechanism. The valve will operate only when connected to a properly designed controller. The controller must supply the necessary square wave step signal at 12-volts DC and 30 to 83.5 PPS for the valve to control properly. Various Sporlan and third party controllers are available for use with the valve. Questions of suitability of a specific controller should be directed to Sporlan, Attention: Mechatronics Product Group. Control algorithms for the valve include a initialization sequence that will first over-drive the valve in the closing direction. This is to assure that the valve is completely shut and to establish the zero open position. The controller then keeps track of the valve s position for normal operation. During this initialization phase, a light clicking sound may be heard, which will serve as proof of the valves operation and closure. The valves have metallic seating for tight shutoff and uniquely characterized pin and port combinations for exceptional control of refrigerant flow. The seats require no service and are not replaceable. The stator may be easily replaced without removing the valve body from the system. Installation The ESX valves are electronically controlled Step Motor Expansion Valves, and are installed before the distributor and evaporator just as one would install a Thermostatic Expansion Valve. Location should be planned to provide serviceability and to allow controller installation within the maximum cable length of forty feet. The valve may be installed in the refrigerated space and may be mounted in any position except with the motor housing below the liquid line. Cable routing should avoid any sharp edges or other sources of potential physical damage such as defrost heaters and fan blades. For neatness and protection, the cable may be fastened to the suction or liquid lines with nylon wire ties.