SWEATMISER ANTI-SWEAT HEATER CONTROLLER UPGRADE MANUAL Table of Contents Upgrade Kit & Record Store Information...2-3 Circuits... 20-22 Check for Sweating... 4 Record Amperage...23 Troubleshoot & Record... 5 Check Wiring...24 Upgrade...6-16 Calibrate & Record SweatMiser... 25-26 Relays... 16-19 Final site check... 27-30 To ensure proper functionality and optimum performance, it is STRONGLY recommended that Hillphoenix specialty cases be installed/serviced by qualified technicians who have experience working with commercial refrigerated display merchandisers and storage cabinets. For a list of Hillphoenix-authorized installation/service contractors, please visit our Web site at www.hillphoenix.com. 09/14
UPGRADE KIT Upgrade kit contains the following items: 1. SweatMiser Manual (5.0 Version or Later) 2. Circuit Summary Sticker 3. Circuit Summary Plastic Sleeve 4. Orange SweatMiser Service Sticker 5. Panel Schedule 6. 1 New Fan 7. 1 New 6.0 or 6.1 Version Circuit Board 8. 1 New Humidity Sensor in Box 9. 3 Zip Tie Sticky Tabs 10. 3 Zip Ties 11. 1 Bundle of 5 Pre-Terminated White Transformer Wires 12. Relays are carried on service vans and replaced as needed Upgrade Objective: The objective of a SweatMiser upgrade is to make an older system like new. Parts that can be re-used are kept in place while obsolete or faulty parts are replaced. The SweatMiser should look like a brand new system after the upgrade is complete. 2
RECORD STORE INFORMATION Record Customer Name, Store #, Install Date and Tech name on the SweatMiser Install Form. 3
CHECK FOR SWEATING Before installation begins, walk each aisle and review EVERY glass door and frame. Look for ice, sweat and moisture build-up that exist before the SweatMiser is installed. If any problem is present, document on the installation form and review the problem(s) with the store manager. The store manager should sign the problem description to acknowledge any prior issue. Note: Every frame should be physically touched to ensure that all pre-existing conditions are identified. Sweating present in the above picture. 4
TROUBLESHOOT & RECORD If any pre-existing conditions are present, determine the cause of sweating and record on the Install Form Voltage present at heaters. Low frame temperature. Low frame temperature caused by damaged seal allowing cold air to pass by the frame. Record the pre-existing conditions. 5
LOCATE SWEATMISER Locate existing SweatMiser these are commonly in the rack house or electrical room. Expect to see an older circuit board and a dirty environment. 6
CLEAN SWEATMISER Clean the SweatMiser compressed air works best and should be used first. Be sure to wear a face mask as debris will be in the air for a few minutes after cleaning the SweatMiser. Afterwards, a rag and liquid cleaner helps finish the job. 7
OBSOLETE PARTS The following parts will be replaced: Circuit board Humidity sensor Fan Wires from the transformer to circuit board Faulty relays Important: The customer s heaters are off when the SweatMiser is off so perform work quickly and safely. The freezer doors could severely sweat after only an hour of downtime and that could create a slipping hazard inside the store. Pull the main fuse in the SweatMiser before removing any parts. 8
REPLACE HUMIDITY SENSOR Replace obsolete humidity sensor with the new SweatMiser humidity sensor. An obsolete SweatMiser humidity sensor will be labeled ASP or General Electric. 9
REMOVE CIRCUIT BOARD Remove the Circuit board. The transformer wires can be removed with the board since they are also being replaced. 10
REMOVE FAN & CLEAN Remove the fan and clean under the fan/circuit board. After unbolting the fan, remove wires from the main terminal block so fan can be completely removed. The metal fan guards will be reused so clean them before reinstallation. Clean area under circuit board and around fan mount. 11
INSTALL FAN & CONTROL BOARD Install fan first reuse fan guards and hardware. Reconnect fan power to the main terminal block. Reuse 3 circuit board screws to secure the new circuit board to the back panel. The Circuit board will not have a screw on the bottom right corner. 12
WIRE TRANSFORMER Use the 5 new white transformer wires to connect the transformer to the circuit board. Match numbers from the transformer to the circuit board. See numbers on transformer. Female connector may need to be tightened to achieve a secure connection. Bottom left corner of circuit board, see numbers to the left of each terminal. 13
WIRE CIRCUIT BOARD Wire the daisy chains from the relays to the circuit board. Wire the humidity sensor wires to the top right of the circuit board. Expect to see different wire color combinations. Replicate how the sensor was previously wired but also verify that the wiring is correct. The SweatMiser can be powered back on after all wires are terminated. 14
ORGANIZE WIRING Use the zip ties and zip tie sticky tabs to organize wiring inside of the SweatMiser. CHECK TERMINATIONS Check previous terminations for bare wires or other wiring errors. Correct any issues found. Ensure all terminations are secure. The box in the top right can be marked complete once all terminations have been checked. 15
CHECK RELAYS Verify relays are working in 'Bypass' mode, relays should be closed and each connected circuit should be pulling amps. If a load is not on the circuit, check for continuity. Verify relays are working in 'Pulse' mode, the relays should be pulsing open and closed so the amps on the circuit will oscillate as the relay is pulsed. Verify relays are working in 'Load Shed' mode, the relays should all be open and no amps should be passing through the SweatMiser. There should be no continuity across a relay. Troubleshoot any faulty relays to determine failure. ALL relays should be verified even if they are not connected to a circuit. The customer may need the relays for a future project. Hold the button on the left and press the button on the right to change modes. Picture on the left shows relay closed in Bypass mode and pulling amps. Picture on the right shows relay opened in Load Shed mode with no amps being drawn. 16
TROUBLESHOOT RELAYS On a relay that does not have amps passing through, flip the respective breaker off and check for continuity or low resistance to verify that a relay is closed. On a relay that always has amps passing through, put the SweatMiser in Load Shed, flip the respective breaker off and then check for continuity. The relay should not have continuity at this time. The relays are normally open but have also failed in the closed position. In the event that a relay is faulty, remove and replace the relay. The above relay always pulled amps and had continuity even in Load Shed. The relay was determined to have failed closed and was replaced. 17
REPLACE RELAYS In the event that a relay is faulty, remove and replace the faulty relay. Be sure to flip the respective breaker off before performing any work and also use thermal paste for the reinstallation. Retest new relays to ensure proper operation. The relay check boxes can be marked complete once all relays have been verified. 18
RECORD REPLACED PARTS Record the number of relays, fans and transformers replaced. The original fan will always be replaced but the relays and transformers will only be replaced if a faulty part is found. 19
CHECK EXISTING CIRCUITS Pull the fuse on the SweatMiser and go inside the store and ensure that the HEATERS are OFF, the freezer LIGHTS are ON and the FANS are ON. You must open a door in every case and listen for the fans. If a heater is still on, flip breakers off until you find the circuit. If you find a fan or light off, power the SweatMiser back on and put it in bypass mode. Then flip the breakers routed through the SweatMiser off until you find the breaker that contains the lights or fan. Add/remove circuits from the SweatMiser as needed to get all the low temperature door circuits in the SweatMiser and all fans/light out of the SweatMiser. Once this step is completed, close the fuse on the unit and change the mode of the SweatMiser to Pulse. Door is open to ensure the fans and lights are on; voltage detector is on door to ensure heaters are off during this step. 20
CHECK CIRCUIT SUMMARY Ensure the SweatMiser is on and in Bypass mode.check the existing circuit summary chart for accuracy. Put a current clamp on a circuit, flip the circuit s respective breaker and ensure the circuit is not pulling an power. Make note of any corrections to the circuit summary chart. 21
NEW CIRCUIT SUMMARY Fill out a new circuit summary chart and attach the new summary in the plastic sleeve to the inside of the SweatMiser. Record the circuit data in the Install form. 22
RECORD AMPERAGE With the SweatMiser still in 'Bypass' mode, measure and record the amps for each channel in the SweatMiser Install Form. View of circuit board in 'Bypass' mode. 23
DOUBLE CHECK YOUR WIRING BEFORE FINISH Pull the fuse on the SweatMiser and go inside the store and ensure that the HEATERS are OFF, the freezer LIGHTS are ON and the FANS are ON. You must open a door in every case and listen for the fans. Once this step is completed, close the fuse on the unit and change the mode of the SweatMiser to Pulse. The 'Load Shed' boxes can be marked complete once all cases have been checked. Door is open to ensure the fans and lights are on; voltage detector is on door to ensure heaters are off during this step. 24
CALIBRATE SWEATMISER Take the Extech Psychrometer inside the store and measure humidity and temperature by the humidity sensor previously installed. Allow at least 5 minutes to pass before making note of the values; slowly move the meter from side to side so air can pass over the tip of the meter. Always be conservative on the humidity; chose the higher percentage if the humidity reading is fluctuating. Now calibrate the SweatMiser using the values found in the store. Change the Store Temp and Store Humidity reading on the SweatMiser to match the readings from the Extech meter. Use the Down bottom on the right to change from Mode to Store Temp. While holding the Select button, press Up or Down until the desired temperature is showing. Relative humidity = 47% Temperature = 73 F 25
RECORD CALIBRATION VALUES With the SweatMiser in 'Pulse' mode, record the following values on the Install form: Calibration Time Relative Humidity (%) Dew Point ( F) Percent Savings ( F) Temp ( F) %SV is percent savings and it can be found on the screen that displays the operation mode. The SweatMiser achieved 10% savings at the time of this calibration. The percent savings changes as the store s dewpoint changes. 26
SERVICE STICKER Apply the orange service sticker to the outside of the SweatMiser as shown in the picture on the right. SWEATMISER MANUAL Place the SweatMiser manual in an appropriate location inside the SweatMiser. Rolled up and above the panduit works well as shown on the bottom right. 27
EMPTY BOX The box should be empty at the end of an upgrade. SITE CLEAN-UP Don t leave your junk on the job site! Clean it up and don t use the customer s trash can! Mark those steps as complete. Monitoring Cable Spooled in EMS will be custom depending on customer, check with your Project Manager for details. 28
VERIFY SET POINTS Verify default set points are in place. CHECK INSTALL FORM Ensure that the Install Form is complete and ALL lines are filled out, if the value is zero, put zero. The final requirement is the Store Manager Signature & Stamp. 29
OBTAIN STORE STAMP Explain the work performed and obtain store stamp and signature from a manager. Above is an example of a store stamp and signature LEAVE JOB SITE Ensure the following steps are complete before leaving: All tools collected and in van Job site clean SweatMiser powered on and in 'Pulse' mode SweatMiser and anti-sweat circuit panel doors closed Rack house door locked upon leaving (if applicable) 30
Phone: 706-743-3352 Fax: 706-740-3049 Email: AMS@hillphoenix.com 2016 Gees Mill Road, Conyers, GA 30013 All Rights Reserved. The information in this manual has been carefully reviewed and is believed to be accurate, however Hillphoenix assumes no responsibility for any errors contained herein. Hillphoenix may not be held liablefor any damages (direct or indirect) resulting from any error of omission in this manual. Hillphoenix reserves the right to make changes to this manual and the products described herein at any time without notice. 00000