Ultra - Temp Installation and Maintenance Manual IOM 101.2
Ultra - Temp Installation and Maintenance Manual IOM 101.2
Ultra - Temp Installation and Maintenance Manual IOM 101.2
INSTALLATION AND
MAINTENANCE
MANUAL
IOM 101.2
August, 2003
Table of Contents
Inspection 2
General Safety Information 2
Installation
Piping Considerations 2-4
Expansion Valve Selection And Installation 5
Unit Cooler (Internal) Wiring Diagrams 6-8
Typical Field Wiring — Sequence of Operations
General Information 9
Air Defrost 9
Hot Gas Defrost 10
Electric Defrost 11-13
Start-Up Procedure 14
Maintenance 14
Troubleshooting Chart 15
Replacement Parts and Nomenclature 16
221 S. Berry St., Brea, CA 92821 • Tel: (714) 529-1935 • Fax: (714) 529-7203
Visit us on the Web: www.russellcoil.com
INSPECTION
Equipment listed on the bill of lading but not received, Also, check unit nameplates to make sure the voltage
along with any equipment damaged in transit, should is correct before installing.
be reported immediately to the carrier and a claim filed.
INSTALLATION
Our unit coolers are designed to draw air in through Drain Line
the coil and discharge it through the fans. For most The condensate drain line should be at least 3/4” I.P.S.
efficient operation, units should be located so that air and should be installed with a minimum of 1/2” of slope
from an open door cannot be drawn directly into the coil. per foot of horizontal run. Keep the length of drain
line within the refrigerated space as short as possible.
FIGURE 1 Provide a trap in the line outside of the refrigerated
space. On freezer units, the drain line within the
A
refrigerated space must be wrapped with heat tape and
insulated to prevent water from freezing in the
line during the defrost cycle.
A A
Refrigerant Piping
AIR
Install all refrigeration components in accordance with
FLOW
accepted piping practices. Liquid and suction lines
should be sized according to ASHRAE recommend-
ations for the intended conditions of operation.
A = 2.0 Ft. for U•U1-118 to 2-236; U•M1-164 to 2-329
U•L1-125 to 2-304; UAH1-182 to 2-365 All horizontal suction lines should be sloped toward
A = 3.0 Ft. for U•U3-474 to 6-1620; U•L2-361 to 6-2070 the compressor at the rate of 1/8” per foot for good
U•M2-390 to 6-2480; UAH2-433 to 6-2730 oil return. Vertical suction risers of more than five feet
should be trapped with a P-Trap at the bottom.
Figure 1 shows the air flow direction and recommended
minimum clearances to walls or other obstructions.
Hot Gas Piping
All units, except single-fan type, are shipped upright as Hot Gas defrost systems can be described as either
in the mounting position. Remove the top and sides of Re-Evap Type “H” (three-pipe) or Reverse Cycle
the crate from the unit leaving the unit sitting on the Type “G” (two-pipe) types. Figures 2 and 3 represent
shipping skid. Using the fastener slot/holes in the unit typical piping arrangements for hot gas defrost units.
mounting hangers as a guide, locate the mounting
fasteners in the ceiling of the refrigerated room. 5/16” Hot Gas Defrost units may be ordered so that they are
threaded rod is sufficient. capable of operating on either of the two systems
mentioned above. All units are equipped with a hot gas
Single-fan units can be lifted into place by hand. All drain pan loop.
other units can be lifted into place by sliding the forks
of a fork lift under the skid to avoid damage to the Re-Evap System — Uses three pipes as shown in
drain pan. Figure 2 - one for the liquid, one for the suction and
one for the hot gas. In addition, a heat exchanger/re-
IMPORTANT: Hot Gas units must be mounted using evaporator is used at the suction line outlet of the
the galvanized steel channel “Pitching Spacer” (one evaporator. The hot gas is taken from the discharge
provided per unit) to allow proper drainage of line between the compressor and the condenser,
condensate coming off the evaporator coil. The unit through a hot gas solenoid valve, then to the
may be pitched toward either end since two drain evaporator drain pan loop. From there it enters the
connections are provided. The unused connection distributor at the side inlet then goes through the
should be capped off with the plastic cap supplied. See coil in the same direction as the normal refrigeration
the instructions attached to the “Pitching Spacer” channel. flow. The condensed refrigerant is trapped in the
2
Table 1: Liquid Line Selection Table 2: Suction Line Selection
Line Equiv. Unit Cooler Capacity Line Equiv. Unit Cooler Capacity — BTUH
Size Lgth. BTUH Size Lgth. R-22 R-404A
(O.D.) (Ft.) R-22 R-404A (O.D.) (Ft.) Suction Temperature °F Suction Temperature °F
-20 0 20 -40 -20 0 20
25 48,000 25,000 25 7,800 12,000 18,000 8,500 8,500 12,000 16,000
50 30,500 17,000 50 3,575 5,500 12,000 4,000 6,000 9,000 12,000
3/8 5/8
100 18,000 10,000 100 2,600 4,000 9,000 3,000 3,000 6,000 7,500
150 15,200 7,000 150 2,275 3,500 6,500 1,000 2,000 3,000 5,000
25 90,350 65,000 25 16,835 25,900 48,000 19,500 17,000 28,000 35,000
50 61,450 42,000 50 11,700 18,000 30,200 11,000 15,000 20,000 28,000
1/2 7/8
100 42,100 35,000 100 9,880 15,200 24,100 9,500 1,000 15,000 19,500
150 33,650 30,000 150 7,865 12,100 18,200 8,000 6,000 1,100 14,000
25 165,100 125,000 25 44,700 68,150 103,650 45,000 52,000 73,000 80,000
50 112,350 85,000 50 30,500 46,500 70,750 21,000 38,000 49,000 63,000
5/8 1 1/8
100 76,800 68,000 100 21,100 32,100 48,450 18,000 20,000 33,000 40,000
150 61,450 59,000 150 16,750 25,400 38,820 14,000 15,000 25,000 29,500
25 438,000 310,000 25 77,350 118,550 180,750 67,000 75,000 110,000 130,000
50 299,150 215,000 50 53,000 81,000 124,120 55,000 60,000 85,000 98,000
7/8 1 3/8
100 204,100 165,000 100 36,200 55,120 84,100 45,000 37,000 55,000 70,000
150 163,100 125,000 150 29,500 44,350 67,150 29,000 33,000 42,000 55,000
25 750,000 625,000 25 123,120 186,100 264,100 110,000 125,000 160,000 250,000
50 600,500 440,000 50 84,150 127,000 180,100 85,000 95,000 125,000 160,000
1 1/8 1 5/8
100 180,000 275,000 100 57,400 87,100 123,200 72,000 77,000 84,000 93,000
150 360,500 240,000 150 46,120 69,500 98,750 64,000 71,000 78,000 87,000
25 257,100 391,100 597,000 220,000 250,000 325,000 450,000
50 175,000 267,100 408,100 125,000 175,000 230,000 335,000
2 1/8
100 120,100 182,100 278,120 110,000 125,000 175,000 235,000
150 96,150 146,100 223,110 88,000 96,000 135,000 180,000
25 452,100 683,100 1,040,100 350,000 475,000 750,000 1,087,500
50 308,100 467,100 710,100 350,000 350,000 575,000 835,000
2 5/8
100 210,000 318,100 484,100 200,000 240,000 425,000 300,000
150 168,120 254,500 387,100 140,000 175,000 220,000 240,000
25 698,100 1,120,100 1,660,100 550,000 750,000 975,000 1,490,000
50 477,100 762,100 1,351,500 320,000 600,000 785,000 1,140,000
3 1/8
100 325,120 520,100 774,120 250,000 300,000 575,000 851,000
150 260,100 416,500 620,150 210,000 225,000 350,000 475,000
re-evaporator as it leaves the coil, there to be A hot gas line is run from the discharge line of the
metered as a heavy vapor into suction line flow compressor close to the junction of the main suction
back to the compressor. line with the three individual suction lines. There the
hot gas line branches into three hot gas lines. Each of
Reverse Cycle - Is a technique in which the hot gas these three lines has a hot gas solenoid valve; the
flows backwards (i.e. opposite to the normal refrig- leaving side of each solenoid valve is teed into one of
erating flow) through the evaporator. Systems employing the three branch suction lines. Each suction line has a
the reverse cycle principle are divided into two types: suction-stop valve installed between the main suction
Alternating Evaporator and Heat Pump systems. line and the hot gas tee-in to keep hot gas from
entering the main suction line to the compressor. In
Alternating Evaporator System — This is the system this way, each evaporator coil has a source for hot
commonly referred to as “Reverse Cycle Defrost”. It gas, controlled by its own defrost solenoid valve. A
must have multiple evaporator coils on the same modular multi-circuit defrost timer is normally employed
system to operate. to synchronize the three defrosts.
Evaporator coils are defrosted in groups of one or The timer initiates defrost on a given coil, opening its
more coils per group. 65% to 75% of the coils will hot gas solenoid (and closing its suction-stop valve),
continue to refrigerate while 25% to 35% are on defrost. allowing hot gas to flow backwards through the
The defrosting coils produce liquid refrigerant which suction line towards the coil. Utilizing the piping
is used to operate the coils which are still refrigerating. shown in Figure 3, the hot gas goes first to the drain
pan loop of the unit, then into the suction inlet of the
The simplest design is a system with one condensing coil. As it leaves the coil, the condensed liquid flows
unit and three evaporator coils. One coil will defrost at through a bypass line around the expansion valve into
a time, while the other two continue to refrigerate. the liquid line. It flows backwards through the branch
liquid line until it reaches the main liquid line, where
3
it is re-introduced into the refrigerating part of the system. Table 3: Hot Gas Defrost Line Selection
The main liquid line is made to operate at a lower Total Maximum Evaporator Capacity - Tons
pressure during defrost so that it will accept the liquid
from the defrosting coil. Line R-22 R-404A
Size Short Long Short Long
A much larger Alternating Evaporator system will still 1/2 1.5 1.0 1.3 0.8
operate in much the same way. Such a system might
have a larger compressor or a parallel compressor rack 5/8 2.8 2.0 2.5 1.5
operating with many more evaporator coils than 7/8 7.0 5.0 6.0 3.5
described above. Now there will be a groups of coils 1 1/8 16.0 11.0 13.0 9.0
defrosting at once instead of just one. It is important,
however, that no one defrost group is larger in refrig-
1 3/8 23.0 17.0 21.0 15.0
erating capacity than 25% to 35% of the total. A given 1 5/8 40.0 27.0 30.0 23.0
hot gas line and solenoid valve will now service its 2 1/8 76.0 52.0 66.0 44.0
evaporator group instead of only one evaporator.
2 5/8 145.0 100.0 130.0 80.0
Heat Pump System — It is not recommended for NOTE: Short - Runs under 50 equivalent feet
refrigeration defrost purposes. Long - Runs over 50 equivalent feet
TXV TXV
LIQUID LIQUID
LINE LINE
CHECK VALVE
SUPPLIED
CHECK VALVE
BY OTHERS
CHECK VALVE
BY OTHERS
HOT GAS
HEAT EXCHANGER - ACCUMULATOR LIQUID LINE
SUCTION LINE
LIQUID LINE
TABLE 5:
Expansion valve selection @ +20°F Suction Temperature
BTU/HR R-22 R-404A, 507
Model
@ 10° TD Sprolan Alco Sporlan Alco
Medium Temperature Units — U•M
U*M 1-164 16400 SB FVE-A -C H FESC -1-1/2-H C SB FSE-A -C H FESC -1-SC
U*M 1-209 20900 SB FVE-A -C H FESC -1-1/2-H C SB FSE-B -C H FESC -1-1/4-SC
U*M 2-270 27000 SB FVE-B -C H FESC -2-H C SB FSE-B -C H FESC -1-1/2-SC
U*M 2-329 32900 SB FVE-B -C H FESC -2-1/2-H C SB FSE-B -C H FESC -2-SC
U*M 2-390 39000 SB FVE-B -C H FESC -2-1/2-H C SB FSE-C -C H FESC -3-1/2-SC
U*M 2-441 44100 SB FVE-B -C H FESC -3-H C SB FSE-C -C H FESC -3-1/2-SC
U*M 3-583 58300 SB FVE-C -C H FESC -5-1/2-H C EB SSE-6-C H FESC -3-1/2-SC
U*M 3-662 66200 SB FVE-C -C H FESC -5-1/2-H C EB SSE-6-C H FESC -5-SC
U*M 4-780 78000 SB FVE-C -C H FESC -5-1/2-H C EB SSE-6-C H FESC -5-SC
U*M 4-882 88200 EB SVE-8-C H FESC -5-1/2-H C EB SSE-6-C H FESC -7-SC
U*M 4-1100 110000 EB SVE-8-C H FESC -8-H C EB SSE-7-1/2-C H FESC -7-SC
U*M 4-1320 132000 EB SVE-8-C H FESC -10-H C EB SSE-10-C H FESC -10-SC
U*M 4-1656 165600 EB SVE-11-C H FESC -15-H C EB SSE-13-C H FESC -10-SC
U*M 5-2065 206500 EB SVE-11-C H FESC -15-H C EB SSE-13-C H FESC -13-SC
U*M 6-2480 248000 EB SVE-15-C H FESC -15-H C O SE-21-C TR A E-20-SC
High Temperature Units — UAH
UA H 1-182 18200 SB FVE-A -C H FESC -1-1/2-H C SB FSE-A -C H FESC -1-1/4-SC
UA H 1-232 23200 SB FVE-A -C H FESC -1-1/2-H C SB FSE-B -C H FESC -1-1/2-SC
UA H 2-300 30000 SB FVE-B -C H FESC -2-H C SB FSE-B -C H FESC -2-SC
UA H 2-365 36500 SB FVE-B -C H FESC -2-1/2-H C SB FSE-B -C H FESC -3-1/2-SC
UA H 2-433 43300 SB FVE-B -C H FESC -3-H C SB FSE-C -C H FESC -3-1/2-SC
UA H 2-490 49000 SB FVE-C -C H FESC -3-H C SB FSE-C -C H FESC -3-1/2-SC
UA H 3-530 53000 SB FVE-C -C H FESC -3-H C EB SSE-6-C H FESC -3-1/2-SC
UA H 3-648 64800 SB FVE-C -C H FESC -5-1/2-H C EB SSE-6-C H FESC -5-SC
UA H 3-736 73600 SB FVE-C -C H FESC -5-1/2-H C EB SSE-6-C H FESC -5-SC
UA H 4-866 86600 EB SVE-8-C H FESC -5-1/2-H C EB SSE-6-C H FESC -5-SC
UA H 4-980 98000 EB SVE-8-C H FESC -8-H C EB SSE-7-1/2-C H FESC -7-SC
UA H 4-1100 110000 EB SVE-8-C H FESC -8-H C EB SSE-7-1/2-C H FESC -7-SC
UA H 4-1452 145200 EB SVE-11-C H FESC -10-H C EB SSE-10-C H FESC -10-SC
UA H 4-1821 182100 EB SVE-11-C H FESC -15-H C EB SSE-13-C H FESC -10-SC
UA H 5-2275 227500 EB SVE-15-C H FESC -15-H C O SE-21-C TR A E-20-SC
UA H 6-2730 273000 EB SVE-20-C H FESC -20-H C O SE-21-C TR A E-20-SC
5
FACTORY WIRING — STANDARD UNIT COOLERS
Air And Hot Gas Defrost
The following 3 pages show the standard factory
(internal) wiring for Air, Hot Gas and Electric Hot Gas Defrost
Defrost in both 230 and 460 volt configurations.
All standard heaters are delta wired for three phase. DIAGRAM 3 — 1 & 2 FAN UNITS
208-230/1Ø
M1 M2
DIAGRAM 4 — 1 & 2 FAN UNITS
GRND
1 2
208-230/1Ø
460/1Ø
208-230/1Ø
M1 M2
M1 N X 4
BLK GRND
4 3 2 1 2
M2 YEL
CAP.
BRN
M1
BLK
3 1
2 M2 YEL
CAP.
DIAGRAM 2 — 3 - 6 FAN UNITS DTFD BRN
M1 M2 M3
DIAGRAM 5 — 3 - 6 FAN UNITS
GRND 208-230/1Ø 208-230/3Ø & 460/3Ø
1 2 3
M1 M2 M3
N X 4
GRND
4 3 2 1 2 3
M1
M1
M2
3 1
2 M2
DTFD
M3
M3
M4
M4
M5
M5
BLK
BLK
M6 YEL M6 YEL
CAP. CAP.
BRN BRN
6
FACTORY WIRING — STANDARD UNIT COOLERS
Electric Defrost
Fan and Defrost Control Circuits Defrost heater Circuits
208-230/1Ø 208-230/3Ø
N X 4
H 1 H2 H 3
GRND
4 3 2 1
1 2 3
M1
BLK
3 1
2 YEL M2
CAP.
DTFD BRN
GRND
4 3 2 1 2
GRND
4 3 2 1 2 3
M1
3 1
2 M2
DTFD
M3
M4
NOTE: See Diagrams 11 through 14 for
M5 3 - 6 Fan Defrost Heater Circuits
BLK
M6 YEL
CAP.
BRN
7
FACTORY WIRING — STANDARD UNIT COOLERS
Electric Defrost
Defrost Heater Circuits - 230/3 Defrost Heater Circuits - 460/3
1 2 3
1 2 3
1 2 3
1 2 3
208-230/3Ø
460/3Ø
K 1 K2 K 3
K 1 K2 K 3
1 2 3
1 2 3
8
TYPICAL FIELD WIRING — SEQUENCE OF OPERATION
General Information
Note: The wiring diagrams on Page 9 to 13 are ° Field terminal block connection
shown to provide visual support for the field wiring —— Field wiring
considerations and sequence of operations —- — Phantom wiring shows alternate methods
discussed below. They are generic relative to the of terminating defrost - pressure control in
high-side, showing only the defrost timer. They do not condensing unit or thermostat in unit cooler.
represent as-built unit cooler wiring. (e.g. the fan
motors on a multi-fan unit are shown as one motor). HTRS “C” Heater Contactor
Refer to pages 6 to 8 for details of internal unit cooler MTRS ”M” Fan Motor Contactor
wiring. Refer to the back cover for the number of fans “S” Solenoid
vs. model number. R1 Lockout relay
R2 Sequencing relay
The basic sequence of operation for electric defrost is R3 Sequencing relay
given on Page 11 - all other electric defrost diagrams
refer back to that sequence with exceptions noted.
Air Defrost
Air Defrost units will require the connection of power to Wiring Diagram 15 — Time Termination is done
the fan motor circuit. by setting the fail-safe dial of the timer to the desired
defrost duration.
An air defrost system is wired so that the evaporator
fans run continuously unless manually de-engerized.
Whenever the compressor stops, the room air
(minimum +34 degrees) warms the coil to room
temperature, melting the frost.
9
TYPICAL FIELD WIRING — SEQUENCE OF OPERATION
Hot Gas Defrost — Re-Evap Type
Wiring Diagram 16 — One and two fan units with power to terminal “X” on the timer. The termination
single phase motor(s) wired for single phase. solenoid in the timer will switch the timer back into
the normal (refrigerating) position, opening the contact
208-230/1Ø
to timer terminal #3 (de-energizing the HGS); and
closing the contact to terminal #4 (energizing the LLS
and bringing power to one side of the unit cooler
fan motors).
TIMER
1
M
N Pressure Termination — The pressure control
3 (by others) will sense the completion of defrost
S HOT GAS SOLENOID
(recommended set point is the refrigerant pressure
4
2 S equivalent to 45°F) and close its contact, supply-
S X LIQUID LINE
SOLENOID ROOM
ing power to terminal “X” on the timer. The balance
THERMOSTAT of the termination sequence is identical to Temperature
MTRS Termination above.
4 1
M 2 N
X 3 The system will begin to refrigerate without the unit
DEFR.
T'STAT
cooler fans running. This prevents water droplets and
UNIT COOLER steam from blowing into the room. The fan delay
function of the DTFD will sense when the coil cools
down to 25°F and will close contact 1-2, energiz-
PRESSURE CONTROL
ing the fan motors. Thus normal refrigeration is
resumed.
Normal Refrigeration — The liquid line solenoid valve
(LLS) receives power from terminal #4 of the defrost Wiring Diagram 17 — Three to six fan units with
timer though the room thermostat. The thermostat will single phase motors delta-wired for three phase,
close on rise of room temperature, energizing the and all 460 volt units.
LLS, allowing refrigerant flow to the unit cooler.
Pressure will build up in the low-side and the low 208-230/1Ø
pressure control (not shown) will close, starting the
compressor.
The room thermostat will open when it reaches its
cut-out set point, breaking power to the LLS. The LLS TIMER
will close, stopping refrigerant flow to the unit cooler. 1 N
M
The system will pump down and the compressor will 3
stop. S HOT GAS SOLENOID
4
Defrost — The defrost timer will switch to the defrost 2 S
S X LIQUID LINE
position at the preset time. Timer contact to terminal ROOM
SOLENOID
#4 will open, breaking power to the LLS and the unit THERMOSTAT
cooler fan motor(s). Timer contact to terminal #3 will
MTRS
close at the same time, supplying power to the hot gas 4 1
C 2 N
solenoid valve (HGS), allowing hot gas to flow to the X 3
unit cooler. A normally open solenoid valve installed DEFR.
T'STAT
in the discharge line to the condenser (not shown) is
UNIT COOLER
typically wired in parallel with the HGS.
NOTE: Both temperature and pressure
terminations are shown in the same writing PRESSURE CONTROL
Normal Refrigeration — The liquid line solenoid valve Wiring Diagram 19 — Three to six fan units with
(LLS) receives power from terminal #4 of the defrost 1-phase motors delta wired for 3-phase , and all 460
timer though the room thermostat. The thermostat will volts units.
close on rise of room temperature, energizing the 208-230/1Ø
LLS, allowing refrigerant flow to the unit cooler.
Pressure will build up in the low-side and the low
pressure control (not shown) will close, starting the
TIMER
compressor. 1 N
M
3 R1 HTRS
The room thermostat will open when it reaches its C
cut-out set point, breaking power to the LLS. The LLS 4
2 S
will close, stopping refrigerant flow to the unit cooler. S X LIQUID LINE
The system will pump down and the compressor will SOLENOID ROOM
THERMOSTAT
stop.
MTRS
4 1
C 2 N
Defrost — The defrost timer will switch to the defrost X 3
position at the preset time. Timer contact to terminal DEFR.
T'STAT C
#3 will close, supplying power to terminal #4 of the M1
normally closed Lock-Out Relay R-1. The holding coil M2
MTRS M
of R1 (not shown) is to be wired in parallel with the M3
compressor contactor holding coil. R-1 will thereby
H1
remain open as long as the compressor is running,
H2
preventing the heaters from operating at the same HTRS
H3
time as the compressor. This eliminates the need for
oversized wiring to the condensing unit. R-1 can also UNIT COOLER C
208-230/3Ø
represent a normally closed auxiliary contact in the OR
compressor contactor. 460/3Ø
208-230/1Ø 208-230/1Ø
TIMER
TIMER HTRS
1 N
1 N HTRS M C
M C 3 R1
3 R1 C
C HTRS
HTRS 4
2 S
4 S X
2 S LIQUID LINE
S X SOLENOID ROOM
LIQUID LINE C C MTRS THERMOSTAT
SOLENOID ROOM
THERMOSTAT
4 1
2 N
MTRS
4 1 X 3
M 2 N DEFR.
X 3 T'STAT
M1 C
DEFR.
T'STAT C M2
H1 MTRS M
M3
H2
HTRS H1
H3
H2
HTRS
UNIT COOLER H3
208-230/3Ø
OR UNIT COOLER C
460/3Ø 208-230/3Ø
MTRS OR
4 1 460/3Ø
M 2 N
4 1
X 3 2 N
DEFR. X 3
T'STAT C DEFR.
H1 T'STAT
M1 C
H2 208-230/3Ø
HTRS OR M2
H3 460/3Ø MTRS M
M3
UNIT COOLER H1
H2
HTRS
H3
UNIT COOLER C
208-230/3Ø
Sequence of operation is the same as Wiring OR
Diagram 18, except: 460/3Ø
1. DTFD contacts 3-2 are wired in series - both Identical to Diagram 20 except that each unit is
units coolers must terminate to terminate the timer. shown with its own fan motor contactor, and
2. The DTFD contact 1-2 for Unit B is not used - the terminal #4 on the defrost timer will supply
fan delay function for both units is controlled power to the holding coils of those contactors
by the fan delay on Unit A. instead of supplying power to the fan motors
3. Each unit cooler is shown with its own defrost directly. A single (larger) contactor could be used.
heater contactor with holding coils parallel. A
single (large) should be used.
12
TYPICAL FIELD WIRING — SEQUENCE OF OPERATION
Electric Defrost
Dual Unit Cooler Systems — Without Sequencing Relays
Wiring Diagram 22 — One and two fan units with Unit B continues defrost until termination temperature
single phase motor(s) wired for single phase. is reached. R3 will then energize - its (N.C.) contact
opens (de-energizing M4) and its (N.O.) contact
closes (bringing power to timer terminal “X”) which
208-230/1Ø terminates defrost.
H2
R3 HTRS 4 1
2 N
H3
X 3
R DEFR.
UNIT COOLER R2
208-230/3Ø R2 T'STAT
M1 C
OR
460/3Ø M2
R3
MTRS MTRS M
4 1 M3
M 2 N
X 3 H1
R DEFR.
H2
R3 T'STAT C HTRS
H1 H3
H2
HTRS UNIT COOLER C
208-230/3Ø
H3 OR
460/3Ø
UNIT COOLER MTRS
208-230/3Ø 4 1
OR 2 N
460/3Ø X 3
R DEFR.
R3 T'STAT
M1 C
Idendical to Wiring Diagram 20 except that term-
M2
ination is accomplished through sequencing relay MTRS M
R2 and R3. M3
H1
The heater of one unit can de-energize when the coil H2
is clean while the other unit can continue to defrost HTRS
H3
if required. This eliminates steaming of the unit
that completes defrost first. UNIT COOLER C
208-230/3Ø
OR
Unit A will energize R2 when it terminates. R2 460/3Ø
normally closed (N.C.) contact will open, de-ener-
gizing heater contactor M2. R2 normally open (N.O.) Identical to Diagram 22 except that each unit has
contact closes. The timer cannot terminate, however, its own (three phase) fan motor contactor, and
until both (N.O.) R2 and R3 contacts close - they terminal #4 on the defrost timer will supply power
are wired in series to timer terminal close - they are to the holding coils of those contactors instead
wired in series to timer terminal “X”. of supplying power to the fan motors directly.
13
START-UP PROCEDURE
System Check Initial Start-up
Before starting the refrigeration system, check the Check the following items after initial unit start-up:
following items: 1. After the initial start-up, the fans will not start until
1. The system is properly wired as shown in the the coil temperature pulls down to about 25°F. The
diagrams in the Installation Section of this bulletin. fans may cycle several times until the room temp-
2. Make sure all electrical connections are tight. erature is pulled down.
3. Check that all piping is done as described in the 2. Check the system for refrigeration charge
Installation Section of this bulletin and in and oil level.
accordance with good piping practice. 3. Make sure that the expansion valve superheat is
4. All fan set screws are tight. set correctly. It should be about 8° to 10°F
5. Make sure that the service valves on the com- 4. Check that the drain line heater is functioning
pressor and receiver are open. properly.
6. Set the unit so it is mounted securely and 5. During initial start-up it is not unusual to have very
pitched properly. Pour water into drain heavy frost loads. It may be necessary to manually
pan to verify that the drain pan and drain initiate defrost cycles as needed until the moisture
line drain completely. level in the room is reduced.
7. Make sure that the drain line is adequately 6. Observe the first defrost cycle to make sure that
heated. all system components are functioning properly.
8. Properly evacuate the system. Check the amp draw of the defrost heaters to
9. Follow proper procedures for handling and start- make sure that the defrost cycle is terminated by
up of systems using polyol ester based lubricants. the termination thermostat and not by the “fail-
safe” on the timer.
MAINTENANCE
General 2. Disconnect motor leads in motor junction box.
3. Remove the 2 bolts that hold the motor in its
Check unit at least once a month for proper defrost-
mounting bracket.
ing. The amount and pattern of frosting can vary
4. Remove motor.
greatly. It is dependent on room temperature, product
5. Re-install by reversing the above procedures.
being stored, turnover of product, percentage of time
the door is open and temperature and humidity
Defrost Heater Replacement
conditions surrounding the room. It may be necessary
to periodically to change the number or duration of
WARNING: Shut off all electrical power to the unit
defrost cycles.
before replacing the heater(s).
At least once every six months, check the following
items: 1. Disconnect the leads in the electrical junction box
1. Tighten all electrical connections. of the heater to be replaced.
2. Tighten fan set screws. 2. To replace a coil heater: Lower the hinged
3. Clean the coil surface. drain pan; remove the clips that hold the heater
4. Check the system refrigerant charge and oil level. to the coil; remove the heater.
5. Make sure the defrost controls are functioning 3. To replace a coil heater - 3 fan units & smaller:
properly. Open the end compartment at the end opposite
6. Clean the drain pan and check the drain pan and the refrigerant connections and disconnect
drain line for proper drainage. the heater from the retaining clips.
7. Check the drain line heaters for proper operation. To replace a coil heater - 4 fan units & larger:
Same as smaller units except that the retaining
Fan and Motor Replacement clips are located at the refrigerant connection end.
WARNING: Make sure all electrical power to the unit 460 volt units: The heaters are wired in series and
is disconnected before replacing fans or motors. will have to be separated at the connection.
The fan may be removed as follows: 4. Slide the heater out from the refrigerant
1. Remove the four screws that hold the fan guard connection end of the coil. A minimum of 12”
in place and remove guard. clearance must be provided to remove the heater.
2. Loosen the set screw(s) in the fan blade. 5. Replacement heaters for the coil may be sent coiled
3. Remove fan. up. TO install, simply push the heater into the coil -
it will straighten as it slides in.
The motor may be removed as follows: 6. The rest of the installation can be completed by
1. Remove fan per above procedures. reversing the above procedures.
14
TROUBLESHOOTING CHART
or overload conditions.
6. Defrost thermostat bulb not sensing 6. Make sure bulb is properly positioned
temperature.
Room temperature too high. 1. Room thermostat set too high. 1. Adjust thermostat.
Defrost heaters will not operate. 1. Main switch open. 1. Close switch.
Coil not clearing frost during defrost cycle. 1. Defective heater(s). 1. Replace heater(s).
2. Not enough defrost cycles per day. 2. Adjust timer for more defrost cycles.
cycles.
6. Fail-safe on timer set too short. 6. Lengthen fail-safe time setting - do not
exceed 40 minutes.
Units stays in prolonged defrost cycle. 1. Defective timer or thermostat. 1. Replace defective component.
2. Defrost thermostat set for termination. 2. Adjust thermostat for lower setting.
15
REPLACEMENT PARTS
ULTRA - TEMP — MODELS U*U, U*L, U*M, UAH
MODEL NUMBER DESCRIPTION PART #'s
ALL MODELS DEFROST CONTROL, ADJUSTABLE, RANCO F-25 204464037
ALL 1 FAN MODELS DEFROST HEATERS, CORE, 1378 WATTS, 40" LENGTH, 208-230/460 V. (4 REQ'D) 206240003
DEFROST HEATERS, CORE, 1378 WATTS, 40" LENGTH,575 V. (4 REQ'D) 206240025
ALL 2 FAN MODELS DEFROST HEATERS, CORE, 2458 WATTS, 70" LENGTH, 208-230/460 V. (4 REQ'D) 206240004
DEFROST HEATERS, CORE, 2458 WATTS, 70" LENGTH, 575 V. (4 REQ'D) 206240026
ALL 3 FAN MODELS DEFROST HEATERS, CORE, 3538 WATTS, 100" LENGTH, 208-230/460 V. (4 REQ'D) 206240005
DEFROST HEATERS, CORE, 3538 WATTS, 100" LENGTH, 575 V. (4 REQ'D) 206240027
UEU4-711, UEL4-817, UEL4-722 DEFROST HEATERS, CORE, 2305 WATTS, 132" LENGTH, 208-230/460 V. (8 REQ'D) 206240002
UEM4-780, UEM4-882 DEFROST HEATERS, CORE, 2305 WATTS, 132" LENGTH, 575 V. (8 REQ'D) 206240024
UEU4-851, UEU4-1080,UEL4-950,UEL4-1100, DEFROST HEATERS, CORE, 2305 WATTS, 132" LENGTH, 208-230/460 V. (12 REQ'D) 206240002
UEL4-1260,UEL4-1380, UEM4-1100 DEFROST HEATERS, CORE, 2305 WATTS, 132" LENGTH, 575 V. (12 REQ'D) 206240024
UEM4-1320, UEM4-1656
UEU5-1350, UEL5-1575 DEFROST HEATERS, CORE, 2837 WATTS, 162" LENGTH, 208-230/460 V. (12 REQ'D) 206240017
UEL5-1725, UEM5-2065 DEFROST HEATERS, CORE, 2837 WATTS, 162" LENGTH, 575 V. (12 REQ'D) N/A
UEU6-1620, UEL6-1890 DEFROST HEATERS, CORE, 3369 WATTS, 192" LENGTH, 208-230/460 V. (12 REQ'D) 206240018
UEL6-2070, UEM6-2480 DEFROST HEATERS, CORE, 3369 WATTS, 192" LENGTH, 575 V. (12 REQ'D) N/A
ALL MODELS DEFROST HEATER, DRAIN PLUG, 27 WATTS, 208-230/460 V. 107807003
FOLLOWING DRAIN PAN HEATERS ARE FOR UNITS PRODUCED AFTER JULY 31,1995**
1-3 FAN MODELS* NOT AVAILABLE N/A
4 FAN MODELS DRAIN PAN HEATER, 133-1/2"LENGTH, SPEC. MOD# AND S/N. ( 2 REQ.), 540 WATTS 115098000
5 FAN MODELS DRAIN PAN HEATER, 163-1/2"LENGTH, SPEC. MOD# AND S/N. ( 2 REQ.), 660 WATTS 115099000
6 FAN MODELS DRAIN PAN HEATER, 196-1/2"LENGTH, SPEC. MOD# AND S/N. ( 2 REQ.), 780 WATTS 115100000
FOLLOWING FAN BLADES ARE FOR UNITS PRODUCED AFTER APRIL 1, 1990.
U*U1-118, U*U2-236, U*L1-125 FAN BLADES, 20" DIAM., 23° PITCH, CCW , 1/2" BORE 202147008
U*L1-152, U*L1-193, U*L2-240, U*L2-304
U*U2-355, U*L2-361, U*L2-408, FAN BLADES, 24" DIAM., 32° PITCH, CW, 1/2" BORE 213455000
U*M4-1100, U*M4-1320, U*M4-1656,
UAH4-1452, UAH4-1821, UAH5-2275,
UAH6-2730, & ALL 3, 4, 5, & 6 FAN
U*U AND U*L MODELS
U*M1-164, U*M1-209, U*M2-270, FAN BLADES, 20" DIAM., 25° PITCH, CW, 1/2" BORE 213456000
U*M2-239, UAH1-182, UAH1-232,
UAH2-300, UAH2-365
U*M2-390, U*M2-441, UAH2-433, UAH2-490, FAN BLADES, 24" DIAM., 14° PITCH, CW , 1/2" BORE 214041000
ALL 3 FAN U*M,& UAH MODELS, U*M4-780,
U*M4-882, U*M5-2065, U*M6-2480,
UAH4-866, UAH4-980, UAH4-1100
U*U1-118, U*U2-236, U*L1-125, U*L1-152, FAN GUARD, AIR STRAIGHTENER (20" FANS) 10692300
U*L1-193, U*L2-240,U*L2-304, U*M1-164,
U*M1-209,U*M2-270, U*M2-329, UAH1-182, FAN GUARD, WIRE, EPOXY COATED, 20" 213484000
UAH1-232, UAH2-300, UAH2-365
U*U2-355,U*L2-361, U*L2-408, U*M2-390, FAN GUARD, AIR STRAIGHTENER (24" FANS) 10709900
U*M2-441, UAH2-433, UAH2-490, & ALL 3, 4,
5, & 6 FAN U*U, U*L, U*M, UAH MODELS FAN GUARD, WIRE, EPOXY COATED, 24" 202136005
FOLLOWING MOTORS ARE FOR UNITS PRODUCED AFTER APRIL 1, 1990.
ALL 1, 2, 3, FAN U*M, AND UAH MOTOR, PSC, 1/3 HP, 1075 RPM, 115V (5 MFD CAPACITOR NOT INCLUDED) 205051005
MODELS, AND U*M4-780, MOTOR, PSC, 1/3 HP, 1075 RPM, 208-230/60/1 (5 MFD CAPACITOR NOT INCLUDED) 205051004
U*M4-882, UAH4-866, UAH4-980, MOTOR, PSC, 1/3 HP, 1075 RPM, 460/60/1 (7.5 MFD CAPACITOR NOT INCLUDED) 205051006
UAH4-1100 MOTOR, PSC, 1/3 HP, 1075 RPM, 575/60/1 (7.5 MFD CAPACITOR NOT INCLUDED) 115950000
U*U2-355, U*L2-361, U*L2-408, AND ALL 3, 4, MOTOR, PSC, 3/4 HP, 1075RPM, 208-230/60/1 (5 MFD CAPACITOR NOT INCLUDED) 205051009
5, & 6 FAN U*U,& U*L MODELS, U*M4-1100, MOTOR, PSC, 3/4 HP, 1075RPM, 460/60/1 (5 MFD CAPACITOR NOT INCLUDED) 205051002
U*M4-1320, U*M4-1656, UAH4-1452,
UAH4-1821, UAH5-2275, UAH6-2730 MOTOR, PSC, 1/2 HP, 1075RPM, 575/60/1 (5 MFD CAPACITOR NOT INCLUDED) 115952000
U*U1-118, U*U2-236, U*L1-125, MOTOR, PSC, 3/4 HP, 1625 RPM, 208-230/60/1 (7.5 MFD CAPACITOR NOT INCLUDED) 205051007
U*L1-152, U*L1-193, U*L2-240, MOTOR, PSC, 3/4 HP, 1625 RPM, 460/60/1 (7.5 MFD CAPACITOR NOT INCLUDED) 205051008
U*L2-304 MOTOR, PSC, 1/2 HP, 1075RPM, 575/60/1 (5 MFD CAPACITOR NOT INCLUDED) 115952000
ALL MODELS MOTOR, MOUNT, 24" 205269000
ALL MODELS CAPACITOR, 5 MFD 202163004
CAPACITOR, 7.5 MFD 202163006
Nomenclature
U • U 1 – 118
ULTRA TEMP BTUH in Hundreds
Number of Fans
A = Air Defrost (M & H) only
E = Electric Defrost U= 4 Fins/Inch (Freezer)
H = Hot Gas Re-Evap (U, L & M only) L = 6 Fins/Inch (Freezer)
G = Hot Gas Rev. Cycle M= 6 Fins/Inch (Cooler)
H= 8 Fins/Inch (Cooler)