Model Series ENGLISH

F31HC / F35HC

Installation, Operation, Service

and
Maintenance Instructions
“UNIT COOLERS FOR COLD ROOMS”

UNIT FOR USE WITH WALK-IN COOLER, FREE-

ZER OR REFRIGERATED WAREHOUSE

March 2020 PT # 31109854

 INSTALLATION AND OPERATION MANUAL
TABLE OF CONTENTS

SUBJECT PAGE #

Warning Symbols And Placards 3

General Safety Information 4
Product Warranty Statement 5
Receiving And Inspection 5
Uncrating And Rigging 5-6
Unit Mounting 6-8
Locating Equipment 7
Drain Line Piping 8-9
Refrigerant Piping 10
Refrigerant Piping (Distributor / TXV / Solenoid Valve) 11
Leak Testing, Evacuation And Charging 12
Evaporator Superheat 12
Refrigerant Blends / Temperature Glide 13
Field & Factory Wiring / Electrical Requirements 13
Typical Field Wiring Diagrams 14 - 22
Start Up 23
Service - Maintenance (Fan / Motor Assy) 24
Service - Maintenance (Coil Corrosion) 24
Service - Maintenance (Defrost Cycle / Heaters) 25
Remove / Replace Fan And Motor Assy 26
Remove / Replace Defrost Heaters 27
Routine Maintenance / Service 28
Replacement Parts 28
Important Notes & Information (Test Press / Approved Refrigerants) 29
Start Up / Service / Maintenance Notes 30
Factory Contact Information 331

2
 WARNING SYMBOLS AND THEIR MEANING

Hand Injury Pos-

Forklift Traffic Electricity Toxic Substan-
sible
ces

Hot Surfaces Automatic Start Overhead Load Sharp Element

MANDATORY SIGNS AND THEIR MEANING

Hand Protection Eye Protection Ear Protection

Check Guard
Required Required Required

Protective Clo- Use Safety Connect To Earth

Hard Hat Area
thing Reqd Footwear Ground

Activate Before
Work

OTHER SIGNS AND THEIR MEANING

This is only a “Right To Know” law

in the state of CA. It does not
No Fire, Open Fla- mean that Lu-Ve products contain
me or Smoking any substance or materials that
may cause cancer or reproductive
harm

3
 GENERAL SAFETY INFORMATION AND PRECAUTIONS

RISK OF PERSONAL INJURY OR DAMAGE TO MATERIALS OR PROPERTY MAY OCCUR

IN THE CASE OF A FAILURE TO FOLLOW THESE INSTRUCTIONS COMPLETELY!

• Installation, maintenance and service are to be performed only by qualified personnel who are familiar with local codes and
applicable regulations. They should also have prior experience working with this type of equipment.

• Avoid contact with sharp edges and coil surfaces as they are potentially hazardous. Wear appropriate personal protection equi-
pment (PPE) whenever necessary to avoid personal injury.

• Read and observe all precautions and warnings on tags, labels, stickers and literature attached to or provided with equipment.

• Employ authorized personnel only for operating any moving and lifting equipment (ex. forklifts, scissor lifts, cranes, etc.)

• In order to avoid potential damage all equipment should be left in the original shipping container until just prior to installation.

• When rigging and lifting units never work directly below suspended loads.

• Always wear appropriate personal protection equipment (PPE) whenever handling, lifting, installing, servicing and performing
routine maintence on equipment.

• Make sure that all power and control wiring to the equipment conforms to the requirements of all relevant local and national
codes and is in accordance with the data listed on the unit rating label.

• All sources of power should be turned OFF, tagged and locked out before attempting any type of service, maintenance or re-
pairs. Failure to do so could result in damage to equipment, personal injury or death to servicing personnel.

• All coil assemblies are shipped internally pressurized with dry air or nitrogen. Before attempting to remove caps or seals to
make any field connections to the coil reduce internal coil pressure to atmosphere.

• Some traces of a transparent liquid may remain inside the coil circuit after the manufacturing process. This is evaporative oil
which is completely compatible with all refrigerants and refrigeration oils in current use. This oil can sometimes collect in small
quantities inside the coil header connections where it may be observed by installing personnel when removing the factory caps.
It can be easily verified that this is oil and not water due to the fact that it evaporates very quickly when touched. If a drop of it
is placed on a flat surface it widens out quickly like a stain and if exposed to flame it burns readily, giving off a white smoke.
• When welding or brazing make sure the torch flame is directed away from any potentially flammable materials, sensitive equip-
ment surfaces and components. Provide adequate shielding, wet rags or thermal paste when necessary. If required, provide a
fire watch with an available means of fire suppressant and clearly post emegency exits in the event of evacuation.

• Refrigerants used in cooling and freezing equipment can be hazardous to people as well as the environment and may even be
fatal in sufficient concentrations. Only personnel who are trained and certified to handle refrigerants should be allowed to do
so. Follow all applicable local and national codes which may apply to transporting, charging, reclaiming and disposing of these
chemicals.

• After any service or routine maintenance is performed be sure to properly reinstall all access / cover panels, fan guards, drain
pans, electrical covers and their fasteners. Never operate equipment with any of these componenents missing or damaged.

• EC fan and motor assemblies are not designed for replacement or servicing of individual parts. Replace only as a complete
assembly.

• LU-VE products are manufactured using the following primary materials;

- Plastic Material; Polyethylene, ABS, Rubber

- Ferrous Materials; Iron, Stainless Steel, Copper, Aluminum (possibly coated / treated for
corrosion protection)

• LU-VE products are manufactured to the following industry standards;

- UL412:2011 Ed.5+R:09 Jan 2017

- CSA C22.2#120 Issued: 01/03/2013 Ed
- 4 Refrigeration Equipment and NSF 7:2016
- PED 2014/68/EU
- Safety of Machinery EN 60204-1
- Directive 2014/30/EC and subsequent modifications
- Electromagnetic compatibility
- Low voltage - Reference Directive 2014/35/EC

4
 PRODUCT WARRANTY STATEMENT
The manufacturer warrants the product(s) supplied to be free from defects in materials and workmanship when selected, applied, instal-
led, operated, serviced and maintained under normal use and in accordance with all established industry standards and generally accep-
ted field practices for a period of (12) months from the date of installation or (18) months from original manufacture date - whichever
ocurrs first.

The manufacturer shall, at their sole discretion, repair or replace any product which, based upon their own or their agents inspection, has
failed due to a defect in design, workmanship or materials. This warranty does not cover any product which has failed due to ordinary
wear and tear, damage during original shipment or installation, improper application or design, operation, service or maintenance, or
which has been subjected to products of corrosion - either internal to the sealed refrigeration system or external in the immediate envi-
ronment of the equipment installation.

In the case of any products which must be returned to the sellers manufacturing facility for inspection and / or repair, return freight will be
pre-paid via regular ground service, the product inspected and either replaced or repaired and re-shipped via ground service. Such ac-
tions shall be construed as satisfactory to satsify any and all warranty obligations by the original manufacturer.

Prior to the return of any product, written approval must be obtained from the manufacturer along with an RMA number (Return
Material Authorization). Any product returned without prior approval and no RMA number will be refused!

The manufacturer shall have no liability whatsover for any or all of the following which might be incurred as a result of product failure.
These include (but may not be limited to);

- Field Labor And Materials

- Product Loss
- Property Damage
- Injury To Personnel
- Temporary Equipment Rental / Storage Charges
- Installation Charges—including but not limited to labor, materials (including refrigerant), rigging and handling equipment,
disposal charges, environmental fees, etc..

For any component / parts or coatings supplied with the unit but not directly produced by the unit manufacturer only the warranty provi-
ded to the manufacturer will be extended to the customer. No other warranty shall be assumed or implied by any third party supplier.
Any repairs or modifications made to equipment or integral components by a third party or end user without previous authorization from
the original equipment manufacturer will be the sole responsibility of that party.

Product warranty coverage shall remain intact for the (1) year warranty period based upon the original unit ship date regardless of any
changes in ownership of the equipment or the servicing agent. Removal or otherwise defacing of the original unit rating label will consti-
tute forfeiture of all product warranty coverage for any reason.

Warranty coverage is applicable only to static equipment installations — the manufacturers products are not intended for installation in
transport or mobile applications of any kind. In order to make any claim of warranty coverage you must first contact the equipment ma-
nufacturer or their authorized agent and present them with the original unit serial number, date of installation and a full description of the
specific failure which has prompted the warranty claim request. Warranty contact information for LU-VE products distributed and sold
within the continental US is as follows;
Zyklus Heat Transfer - PO Box 60 - Jacksonville, TX 75766 - 903-589-3355 - support@[Link]

RECEIVING AND INSPECTION

When the equipment is initially received, a responsible individual acting on behalf of the equipment purchaser must be present to check
the quantity of cartons and crates being delivered against the bill of lading to confirm that all items listed therein are accounted for. In-
spect all shipping containers (boxes and crates) for any signs of visible damage. Report any damage or shortages to the delivering
freight company immediately. It is the customer's responsibility to file all claims with the freight company. Damaged equipment may be
refused but must not be returned to the manufacturer for any reason without prior authorization.

Installing personel must excercise caution when removing equipment from crates and boxes to prevent physical injury to themselves or
the product. Always wear appropriate personal protection equipment (PPE) such as hard hats, gloves, safety glasses, safety shoes,
long sleeve shirts and pants, etc. to avoid physical injury. When lifting smaller units by hand always utilize proper lifting techniques to
avoid personal injury. Equipment should be left in the original shipping container whenever possible until just prior to installation. Do not
use piping connections, fan guards, drain pans or other such similar components as lifting points. On larger units which must be remo-
ved from the shipping container or skid with lifting straps make sure to utilize a spreader bar to avoid damage to the units sheet metal
housing.

REMOVING EQUIPMENT FROM SHIPPING CONTAINERS / PACKAGING

If using a forklift roll the unit over onto a wooden pallet with the shipping skid “up” (Figure 1 - Steps 1 & 2 - Page 6).
Remove the banding which holds the cardboard box to the shipping skid, then using a razor knife, carefully cut the box down all (4) cor-
ners and fold the cardboard down onto the pallet, leaving the unit resting on the original cardboard shipping blocks and carton top flaps
(Figure 2 - Step 3 - Page 6).

Remove both the left and right side cover panels to gain access to the nuts and bolts holding the front mounting feet to the shipping skid.
Remove all (4) bolts and lay aside the shipping skid (Figure 2 - Steps 4, 5 & 6 - Page 6).

With the carboard shipping container cut away and the side access panels removed from the unit check closely for any concealed or
hidden damage. If any damage is noted, report it to the manufacturer immediately before proceding with the equipment installation. All
units are shipped with approx. 25 PSIG of dry air or nitrogen holding charge in the coil. Use an accurate suction service gauge to verify
internal coil pressure prior to proceeding with the unit installation. Although the absence of pressure or a lower than normal pressure
reading does not necessarily indicate a leak, if the reading is “low” a leak test must be performed before contrinuing with the installation
or returning the unit to the distributor or manufacturer (Figure 3 - Step 7 - Page 6).

5
 RIGGING AND MOUNTING
Fig. 1 The unit can now be lifted to it’s final mounting position by inserting the
lifting forks into the pallet (Figures 4 & 5 - Step 8) and raising the unit
2 into place (Figures 4 & 5 - Step 9). On longer units it is important to find
the center “balance point” of the unit and spread the lifting forks wide
enough to avoid tipping.

1 F35HC
Fig. 2 14.8

Fig. 2 14.8

0.39

Fig. 5

F31HC
375 (14.8) 9
Fig. 4 375 (14.8)

(0.39
Check coil pressure with an
accurate service gauge. If
pressure is “low” or “0” the
unit must be checked for 7
leaks before installation.
(Figure 3 - Step 7).

Do not return the unit to the

distributor or manufacturer
9 without prior authorization! Fig. 3
UNITMOUNTING
UNIT MOUNTINGPOINTS
POINTS

5.28 5.28 0.39

14.8
0.59
F31HC

F35HC
16.3

19.2

3/4”MPT

F31HC 16.4 1.33

F35HC 16.4 1.73

F31HC

F35HC
18.7

19.1

DIMENSIONAL DATA

F31HC 115-4 116-4 125-4 126-4 135-4 136-4 146-4

Unit Model Series
F31HC 215-6 216-6 225-6 226-6 235-6 236-6 246-6
Number of Fans 12.4” Diam 1 1 2 2 3 3 4
Refrig Conn Liquid ½” ½” ½” ½” ½” ⅝” ⅝”
Refrig Conn Suction ⅝” ¾” ¾” ⅞” ⅞” 1-⅜” 1-⅜”
Dimension A 30 30 47-5/8" 47-5/8" 65-3/8" 65-3/8" 83-1/16"
Dimension B 19-3/8" 19-3/8" 37-1/8" 37-1/8" 54-13/16" 54-13/16" 72-1/2"
F35HC 73-4 106-4 145-4 215-4 272-4 323-4 362-4 430-4
Unit Model Series
F35HC 59-6 84-6 117-6 174-6 218-6 261-6 290-6 348-6
Number of Fans 13.8” Diam 1 1 2 2 3 3 4 4
Refrig Conn Liquid ½” ½” ½” ⅝” ⅝” ⅝” ⅝” ⅞”
Refrig Conn Suction 1-⅛” 1-⅛” 1-⅛” 1-⅛” 1-⅜” 1-⅜” 1-⅝” 1-⅝”
Dimension A 34" 34" 56" 56" 77-3/4" 77-3/4" 99-5/8" 99-5/8"
Dimension B 23-1/2" 23-1/2" 45-3/8" 45-3/8" 67-3/16" 67-3/16" 89-1/16" 89-1/16"
Dimension C --- --- --- --- --- --- 44-1/2" 44-1/2"

6
 RECOMMENDED UNIT COOLER PLACEMENT
Air flow within the refrigerated space is critical to achieving optimum cooling and freezing results. If air flow is compromised
for any reason the unit may not provide satisfactory cooling performance. There are many potential reasons for poor air
flow - few of which are the result of inadequate system capacity or unit malfunction. Some of the more obvious reasons for
poor airflow include;
- Unit installed above doors (coil blocked with frost / ice) - Units mounted perpendicular / blowing at right angles to each other
- Insufficient return air space between unit and wall - Poor product packaging or improper product stacking arrangement
- Insufficient free area in front of the unit - Too much product loaded into the room at one time
- Unit mounted to close to beams or product racking - Wrong unit design for application
- Multiple units installed to close together - Too few units for room volume
- Low ceiling height / unit mounted to close to floor level - Multiple, miss-matched units or fan types used in the same room

For the best possible cooling performance always consider the following design recommendations;
• Always locate units as far away from door openings as possible - preferably blowing directly towards doors or other openings.

• Allow a minimum return air space behind the coil equal to the height of the unit (Figure 10 - below).

• On larger installations place units where they can blow freely down open aisleways between product racking / shelves.

• Mount units directly to the ceiling whenever possible (greater overall air throw is partially achieved by increasing the distance
between the unit and the floor).
• For blast chilling or freezing applications consideration must be given for installing air baffles, discharge chutes, coves, return
air plenums, etc. to prevent air bypass / recirculation due to high external static pressure.
TYPICAL UNIT COOLER PLACEMENT IN COOLER / FREEZER

Minimum clearance required for coil heater replacement is the length of the unit (electric defrost models). Heaters are remove-
* able from the refrigerant connection end of the unit.

In addition to the above consideration should also be given to the potential length and layout of refrigerant piping runs and condensate
drain lines based upon the unit coolers’ physical location. It is always preferable to minimize the length of these runs - particularly in-
side the conditioned space. Minimum clearances must also be maintained around the unit to allow access for service, routine mainte-
nance and cleaning of the unit when required. For electric defrost units the minimum service access required to replace the coil de-
frost heaters is illustrated below (Figure 11- below).

HEATER

19.2”

Fig. 10 Fig. 11

7
 UNIT MOUNTING DETAIL
Units should be mounted flush to a level ceiling panel using 3/8” stainless steel bolts, hangar rods or lag screws.
There is no need to block or pitch the unit to ensure proper condensate drainage if the unit is mounted level.

NSF SANITATION

Seal the gap between the top of the unit and the ceiling with NSF approved sealant to prevent accumulation of dirt and foreign material.

CONDENSATE DRAIN PAN CONNECTION

Apply an approved pipe thread sealant to the threads of the drain pan
fitting before making the field piping connection.

Do not torque / over-tighten the field pipe fitting attached directly to the
drain pan connection! Use a backer wrench on the drain pan fitting and tighten
the attached pipe fitting no more than approx. 1/2 turn beyond hand tight.

8
 CONDENSATE DRAIN LINES
• It is the installers responsibility to ensure that all drain line piping is installed in accordance with local and national plumbing
codes.
• Drain line piping runs should be kept as short as possible within the conditioned space whenever possible.

• Pitch all field piping in the direction of flow a minimum of 1/4” per foot of pipe run.

• Use an approved pipe thread sealant on the threads of the drain line fitting. DO NOT OVER-TIGHTEN THE FITTING
ATTACHED DIRECTLY TO THE DRAIN PAN CONNECTION!
• Install a P-trap in all unit drain lines. Traps in freezer drain lines should be located outside the freezer whenever possible.

• The use of plastic (PVC) pipe is acceptable only on cooler applications operating above freezing.

• For all freezer applications (+32 degrees and lower) use copper pipe only.

• Use an insertion type drain line heater on all freezer applications or wrap all piping and P-traps exposed to freezing temperatures
with self regulating type heat tape and insulate wherever practical. A minimum of 20 watts / foot of drain line is generally recom-
mended for freezers operating down to 0 degrees and 30 watts / foot of drain line for those operating from 0 down to -20 de-
grees.
• Common drain lines serving multiple units (whether in the same space or different rooms) must be adequately sized to handle the
condensate flow from ALL connected evaporators. DO NOT REDUCE THE DRAIN LINE PIPE SIZE SMALLER THAN THE
CONNECTION ON THE DRAIN PAN! The branch lines from each individual evaporator must also be separately trapped.
• All drain lines must terminate above an open floor drain or in an outdoor area where the condensate will not pose any personal
safety or environmental issues. Do not connect drain lines directly to the building sewer system.
• Check the unit drain pan after an initial period of operation to ensure there is no standing water in the pan. Check unit for level or
correct field piping if necessary to eliminate standing water.

CONDENSATE DRAIN LINE PIPING — SINGLE UNIT

Air Flow Air Flow

P-Trap

COOLER (Above +32) COOLER (Above +32)

FREEZER (Below +32)

P-Trap
Open
Floor Open
Drain Floor
Drain

CONDENSATE DRAIN LINE PIPING — MULTIPLE UNITS ON A COMMON DRAIN LINE

UNIT 3 UNIT 2 UNIT 1

P-Trap P-Trap
P-Trap

Pitch In Direction Of Flow - 1/4" / Foot (MINIMUM))

• Units which are located in different rooms but piped to a com-

mon drain line must be individually trapped.

• Units operating near or below freezing should be trapped out-

Open Floor Drain side the room or adequately protected from freezing.

9
 REFRIGERANT PIPING
Use only clean, sealed ACR grade copper tubing for refrigerant duty. Unit warranty cover-
CAUTION! UNIT IS PRESSURIZED age may be voided if system is installed with any other type of tubing. All piping must be
WITH DRY AIR OR INERT GAS installed according to local and national codes as well as accepted commercial refrigeration
FOR SHIPPING industry standards and practices. All tubing should be cut using a wheel type tubing cutter
(no hacksaws) and all cut tubing must be de-burred. Clean all joints with sand cloth and
apply a small amount of high quality paste flux (being careful to avoid placing any flux near
THIS HOLDING CHARGE MUST the ends of the tubing) before firmly joining connections. When brazing, use only high tem-
BE VENTED AND THE SYSTEM
LEAK TESTED AND EVACUATED perature, silver bearing solder on all joints while continuously flowing a regulated, low pres-
BEFORE CHARGING WITH RE- sure, inert gas through the inside of the piping to avoid the formation of scale and copper
FRIGERANT
oxides.
Note: The line sizing required for the system is not necessarily the same size as the factory
CHARGE SYSTEM WITH ONLY pipe connections supplied on the unit. We strongly recommend that you work directly with
PURE, VIRGIN REFRIGERANT an experienced consulting engineer to properly size and design system piping however as a
convenience to our customers (and with no liability for services provided as gratis) we can
supply the installer with line sizing charts which may be used to select the field line sizing
based upon the calculated, overall equivalent feet of tubing (lineal feet plus allowances for
fittings), refrigerant type, unit capacity and SST.

GENERAL UNIT PIPING GUIDELINES

Refer to ASHRAE REFRIGERATION HANDBOOK for detailed system piping design information!
• Always consider the overall length of field piping runs when locating unit coolers and matching condensing units. Excessivel y
long piping runs should be avoided whenever possible.
• Select the optimum pipe size which minimizes total system pressure drop while maintaining sufficient internal gas velocities to
ensure continuous oil return back to the compressor. Often times pipe selection is a compromise between operating efficiency
over the lifetime of the system and initial, installed cost.
• Pitch all horizontal suction lines in the direction of refrigerant flow (minimum - 1/4” / foot of run) to ensure oil return. Install a P-
trap at the bottom of ALL vertical suction risers (Figure 1). This not only helps with oil return but protects the expansion valve
sensing bulb from the affects of liquid drain back at the outlet of the evaporator.
• Install an intermediate P-trap in all risers over 20’ and every 15’ thereafter.

• A P-trap is not required at the outlet connection if the field piping travels horizontally leaving the unit and is pitched sharply
away from the unit (Figure 2). Likewise a trap is not needed if the piping turns down immediately exiting the unit.
• Reduce suction riser size when necessary to help maintain minimum gas velocity and ensure continuous system oil return.

• Install inverted P-traps at the top of individual suction risers when piping multiple suction risers from individual units into a com-
mon suction line located above the evaporator outlets.
• Provide adequate pipe supports near the unit cooler connections and at regular intervals to help maintain pitch (prevent line
sagging) and excessive movement / breakage. Support all external valves and piping components individually.
• Install auxiliary suction to liquid heat exchangers whenever necessary to overcome excessive liquid line heat gain and / or pres-
sure drop due to exposure to high ambient temperatures or tall vertical risers. When properly selected and applied such devic-
es will help maintain 100% bubble free liquid at the TXV inlet.
• Insulate all field piping (both suction and liquid lines) where practical to avoid excessive heat gain and condensation drippage
which may pose a potential safety hazard to personnel and the immediate environment. Protect insulation from physical dam-
age and destructive UV rays with industry approved jacketing materials or coating.
• Although the suction line is the most critical from an overall system capacity and oil return standpoint the liquid line must also
be properly sized to minimize pressure drop and ensure 100% vapor free liquid is continuously delivered to the inlet of the TXV.
Condensing Unit Pitch To Flow

Air Flow Air Flow

Unit Cooler Unit Cooler
Vertical
Suction Pitch
Riser
To
Flow

P-Trap

Suction
Line

Figure 1 Figure 2 Condensing Unit

10
 REFRIGERANT PIPING — CONTINUED
All F31HC and F35HC model series unit coolers are equipped with a venturi-flo refrigerant distributor
which ensures maximum efficiency of the coil under most all operating conditions. There is no orifice
or nozzle plate to select / install in the distributor inlet. For optimum coil performance the TXV should
be mounted within the end compartment of the unit and as short a distance as possible from the dis-
tributor inlet. Do not install any elbows between the outlet of the TXV and the inlet of the distributor!
A 1/4” O.D. equalizer tube is supplied on all units. Never cap this line - use only externally equalized
valves. See Figures 4, 5 & 6 (below) for location and mounting of the TXV sensing bulb.
If not supplied with the unit, the expansion valve must be selected according to the design characteris-
tics of the particular system - taking into consideration the following criteria; Refrigerant type, design
room temperature, system TD or design saturated suction temperature (SST), liquid temperature
(subcooling) and the minimum operating head pressure (SCT) of the system. LU-VE can provide a
separate valve selection table of suggested expansion valves for the most common refrigerants, oper-
ating temperatures and system TD’s however we strongly recommend that you consult with your sup-
plier or valve manufacturer for selection assistance - especially for any unusual or non-standard appli-
cations.
If a liquid line solenoid valve is to be installed in the system we recommend placing it in the field piping reasonably close to the unit
cooler. Do not select valves based only on the physical connection size - the valve you install may be much to large for the application
which can result in operational problems with the valve and possibly even damage to the connected unit cooler or system piping. Re-
fer to the valve manufacturers capacity charts or selection software or consult with your local valve supplier for assistance. Always be
sure to provide adequate pipe clamps and supports for external piping and components - never allow the unit coil connections to sup-
port the weight or unrestricted movement of any field installed piping components. Any damage to the coil which is determined to be
caused by improper field piping design / installation will void the product warranty coverage.

Do not bend or forcibly move the suction

header connection or liquid distributor
assembly of the coil in order to line up
with the field installed piping. Adjust all
field piping to the unit connections!
YES
NO

NO
Always direct the torch flame
away from all unit and valve
connections when brazing to
avoid overheating and potential-
ly damaging components. Use
wet rags or thermal paste when
NO necessary and always flow low
YES YES
pressure nitrogen while brazing
to prevent scale / oxidation from
forming inside the system.

Mount the TXV sensing bulb on a straight, horizontal section of the suction line tubing (Figure 4) as close to
the evaporator outlet as possible and before the suction line P-trap (Figure 5). Position the bulb on the
side of the pipe at one of the locations noted (Figure 6). Securely fasten the bulb to the side of the pipe
with the provided straps. Completely wrap the bulb and piping with insulation to complete the installation.

7/8” OD Pipe and Smaller

NO

YES
7/8” OD Pipe and Larger
Figure 4 Figure 5 Figure 6

11
 LEAK TESTING
Once all field piping connections have been made and the braze joints visually inspected for any obvious voids or gaps introduce a
trace amount of the system refrigerant through a service gauge manifold to achieve an equalized, static pressure of 25 to 30 PSIG.
Make sure that all service and shut off valves are in the open position and slowly introduce a regulated, inert gas such as nitrogen to
increase the static system pressure to approx. 150 PSIG.
Note: Always verify the MAXIMUM system test pressure allowed for all other components in the system before pressurizing
to this level!
Allow sufficient time for the entire sealed system to achieve an equalized test pressure before physically checking all braze joints and
installed system components (both field and factory) with an electronic leak detector. Be sure to turn off the fans of any units operating
nearby or block all air movement with tarps or baffles during testing. If any leaks are indicated double check the suspected area using
soap bubbles, a strong light and an inspection mirror (if necessary). Note the location of any leaks found, reduce the system pressure
to atmosphere, repair the leak(s) (being sure to again flow low pressure nitrogen inside the system while brazing), then repeat the pre-
viously used test procedure to confirm all leaks have been satisfactorily repaired. Allow the system to stand at test pressu re overnight
if possible (or several hours at a minimum), and confirm that there has been no discernable pressure decay during that time.

EVACUATION AND CHARGING

All refrigeration systems must be properly evacuated prior to charging with refrigerant. Simply purging the system with refrigerant or
skipping this important step entirely will result in system operational problems, shortened equipment life and voiding the product war-
ranty coverage. Use a deep vacuum pump which has been properly maintained and the oil recently changed. Connect the pump
(along with an electronic micron gauge) using a service gauge manifold with large bore hoses or tubing. Operate the vacuum pump
continuously during the entire evacuation process (larger volume systems may take several hours and multiple pump oil changes to
achieve a satisfactory vacuum level). Monitor the micron gauge during this time and when a minimum reading of 400 microns is
achieved, blank off the gauge, shut off the pump and observe the gauge for 10-15 minutes. At this point, if the system is tight and dry,
there should be no observed decay of the vacuum gauge reading. Break the vacuum with the correct system refrigerant and charge
as per the system design requirements.
Note: Always refer to the manufacturers charging data for the system condensing unit as the unit cooler operating charge
represents only a very small portion of the total, year round operating charge required for the entire system. Be sure to
charge any refrigerant blend (ex. R-404A, R-407A - F, R-448 / 449A) as a liquid (not vapor) in order to avoid fractionization.
EVAPORATOR SUPERHEAT

In order to maximize evaporator efficiency and total system capacity a superheat reading must be taken at all system evaporators and
the expansion valve(s) adjusted when necessary to optimize coil performance. Pressures and temperatures should be monitored dur-
ing the initial room pulldown, final readings taken and valve adjustments made (if required) once the room is at or near the design op-
erating temperature and ideally, before the product has been loaded. For most applications with normal traffic patterns, stable operat-
ing room temps and uniform frost loading on the coil (SST below +32 degrees) the optimum, operating superheat at the evaporator
outlet should be in the range of 6-10 degrees. If valve control is extremely stable then lower is typically better to ensure maximum coil
performance. If box traffic and product loading is excessive, coils are located near areas of high moisture infiltration (not recommend-
ed) then a slightly higher operating superheat is recommended in order to protect the system compressor from possible valve over-
feeding. Most compressor manufacturers recommend a minimum of 20 degrees superheat at or near the compressor inlet and on
very close coupled systems some compromise may need to be made to protect the compressor. The use of a suction to liquid heat
exchanger or suction accumulator may be necessary in applications where minimum compressor superheat cannot be maintained.

TAKE THE FOLLOWING TEMPERATURES AND PRESURES

CHECKING EVAPORATOR SUPERHEAT
RAT - Return Air Temperature to the unit.

SP - Suction Pressure at evaporator coil outlet (converted to the

equivalent SST of system refrigerant).

ST - Suction Temperature measured at the expansion valve

sensing bulb

For optimum unit cooler performance the superheat at the coil

outlet (ST - SST) should be as low as possible, considering
stable valve operation (little to no hunting) and as close as pos-
sible to the RAT.

The thermostatic expansion valve must be properly sized for the

design operating conditions of the installation and adjusted to
maximize unit cooler performance. ST SP
RAT
Always refer to the valve manufacturers installation and
operation instructions for detailed information on adjusting < 6”
the specific valve installed on the unit.

12
 REFRIGERANT BLENDS — TEMPERATURE GLIDE
The majority of HFC refrigerants in use today are referred to as refrigerant “blends” (composed of two or more different refrigerants).
As such, each component within this “blend” evaporates (or condenses) at different temperatures. The temperature range within which
each of these different refrigerants completely changes state from a liquid to a gas (or vice versa) is referred to as “temperature glide”.
Essentially this means that the traditional way we measure superheat and liquid sub-cooling must be adjusted to account for this tem-
perature “glide”. Depending upon which one of these refrigerant is used in the system the temperature glide could range from as low
as 6 to perhaps as high as 12 degrees. Technically R-404A is also a blend but since it’s temperature glide is only around 1 degree it is
typically treated as an azeotrope (a refrigerant whose components boil and evaporate at the same temperature).

When measuring superheat at the evaporator outlet of a system utilzing any of these high glide rfrigerants you must always refer to the
refrigerants’ “Dew Point” which is the point at which the last droplet of liquid refrigerant has vaporized. These values are all listed for
easy reference on all current temperature pressure charts, mechanical and electronic service gauge manifolds and apps commonly
used by todays field service technicians. If in doubt about the values you’ve measured always refer to published data supplied by the
various refrigerant manufacturers to confirm your field measurements. Regardless of which type of refrigerant is used in the system
the service technicians goal is still the same - to maximize the evaporator performance while ensuring both adequate compressor motor
cooling and the prevention of liquid floodback .

The diagram on the right graphically illustrates the relationship

or “glide” of two different components making up a single refrig-
erant blend as they pass through the evaporator coil. The
number on the left of the / mark represents the percentage of
refrigerant “A” and the number to the right of the / mark repre-
sents the percentage of refrigerant “B” which is present at each
location (1, 2 & 3) in the evaporator coil.
Note that the mixture is only equal (50/50) at the inlet
(100% liquid) and at the outlet (100% vapor) of the evapo-
rator coil.

FIELD WIRING — ELECTRICAL REQUIREMENTS

The electrical characteristics of each unit are clearly marked on the unit rating label located on the front facing, left hand end cover of
the unit (as viewed facing the fans). This label lists the operating voltage, phase and amp draw of the fan motors and defrost heaters
(when equipped). It also lists the MINIMUM CIRCUIT AMPACITY (MCA) and MAXIMUM OVER CURRENT PROTECTION DEVICE
(MOPD) which should be used in order to determine the minimum wire gauge size required to supply power to the unit and the largest
circuit breaker / fuse size it should be fed from. These values apply only to the main power supply to the unit - there may be separate,
field control circuit wiring required which can be ran in smaller gauge wiring, but must still be suitable for the applied voltage.
All field wiring must be ran using copper conductors only and in total compliance with the National Electrical Code (NEC) as well as
any local or state codes. There are multiple knockouts supplied on the electrical end of the unit (opposite the refrigerant connection
end) to accommodate field installed wiring / conduit connections. Field wiring must be landed on the factory supplied terminal block
located inside the electrical end panel. Refer to the unit wiring diagram located on the inside of the electrical end cover panel for the
specific terminals to connect to. When making the field wiring connections it is always advisable to double check the factory wiring
connections to be sure that none have loosened in shipment or are otherwise dislodged from their terminals. The unit must also be
properly grounded which may require that a dedicated ground wire be ran to the unit (depending upon local code requirements and
the type of conduit utilized in the installation).

FACTORY WIRING
Fig. 5
Heater Safety NP
MOTORS
Field Power Wiring

The fan motors for all air defrost units are factory
wired to the terminal block. On electric defrost units
all fan motors, defrost heaters, heater safety and fan K
delay / defrost termination controls are factory wired.
If not provided as a factory mounted option it is the
installing contractors responsibility to install and wire
a room thermostat, liquid line solenoid valve and de-
frost timer (when required). The typical wiring dia-
grams supplied on the following pages will assist with Factory Mounted
the field wiring of these controls - as well as wiring for Junction Box / Defrost Termination
multiple units on a single system when required. Terminal Block
J
Fan Delay Control

13
 FIELD WIRING DIAGRAMS — TYPICAL
AIR DEFROST — 115/1/60 OR 208/230/1/60 UNIT COOLER

IMPORTANT WIRING NOTES - INSTALLER PLEASE READ CAREFULLY!

Sub-circuit fusing or service disconnect switches are not shown but may be required as per the NEC and / or local codes.
** It is the responsibility of the installing contractor to interpret and comply with all applicable electrical codes.
Field install an 18 GA jumper wire between terminals 3 & 4 on terminal block TB2 for continuous low speed fan operation (950
RPM). Fan motors will operate continuously on high speed without jumper wire installed (F31 Models Units - 1300 RPM / F35
* model units - 1450 RPM). See page 21 for optional two speed fan relay control wiring if required.

+ An air defrost time clock may be supplied as an option (either field installed or factory mounted on the system condensing unit).
The room thermostat and liquid line solenoid valve are shown as field installed but may be factory mounted in the unit cooler.
< Make sure the solenoid holding coil is wired for the correct control voltage (115 or 230).

14
 FIELD WIRING DIAGRAMS — TYPICAL
ELECTRIC DEFROST — 208/230/1/60 — (1) UNIT COOLER (TIMER ONLY)

IIMPORTANT WIRING NOTES - INSTALLER PLEASE READ CAREFULLY!

Sub-circuit fusing or service disconnect switches are not shown but may be required as per the NEC and / or local codes.
** It is the responsibility of the installing contractor to interpret and comply with all applicable electrical codes.
Field install an 18 GA jumper wire between terminals 3 & 4 on terminal block TB2 for continuous low speed fan operation (950
RPM). Fan motors will operate continuously on high speed without jumper wire installed (F31 Models Units - 1300 RPM / F35
* model units - 1450 RPM). See page 21 for optional two speed fan relay control wiring if required.
The defrost time clock and block out relay are typically located in the system condensing unit. All unit cooler power should
+ feed from this unit. Make sure that the heater amp draw does not exceed the defrost timer contact rating (typically 40 resistive
amps for an 8145-20 or equivalent timer). Also be sure the wire gauge size is adequate to carry the total amp load required.

# Factory installed jumper — remove if using a heater contactor.

The room thermostat and liquid line solenoid valve are shown as field installed but may be factory mounted in the unit cooler.
< Make sure the solenoid holding coil is wired for the correct control voltage (115 or 230).

15
 FIELD WIRING DIAGRAMS — TYPICAL
ELECTRIC DEFROST — 208/230/1/60 — (1) UNIT COOLER WITH HEATER CONTACTOR

IMPORTANT WIRING NOTES - INSTALLER PLEASE READ CAREFULLY!

Sub-circuit fusing or service disconnect switches are not shown but may be required as per the NEC and / or local codes.
** It is the responsibility of the installing contractor to interpret and comply with all applicable electrical codes.
Field install an 18 GA jumper wire between terminals 3 & 4 on terminal block TB2 for continuous low speed fan operation (950
RPM). Fan motors will operate continuously on high speed without jumper wire installed (F31 Models Units - 1300 RPM / F35
* model units - 1450 RPM). See page 21 for optional two speed fan relay control wiring if required.
The defrost time clock, block out relay / auxiliary switch and heater contactor are typically located in the system condensing
+ unit. All unit cooler power should feed from this unit. Make sure the total heater amp draw does not exceed the resistive rating
of the contactor. Also be sure the wire gauge size is adequate to carry the total amp load required.
When using a heater contactor with unit cooler defrost heaters factory wired for single phase remove factory installed jumper
# between terminals 2 & 3 on TB1 and wire directly to heater contactor as shown above.
The room thermostat and liquid line solenoid valve are shown as field installed but may be factory mounted in the unit cooler.
< Make sure the solenoid holding coil is wired for the correct control voltage (115 or 230).

16
 FIELD WIRING DIAGRAMS — TYPICAL
ELECTRIC DEFROST — 208/230/1/60 — (2) UNIT COOLERS / TIMER ONLY

IMPORTANT WIRING NOTES - INSTALLER PLEASE READ CAREFULLY!

Sub-circuit fusing or service disconnect switches are not shown but may be required as per the NEC and / or local codes.
** It is the responsibility of the installing contractor to interpret and comply with all applicable electrical codes.
Field install an 18 GA jumper wire between terminals 3 & 4 on terminal block TB2 for continuous low speed fan operation (950
* RPM). Fan motors will operate continuously on high speed without jumper wire installed (F31 Models Units - 1300 RPM / F35
model units - 1450 RPM). See page 21 for optional two speed fan relay control wiring if required.
The defrost time clock and block out relay are typically located in the system condensing unit. All unit cooler power should
feed from this unit. When connecting multiple unit cooler defrost heaters to (1) defrost time clock make sure the total heater
+ amp draw does not exceed the defrost timer contact rating (typically 40 resistive amps for an 8145-20 or equivalent timer),
Also be sure the wire gauge size is adequate to carry the total amp load required.. If the combined heater amp draw exceeds
the defrost timer rating a heater contactor must be installed (see alternate wiring diagram for 1 or 2 heater contactor wiring
arrangement).
When connecting (2) electric defrost unit coolers to (1) defrost timer remove the black wire from the defrost termination / fan
! delay control which is factory wired to terminal 2 - TB2 on unit cooler #2 and cap the wire. This will allow the fan delay on
unit cooler #1 to control the fans on both unit coolers.
When connecting (2) electric defrost unit coolers to (1) defrost timer remove the red wire from the defrost termination / fan
delay control which is factory wired to terminal 4 - TB1 on unit cooler #2 and hard wire to a field wire connected to terminal 1
^ - TB2 on unit cooler #1. This will place the (2) defrost termination controls in series so that both units must reach temperature
in order to terminate the defrost cycle.

When using a heater contactor with unit cooler defrost heaters factory wired for single phase remove factory installed jumper
# between terminals 2 & 3 on TB1 and wire directly to heater contactor.
The room thermostat and liquid line solenoid valve are shown as field installed but may be factory mounted in the unit cooler.
< Make sure the solenoid holding coil is wired for the correct control voltage (115 or 230).

17
 FIELD WIRING DIAGRAMS — TYPICAL
ELECTRIC DEFROST — 208/230/1/60 — (2) UNIT COOLERS / (1) HEATER CONTACTOR

IMPORTANT WIRING NOTES - INSTALLER PLEASE READ CAREFULLY!

Sub-circuit fusing or service disconnect switches are not shown but may be required as per the NEC and / or local codes.
** It is the responsibility of the installing contractor to interpret and comply with all applicable electrical codes.
Field install an 18 GA jumper wire between terminals 3 & 4 on terminal block TB2 for continuous low speed fan operation (950
* RPM). Fan motors will operate continuously on high speed without jumper wire installed (F31 Models Units - 1300 RPM / F35
model units - 1450 RPM). See page 21 for optional two speed fan relay control wiring if required.
The defrost time clock, block out relay / auxiliary switch and heater contactor are all typically located in the system condensing
unit. All unit cooler power should feed from this unit. When connecting multiple unit cooler defrost heaters to (1) heater con-
+ tactor make sure the total heater amp draw does not exceed the resistive amp rating of the contactor. Also be sure the wire
gauge size is adequate to carry the total amp load required.

# When using a heater contactor with unit cooler defrost heaters factory wired for single phase remove factory installed jumper
between terminals 2 & 3 on TB1 and wire directly to heater contactor as shown above.
When connecting (2) electric defrost unit coolers to (1) defrost timer remove the black wire from the defrost termination / fan
! delay control which is factory wired to terminal 2 - TB2 on unit cooler #2 and cap the wire. This will allow the fan delay on unit
cooler #1 to control the fans on both unit coolers.

When connecting (2) electric defrost unit coolers to (1) defrost timer remove the red wire from the defrost termination / fan de-
lay control which is factory wired to terminal 4 - TB1 on unit cooler #2 and hard wire to a field wire connected to terminal 1 -
^ TB2 on unit cooler #1. This will place the (2) defrost termination controls in series so that both units must reach temperature in
order to terminate the defrost cycle.

The room thermostat and liquid line solenoid valve are shown as field installed but may be factory mounted in the unit cooler.
< Make sure the solenoid holding coil is wired for the correct control voltage (115 or 230).

18
 FIELD WIRING DIAGRAMS — TYPICAL
ELECTRIC DEFROST — 208/230/3/60 — (1) UNIT COOLER WITH HEATER CONTACTOR

IMPORTANT WIRING NOTES - INSTALLER PLEASE READ CAREFULLY!

Sub-circuit fusing or service disconnect switches are not shown but may be required as per the NEC and / or local codes.
** It is the responsibility of the installing contractor to interpret and comply with all applicable electrical codes.
Field install an 18 GA jumper wire between terminals 3 & 4 on terminal block TB2 for continuous low speed fan operation (950
RPM). Fan motors will operate continuously on high speed without jumper wire installed (F31 Models Units - 1300 RPM / F35
* model units - 1450 RPM). See page 21 for optional two speed fan relay control wiring if required.
The defrost time clock, block out relay / auxiliary switch and heater contactor are typically located in the system condensing
+ unit. All unit cooler power should feed from this unit. Make sure the total heater amp draw does not exceed the resistive rating
of the contactor. Also be sure the wire gauge size is adequate to carry the total amp load required.
When using a heater contactor with unit cooler defrost heaters factory wired for single phase remove factory installed jumper
# between terminals 2 & 3 on TB1 and wire directly to heater contactor as shown above.
The room thermostat and liquid line solenoid valve are shown as field installed but may be factory mounted in the unit cooler.
< Make sure the solenoid holding coil is wired for the correct control voltage (115 or 230).

19
 FIELD WIRING DIAGRAMS — TYPICAL
ELECTRIC DEFROST — 208/230/3/60 — (2) UNIT COOLERS / (1) HEATER CONTACTOR

IMPORTANT WIRING NOTES - INSTALLER PLEASE READ CAREFULLY!

Sub-circuit fusing or service disconnect switches are not shown but may be required as per the NEC and / or local codes. It is
** the responsibility of the installing contractor to interpret and comply with all applicable electrical codes.
Field install an 18 GA jumper wire between terminals 3 & 4 on terminal block TB2 for continuous low speed fan operation (950
RPM). Fan motors will operate continuously on high speed without jumper wire installed (F31 Models Units - 1300 RPM / F35
* model units - 1450 RPM). See page 21 for optional two speed fan relay control wiring if required.
The defrost time clock, block out relay / auxiliary switch and heater contactor are all typically located in the system condensing
+ unit. All unit cooler power should feed from this unit. Make sure the total heater amp draw per unit cooler does not exceed the
resistive amp rating of the contactor. Also be sure the wire gauge size is adequate to carry the total amp load required.
When connecting (2) electric defrost unit coolers to (1) defrost timer remove the black wire from the defrost termination / fan
^ delay control which is factory wired to terminal 2 - TB2 on unit cooler #2 and cap the wire. This will allow the fan delay on unit
cooler #1 to control the fans on both unit coolers.

When connecting (2) electric defrost unit coolers to (1) defrost timer remove the red wire from the defrost termination / fan
delay control which is factory wired to terminal 4 - TB1 on unit cooler #2 and hard wire to a field wire connected to terminal 1 -
! TB2 on unit cooler #1. This will place the (2) defrost termination controls in series so that both units must reach temperature in
order to terminate the defrost cycle.

The room thermostat and liquid line solenoid valve are shown as field installed but may be factory mounted in the unit cooler.
< Make sure the solenoid holding coil is wired for the correct control voltage (115 or 230).

20
 FIELD WIRING DIAGRAMS — TYPICAL
ELECTRIC DEFROST — 208/230/3/60 — (2) UNIT COOLERS / (2) HEATER CONTACTORS

IMPORTANT WIRING NOTES - INSTALLER PLEASE READ CAREFULLY!

Sub-circuit fusing or service disconnect switches are not shown but may be required as per the NEC and / or local codes. It is
** the responsibility of the installing contractor to interpret and comply with all applicable electrical codes.
Field install an 18 GA jumper wire between terminals 3 & 4 on terminal block TB2 for continuous low speed fan operation (950
* RPM). Fan motors will operate continuously on high speed without jumper wire installed (F31 Models Units - 1300 RPM / F35
model units - 1450 RPM). See separate wiring diagram for optional two speed fan relay wiring if required.
The defrost time clock, block out relay / auxiliary switch and contactors are typically located in the system condensing unit. All
+ unit cooler power should feed from this unit. Make sure the total heater amp draw does not exceed the resistive amp rating of
the contactors supplied. Also be sure the wire gauge size is adequate to carry the total amp load required.
When connecting (2) electric defrost unit coolers to (1) defrost timer remove the black wire from the defrost termination / fan

^ delay control which is factory wired to terminal 2 - TB2 on unit cooler #2 and cap the wire. This will allow the fan delay on unit
cooler #1 to control the fans on both unit coolers.

When connecting (2) electric defrost unit coolers to (1) defrost timer remove the red wire from the defrost termination / fan
! delay control which is factory wired to terminal 4 - TB1 on unit cooler #2 and hard wire to a field wire connected to terminal 1 -
TB2 on unit cooler #1. This will place the (2) defrost termination controls in series so that both units must reach temperature
in order to terminate the defrost cycle.

The room thermostat and liquid line solenoid valve are shown as field installed but may be factory mounted in the unit cooler.
< Make sure the solenoid holding coil is wired for the correct control voltage (115 or 230).

21
 FIELD WIRING DIAGRAMS — OPTIONSs
TWO SPEED FAN MOTOR RELAY WIRING OPTION

Installing this relay will allow the unit cooler fans to operate at low speed whenever the room thermostat is satisfied or the
unit is in defrost (when optional, off-cycle “air” defrost timer is used), resulting in reduced operating costs over the life of the
equipment.

* Remove jumper wire (if installed) between unit cooler terminals 3 & 4 before connecting relay wires.

< Be sure that fan relay coil voltage matches unit cooler control voltage. Wire across normally open (NO) relay contacts.

+ Single Pole — Single Throw Thermostat

ELECTRONIC ROOM THERMOSTAT WIRING OPTION

Be sure that room thermostat

power wiring matches the unit
* cooler control voltage.
Wire across normally open
+ (NO) thermostat contacts.

22
 START UP

Check The Following Items Before And After Initial Start Up

• Verify that all electrical connections (both main power and control wiring) have been properly secured and all access co-
vers replaced.
• Check to be sure that all field piping has been insulated, properly supported and secured with clamps.

• Confirm that the TXV sensing bulb has been securely fastened to the suction line and insulated.

• Verify that all condensate drain line piping has been completed, all piping is properly pitched, supported and secured with
clamps. On low temperature applications make sure that all drain line piping is insulated, drain line heaters are installed
and wired to a dedicated power source for continuous operation.
• Check to be sure that all pipe and conduit penetrations into the cooler / freezer have been properly sealed to prevent the
infiltration or warm, moist air into the conditioned space. Unsealed gaps or voids will quickly become “conduits” through
which moisture laden outside air will flow into the cooler or freezer placing an unnecessary burden on the refrigeration sys-
tem and potentially creating both safety concerns for operating personnel as well as operation problems for the unit cooler,
(ex. coil icing / steaming, stalled / burned out fan motors, broken fan blades, liquid flood back to the compressor, etc.).
• Measure the incoming voltage at the main power terminal block. Voltage measured should be within +/- 10% of the unit
nameplate rating.
• On initial start up and pulldown of a warm box (electric defrost units only) the defrost termination / fan delay control will hold
out the fans until the coil temperature reaches (and continuously maintains) approx. +25 degrees F (+/-). Prior to start up
of these units a jumper wire should be physically installed between terminal 4 - TB2 and terminal 2 - TB1 (units with defrost
heaters wired for single phase) or between terminal 1 and terminal 3 - TB2 (units with defrost heaters wired for three
phase). This will bypass the fan delay side of the switch, forcing the fans to run continuously. Once the room temperature
has dropped down near freezing the jumper wire should be removed for proper operation.
• Once the unit is running check all fan motors for proper rotation and air throw. If poor air circulation is noted refer to page
7 of this manual for possible causes and correction of air flow issues.
• Observe the unit for any unusual noise or vibration. Investigate and correct the cause of any issues noted.

• With the system fully charged with refrigerant and the room at or near design operating temperature check superheat at
the evaporator coil outlet. Adjust the expansion valve (if required) to obtain correct, operating superheat (see EVAPORA-
TOR SUPERHEAT - Page 12).
• Check for any standing water in the condensate drain pan. If the drain pan is holding water check for proper P-traps in the
line (in the absence of a trap, negative pressure at the drain pan connection fitting can cause water to hold up in the pan).
Verify unit is mounted level. Check drain line piping for correct pitch or possible obstructions / debris and correct as re-
quired.
• On electric defrost units manually force system into a defrost cycle. Check the amp draw of the heaters and compare this
reading to the unit rating label in order to verify that all defrost heaters are functioning correctly. Allow the system to oper-
ate through a complete defrost cycle and observe that the unit terminates the defrost cycle on the defrost termination tem-
perature control (approx. +70 degrees +/-). Observe that the fans are delayed no more than approx. (2) minutes immedi-
ately following the defrost cycle.
• Adjust the system defrost control / timer to periodically initiate a defrost cycle. For “Air Defrost” or off cycle timers a typical
setting would be 2-3 times per day for 45 minutes per cycle. Electric defrost timers are typically set to provide (4) 30 mi-
nute defrost cycles per day however it should be noted that every installation is potentially different and that defrost is a
“necessary evil”. Generally speaking fewer defrost cycles per day is always better - particularly if any steaming is observed
near the end of the defrost cycle. Steaming is characterized by a hissing sound which is caused by water droplets as they
contact an over-temp heater sheath and immediately vaporize into steam which then condenses on any adjacent cold sur-
faces such as fan panels, drain pans, fan blades, motor mounts, ceiling panels, etc.. Although in many cases a techni-
cians initial reaction is to increase or lengthen the defrost cycle the exact opposite is usually the best course of corrective
action. Reduce the number of cycles per day and verify the cycle is being terminated by the defrost termination tempera-
ture control (Refer to Troubleshooting Defrost Cycle - Page 25).

23
 SERVICE — MAINTENANCE
TROUBLESHOOTING EC MOTOR AND FAN ASSEMBLY

Observation Possible Cause Corrective Action

Fan Motor Rocks Back And
Normal pre-start alignment for EC motor Not Applicable
Forth
No power to unit
Check breaker or incoming power from defrost timer
(check voltage at power term block)
Bad connection at motor lead plug or terminal Repair / replace burned, damaged or
block loose connections
Obstruction blocking fan blade Clear obstruction to ensure blade / motor turns freely
Control closes at +25° F.
Fan delay control open on electric defrost unit
Fan Motor(s) Don’t Temporarily jump out or replace defective control
Operate
Motor physically locked up If blade is free but motor will not turn replace assy.

Check resistance of all (3) motor lead wires to ground

Check resistance between motor lead wires
Motor windings shorted, open or burned.
2 & 1 (Com & High) and 2 & 3 (Com & Low)
Replace motor / fan assembly
Check voltage at motor leads. Must be +/- 10% of
Low Voltage
unit nameplate
Jumper wire installed between lead wires 1 & 3
Remove jumper wire
(low speed)
Fan Motor(s) Turn Slow
Coil fouled with frost / ice / dirt Clear / clean coil of all frost / ice build-up / dirt

Product stacked too close to coil face Relocate product to clear return air path to coil
Fan hitting obstruction / damaged Rotate motor / fan assembly by hand.
or out of balance blade Clear obstructions or replace fan / motor assy.
Motor / Fan Assembly
Noisy Motor bearings worn or damaged Replace defective motor / fan assembly

Damaged / broken motor mount Replace damaged / broken motor mount

Do not attempt to remove / replace fan blade in the field! Blade & motor must be replaced as an assembly.
See illustrations on page 26

TROUBLESHOOTING CORROSION OF THE COIL ASSEMBLY

Observation Possible Cause Corrective Action

Wrong cleaning agent or too high of concentra- Use correct cleaner for the application. Follow the manu-
tion of cleaner being used. Inadequate / im- facturers directions completely. Use copious amounts of
proper rinsing of cleaner from the coil surface rinse water
Visible deterioration of the
Identify the source of corrosion. Some potential sources
coil fins. Flakes of aluminum
include; vinegar based salad dressings (acetic acid) and
or white powder present in
various spices often found in prepared foods, sulfur
drain pan, on product or
Corrosive agent present in air attacking (from water / melting ice, forklift charging stations), prod-
elsewhere in the room
aluminum fins ucts of combustion present in automobile exhaust (un-
trapped drain lines near drive throughs / driveways),
exhaust from fork lifts, cooking areas / vent hoods,
sewer gas from drains / vents, etc.
Similar scenario to the above - attempt to identify the
potential source of the corrosive agent. Some possible
Corrosive agent present in air attacking the
Pin hole leaks in copper sources include; chlorine or ammonia (present in many
copper tubing or phosphorous in braze joints
tubes / return bends or commercial cleaners), urine, sulfur (from water / melting
(copper may also appear discolored -
factory braze joints ice), dairy products (lactic acid), bread or bread dough
possibly black or green)
(active yeast), ethylene gas (ripening fruits), acids in
dried sausage / pepperoni, etc.

If the source of the corrosion cannot be identified and / or effectively eliminated from the immediate area of the unit installation then a
replacement unit with a coated coil assembly is highly recommended. Depending upon the concentration of the corrosive agent and
level of exposure it is possible to experience premature failure of the coil surface within a very short period of time after installation.
(even if the coil has been coated). Regardless of the time frame between exposure and failure any coil which has failed due to expo-
sure to environmental corrosion is considered to be outside the product warranty coverage.

24
 SERVICE — MAINTENANCE
TROUBLESHOOTING DEFROST CYCLE AND DEFROST HEATERS

Observation Possible Cause Corrective Action

Relocate unit away from doors / other openings

Excessive moisture infiltration into cool- Seal / repair all sources of air leaks into walk-in box
er / freezer (fan guard, motor / fan assem- Install strip curtains on access doors
bly, unit housing, wall / ceiling panels may
also be covered with heavy frost Limit door openings / close door when entering / exiting walk-in
accumulation) Install door switch (interlock fans and liquid solenoid valve)
Install P-trap in drain line at unit cooler
Fan motor out See motor troubleshooting chart
Defrost cycle not being initiated by timer Check / replace defective defrost timer
Check voltage at term block. Must be +/- 10% of nameplate
Coil Blocked with Frost /
Ice Check for loose or burned wires / connections at terminal block.
Repair or replace as necessary
Defrost heater(s) not energized during Check heater safety (opens at +70). Replace defective control
defrost
Heaters burned out. Check resistance across heater leads.
Replace any heaters reading "open" (infinite resistance)
Check external heater contactor (when supplied).
Replace if defective
Set room thermostat to min +34 degrees
Box temperature too low (air defrost unit) Install off-cycle “air” defrost timer
Install defrost heaters / replace with electric defrost unit
Heater restraining clips broken / missing
Reposition heaters / replace restraining clips
(heaters shifted)
Excessive moisture infiltration into cool-
See above
er / freezer
Too few defrost cycles / day Increase number of defrost cycles per day
Incomplete Defrost Cycle
(All Heaters Energized) Defrost cycle too short
Set defrost timer to minimum 30 min per cycle
(terminates on time)
Defrost cycle too short (terminates on Check defrost termination control (closes at +55 deg).
temp) Replace defective control
Incoming voltage too high Check voltage at term block. Maximum 10% of nameplate
Too many defrost cycles / day Reduce number of defrost cycles / day
Check defrost termination control (closes at +55 deg)
Ice build-up on fan guard, Defrost cycle too long
Replace defective control
fan / motor assembly, mo-
tor mount, fan panel (also No P-trap installed in drain line at unit cooler. Install trap
ice droplets on ceiling pan-
el in front of fans and be- Coil not building frost uniformly Superheat too high. Adjust TXV / lower superheat
hind coil / on upper back Poor refrigerant distribution in coil (liquid temp too low).
wall and on product. Also Insulate liquid line / increase liquid temp to TXV
ice on floor around unit
Fans start immediately following defrost Check fan delay control (closes at +25 deg).
cycle Replace defective control
Heater restraining clips broken / missing
Reposition heaters / replace restraining clips
(heaters shifted)
Unit not mounted level Check / adjust level of unit as required
Insufficient / improper drain line pitch Pitch drain line a minimum of 1/4" / foot
Drain line too small Drain line must be no smaller than outlet connection on pan
Drain Pan Filled With Ice Drain line blocked / plugged with debris Clear blockage / manually clear ice build-up from drain pan
Ice build-up on floor P-trap located outdoors
Re-locate trap / add heat / insulate
(un-heated in winter)
Defective drain pan heater Check heater resistance / replace if defective
Replace defective heater / add additional heat if required.
Defective / inadequate drain line heater
Insulate drain line piping
See detailed instructions for replacing defrost heaters on page 27

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 SERVICE — MAINTENANCE
IMPORTANT! Before any service / maintenance operations are performed to the unit, locate and lock out the main power supply to the
unit. Note: In some cases more than (1) power source (breaker or service disconnect switch) may be supplied.

BE SURE TO LOCK OUT / TAG OUT ALL SOURCES OF POWER!

MODEL SERIES F35HC — MOTOR / FAN ASSEMBLY REMOVAL

MODEL SERIES F31HC — MOTOR AND FAN ASSEMBLY REMOVAL

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 SERVICE — MAINTENANCE

IMPORTANT! Before any service / maintenance operations are performed to the unit, locate and lock out the main power supply to the
unit. Note: In some cases more than (1) power source (breaker or service disconnect switch) may be supplied.

BE SURE TO LOCK OUT / TAG OUT ALL SOURCES OF POWER!

COIL AND DRAIN PAN HEATER REPLACEMENT PROCEDURE

1. Before removing the electric heaters make sure

that they are all at ambient temperature

2. Remove both left and righthand unit end covers

by removing (3) Philips head screws per side

3. If the drain pan heater (SHB) is to be replaced

remove the field installed condensate drain line
from the unit, then detach the drain pan by re
moving (4) Philips head screws (Items 1 & 2)

4. Identify the coil heater to be replaced (FHC) and at-

tach pulling wires for the replacement heater to the
(2) wire leads of the defective heater (Items 3 & 4)

5. The heater retaining clip (item U) must be re-

moved from the old heater by squeezing the clip
together to release it from the hole in the tube
sheet (Item V)

6. Remove the defective heater by pulling it straight out

from the retaining clip end of the heater (Items 5 & 6)
being careful to leave the (2) pulling wires inside the
coil (Item 3)

7. Install the retaining clip (U) onto the replacement

heater (Item 9)
New Heater
8. Attach the (2) pulling wires still in the coil (Item 3)
to the wire leads of the replacement heater (Item
7) and guide the boot ends of the heater through
the holes in the tube sheet (Item 11) and straight
into the coil (Item 12) while an assistant pulls New Heater
gently on the opposite end of the (2) pulling wires

IMPORTANT! Be careful when inserting a replacement

heater into the coil assembly in a confined area. The
heaters are annealed to allow some flexibility and
bending during installation however sharp bends or
kinks must be avoided to prevent damaging the replace-
ment heater. The ends of the heater entering the coil
must always be inserted straight - attempting to force
the heater into the coil at an angle (Item 8) may result in
internal damage to the coil assembly!

9. When the replacement heater is in its final position

insert the heater retaining clip into the hole in the
tube sheet to prevent any movement of the heater
during operation

10. Reconnect the (2) heater wire leads being careful to

properly secure any excess wire in order to prevent it
from contacting the heated portion of any of the
heaters and gently prying up the metal retainer clips (Item Z) to
release the heater
11. Replacement of the drain pan heater (SHB) is
accomplished by disconnecting the (2) wire leads 12. Replacement is the reverse of this procedure

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 RECOMMENDED ROUTINE MAINTENANCE — SERVICE

Routine service / maintenance should be performed only by qualified individuals who are properly trained
and knowledgeable of the type and scope of work required. Before performing any service / maintenance (or introducing
water into the immediate area of the unit) disconnect and lock out ALL sources of power to the unit!
Check room temperature vs. thermostat setting Adjust / calibrate as required to maintain desired room temperature
Troubleshoot any non-functional motors, motors turning slowly or
Observe fan motors for normal operation and sound level making abnormal noise / vibrations
(see Troubleshooting EC Motor chart)
Troubleshoot the possible causes for abnormal build-up
Visually check the coil and unit for excess frost / ice accumulation
(see Troubleshooting Defrost Cycle chart)

Visually check condensate drain pan for debris Remove ice with hot water. Remove and clean pan with warm
(check for standing water / ice build-up) soapy water if required
Clear drain with plumbers snake, high pressure air
Check condensate drain line
or warm water if plugged.
Confirm drain line heater is energized and functioning. Trou-
Check drain line heater (electric defrost units only)
bleshoot non-functional heater

Manually initiate a defrost cycle and check heater amp draws (see
Check operation of coil and drain pan heaters
Troubleshooting Defrost Heater chart)
If it becomes necessary to clean the coil assembly due to the accumulation of grease, dirt or debris, use a mixture of hot water
and Dawn dishwashing liquid in a pump-up sprayer and thoroughly saturate the entire coil assembly with the solution. Allow the
mixture to soak on the coil for several minutes, then flush thoroughly and completely with warm water. Repeat as necessary.

REPLACEMENT PARTS INFORMATION

Replacement Parts For Unit Model Series F31HC Replacement Parts For Unit Model Series F35HC
Part Description Part # Part Description Part #
EC Fan And Motor Assembly (115/230 Volt) 30341400 2 Speed EC Fan And Motor Assembly (115/230 Volt) 31032381
Defrost Heater; 850 Watt / 240 Volt ( 1 Fan Models) 31032480 Defrost Heater; 800 Watt / 240 Volt (2 Fan Models) 31022185
Defrost Heater; 1450 Watt / 240 Volt (2 Fan Models) 31022176 Defrost Heater; 1150 Watt / 240 Volt (3 Fan Models) 31032513
Defrost Heater; 2025 Watt / 240 Volt (3 Fan Models) 31032481 Defrost Heater; 1500 Watt / 240 Volt (4 Fan Models) 31032514
Defrost Heater; 2600 Watt / 240 Volt (4 Fan Models) 31032485 Drain Pan Assembly w/ Drain Fitting (2 Fan Models) 31106841
Drain Pan Assembly w/ Drain Fitting (1 Fan Models) 31106814 Drain Pan Assembly w/ Drain Fitting (3 Fan Models) 31106847
Drain Pan Assembly w/ Drain Fitting (2 Fan Models) 31106824 Drain Pan Assembly w/ Drain Fitting (4 Fan Models) 31106850
Drain Pan Assembly w/ Drain Fitting (3 Fan Models) 31106829 Drain Pan Fitting; 2 Piece, 3/4” MPT (Includes Gasket) 31097930
Drain Pan Assembly w/ Drain Fitting (4 Fan Models) 31106831 Drain Pan Heater Kit (2 Fan Models) 31033165
Drain Pan Fitting; 2 Piece, 3/4” MPT (Includes Gasket) 31097930 Drain Pan Heater Kit (3 Fan Models) 31034220
Drain Pan Heater Kit (1 Fan Models) 31034200 Drain Pan Heater Kit (4 Fan Models) 31034221
Drain Pan Heater Kit (2 Fan Models) 31022188 Side Access Panel (Left / Right Hand) 30085031
Drain Pan Heater Kit (3 Fan Models) 31032481 Jet Streamer Fan Guard (All Models) 30087591
Drain Pan Heater Kit (4 Fan Models) 31032485 Defrost Termination / Fan Delay Control 31022207
Side Access Panel (Left / Right Hand) 30085032 Heater Safety / Hi Limit Switch 31022206
Jet Streamer Fan Guard (All Models) 30087635
Defrost Termination / Fan Delay Control 31022207
Heater Safety / Hi Limit Switch 31022206

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 IMPORTANT NOTES AND INFORMATION

LU-VE unit coolers are suitable for use with any of the following refrigerants;
R-12, R-22, R-134A, R-404A, R-407A, R-407C, R-407F, R-448A, R-449A, R-449B and R-507

They may also be used with any EPA approved replacements for;
R-12, R-22, R-502 And Water / Glycol
Unit Coolers are also suitable for use with Refrigerant R-744 (Carbon Dioxide) in a SECONDARY LOOP or CASCADE
system. All units which are suitable for use with Refrigerant R-744 will include “CO2” listed in the unit model
nomenclature - followed by either 870 PSIG or 1,230 PSIG.
All units designed for use with Water / Glycol must be custom circuited for the specific application. These units ARE
NOT SUITABLE for use with CO2.
Unit coolers constructed with copper tube coils are not suitable for use with ammonia (R-717)

Maximum Working And Test Pressures

• The maximum working pressure of all units which are suitable for use with CFC, HCFC and HFC refrigerants is 350
PSIG. The maximum, recommended unit test pressure for field leak testing of these units is 150 PSIG.
• The maximum working pressure of all units specifically designed for use with CO2 refrigerant is 870 PSIG for cascade
systems and 1,230 PSIG for secondary loop systems. The maximum, recommended unit test pressure for field leak test-
ing of these units is 300 PSIG.

Additional Notes
• Always verify the maximum test pressure rating of any directly connected valves, system components or controls (ex.
solenoids, expansion valves, pressure transducers, etc.) to avoid possible damage to these components during pressure
testing. If required, install shut off / isolation valves between the unit cooler and any such accessories for purposes of
system pressure testing.

For Any Unit Coolers Which Will Operate With R-744 Refrigerant (CO2)
• If the refrigeration system is de-energized, venting of the R-744 refrigerant through the system pressure regulating / relief
valves can occur. In such cases, the system may need to be recharged with R-744, but in any case, pressure regulating /
relief valves must not to be defeated or capped. The relief setting must not be altered in any way.
• A sufficient number of pressure relief and pressure regulating / relief valves may need to be provided based on the sys-
tem capacity and located such that no stop valve is provided between the relief valves and any parts or sections of the
system being protected

LU-VE reserves the right to make changes and / or modifications to our equipment in order to improve the perfor-
mance or appearance of our products at any time without notice and without any obligation to previous production
units. All technical characteristics are stated in the current, published product catalog.

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START UP — SERVICE — MAINTENANCE NOTES

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 [Link]

[Link]

USA Customer Service — Toll Free Number

833-908-3355

For Replacement Parts and Equipment Orders

ordersusa@[Link]

For USA Equipment Sales

salesusa@[Link]

Zyklus Heat Transfer Products, Inc

PO Box 60 - Jacksonville, TX 75766

31