Hussman Dccg Users Manual

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January 2006

HUSSMANN - GLOVERSVILLE

INSTALLATION & SERVICE

INSTRUCTIONS

FOR

DCCG and DCSG (-D) MODELS

Dipping and Display Case

P/N OII – DCCG - DCSG

January 2006

First Call for help (US and Canada):

1-800-922-1919

Soporte Tècnico y Asistencia (Mèxico):

01-800-522-1900

For a Service Network Locator and other

Information visit us at

www.hussmann.com

select Worldwide Locations

TABLE OF CONTENTS

Introduction

3

Inspection 3

Specifications

Construction

3

Cabinet Dimensions 4

Cabinet Capacities 4

Electrical Data

4

Installation and Start Up

5

Location

5

Power Requirements 5

Start

Up

Procedures

5

Operation

and

Maintenance

Temperature

Control

6

Display Lighting 6

Anti-sweat Heaters 6

Defrosting 6

Condensing Unit 7

Cleaning the Condenser 7

Cleaning Exterior 7

Cleaning Interior 7

Serial Plate Location and Refrigerant Charges 7

Temperature Control Replacement 7

Operational

Data

8

Trouble

Shooting

Chart

8

-

9

1

TABLE OF CONTENTS CON’T

Dipping

Using

Guide

Loading

10

Storage 10

Lids 10

Temperature Control 10 -11

Load Limits 11

Dipping

11

Maintenance

11

Warranty

and

Parts

Information

12

-

13

2

INTRODUCTION, INSPECTION, SPECIFICATIONS

INSTALLATION and START UP

INTRODUCTION

–

The DCSG/DCCG-4 8, 12, and 16

are

specifically designed for

dipping/display

of bulk ice cream, sherbet, or froz

en

yogurt. Wide glass front and one-

piece

molded lids provide an unobstructed

view

of the product for impulse merchandising.

Optional items include easy to use

can

holder trays and dipper wells. The –

D

models on -8, -12 and -16 include

the

labor saving storage doors feature.

INSPECTION –

Upon receipt of the cabinet, ca

refully

examine the crating for damage.

If

damage is found, make anote on

the

delivery ticket before signing.

Carefully

remove shipping crate and examine

the

cabinet for “concealed” damage.

If

damage is found contact the

delivering

carrier immediately and have his

agent

prepare an inspection report for

the

purpose of filing aclaim.

This is your

responsibility.

durability. The entire assembly is

then

chemically treated and finished w

ith

baked-on powder paint.

The liner is an all welded assembly

of

electro zinc steel. Copper

evaporator

tubing is fastened to the liner

and

applying aconductive material on

both

top and bottom of the tubing

further

enhances maximum heat transfer.

The

liner is also chemically treated

and

painted with baked-on powder paint.

All models incorporate aslide-ou

t

condensing unit for easy access to a

ll

components.

SPECIFICATIONS

CONSTRUCTION

–

The base is an all welded assembly o

f

heavy dusty steel to provide a

strong

frame on which the rest of the cabinet

is

built.

The shell is formed from heavy

gauge

steel, welded together as an assembly,

and

then welded to the base for strength and

3

CABINET DIMENSIONS

–

Cabinet

Dimensions (inches)

Model Length Width Height Ship

DCSG/DCCG Outside Inside Outside * Inside Outside Wt.

-4 25 3/8 21 25 13/16 21 ½ 51 ¼

260

-8 47 7/16 43 1/8 25 13/16 21 1/2 51 1/4 405

-12 67 5/16 63 25 13/16 21 1/2 51 1/4 515

-16 87 7/16 83 1/8 25 13/16 21 1/2 51 1/4 625

* -D models (with doors) outside width = 27 9/16

CABINET CAPACITIES

–

Cabinet

Model Cu. Capacity (9 1/2 dia. 3 gal cans) # of lids

DCSG/DCCG Ft. Upper Display Lower Display

-4 3.3 4 - 1

-8 8.9 8 4 1

-12 14.5 12 8 2

-16 20.2 16 12 2

(Capacities of D models are the same as models without doors)

ELECTRICAL DATA

Cabinet Compressor Cabinet *

Model Volts HP L.R. F.L. Nominal Fuse

DCSG/DCCG Amps Amps Run Amps Amps

-4 115 1/3 33.0 6.4 6.9 15

-8 115 1/2 58.0 8.6 9.5 15

-12 115 1/2 45.0 7.8 9.9 15

-16 115 3/4 59.8 10.2 10.5 15

(electrical data of D models are the same as standard models)

* Includes main top heaters and

condenser

fan motors

Due to compressor change from semi-hermetic to hermetic these are the value changes

-8 (*hermetic)

115

½

51.0

.9

8.4

15

-12 (*hermetic) 115 ½ 87.0 7.9 12.0 15

*

effective

Aug.

2002

the

DCCG/DCSG-8

compressor

changed

from

a

semi-hermetic

HA TB-00 5E-IAA to her metic T2155GK .

*

effective

Nov.

2003

the

DCCG/DCSG-12

compressor

changed

from

a

semi-hermetic

KAGB-0050-IAA to hermetic J2212GK Aspera

4

INSTALLATION and

START UP

LOCATION –

The location of your cabinet is

important.

Make sure your selected location is

NOT

in any of the following areas as it cou

ld

seriously affect the operation.

•

Not in direct sunlight.

•

Not in the air path of heat or air

conditioning ducts.

•

Not at an exit or entrance affected by

extreme temperature change.

Allow 2 feet of clearance at the rear of

the

case to allow adequate air

movement

across the condenser for

proper

refrigeration system performance, do

not

obstruct the grille at the rear intake

and

discharge. If desired, the blank off

panel

behind the front (customer side)

louvered

panel –may be removed for rear

air

intake and front air discharge, but

then

insure 2 feet of unobstructed clearance

is

left at the case front.

Level case front to back and end to

end,

shimming where necessary

upon

installation to assure proper op

erating

drains, and refrigeration system.

equipment on the same circuit. Use

a

time delay fuse or circuit breaker.

The

supply circuit must be properly

grounded

and conform to National and

Local

Electrical Codes. Voltage, as measured

at

the compressor terminals

during

operation, must not vary more than

5%

from cabinet serial plate rating. If a

low

voltage condition exists, contact

your

electrician or power company.

Awiring diagram is provided on the

condenser shroud for each unit.

A power (ON-OFF) switch is provided

on

each model. The switch is accessib

le

through ahole provided in the rear

(operator side) access panel

STAR T UP P ROCE DURE -

•

Cut the band which holds

the

compressor in place during shipment.

•

Make sure fan turns freely. Check

for

any connections or parts that

might

have loosened during shipment.

•

Start cabinet, and allow

temperature

to pull down to normal level

before

loading product.

POWER REQUIREMENTS

–

The DC models are equipped with

a

three-wire grounded service core for

your

protection. The cabinets are designed

to

operate on 115V single-phase

60hz

current. Aseparate circuit

is

recommended to prevent product loss

due

to

overloading

or

malfunction

of

other

5

OPERATION AND MAINTENANCE

SERVICING DATA AND

PROCEDURES

OPERATION and

MAINTENANCE

TEMPERATURE CONTROL –

The thermostat, which senses the

cold

wall temperature, is located at the low

er

rear right corner of the cabinet

through

the access panel. It has been pre-set

at

the factory to maintain

product

temperatures between +10° and +4°.

The

thermostat is adjustable. If other

than

normal temperatures are required,

adjust

the control by turning the knob clockw

ise

for colder and counter-clockwise fo

r

warmer temperatures.

DISPLAY LIGHTING –

All models are equipped with

fluorescent

light fixtures installed in the canopy.

An

ON-OFF switch is located in the

right

service side of the canopy and is

so

labeled.

ANTI-SWEAT HEATERS –

Aresistance heater is installed in

the

perimeter of the base frame of the

canopy

to prevent condensation. Continuity

of

the heater circuit maybe checked at th

e

splice located inside the ballast

enclosure

in the compressor compartment.

Should the heater fail it may be replaced

by:

•

Raise top and canopy as an assembly

and place wood spacers between

top

and cabinet.

•

Remove heater from under base

frame.

•

Disconnect spade terminal splices and

remove.

•

Reassemble reverse order –

resistance

heater wire must be taped back

into

position

DEFROSTING –

It must be recognized that

accumulation

of frost on the cabinet walls does

impair

refrigeration. Daily scraping of

the

interior walls with a plastic scraper w

ill

extend the length of time betw

een

complete defrosting.

Most installations will require a c

omplete

defrosting every seven to ten

days.

Usually the best time to defrost is at

the

close of business so the cabinet will

be

regulated for the start of the nex

t business

day.

The ice cream should be removed

from

the cabinet and placed in awalk-in

or

storage freezer during the

defrosting

operation. Apower switch for

turning

the case off for defrosting is

located

through the access panel.

•

Remove screws holding aluminum top

to cabinet.

Defrosting may be accomplished with

the

aid of a hair dryer, plastic scraper or

by

merely letting the cabinet remain

open

until the walls are cleared. Care should

6

be taken not to puncture the inter

ior

walls or remove paint from the w

alls

during this procedure.

Be sure to disconnect power from

the

cabinet prior to starting

defrost

operation. After the cabinet is co

mpletely

defrosted, wash thoroughly,

remove

defrost water (Hussmann dipping

cases

are provided with an outside

drain

located on the operator’s side of the

case

base to assist you in this operation), w

ipe

the interior dry, and turn the power

back

on.

Be sure to allow the cabinet to cool dow

n

to its operating temperature

before

reloading.

CONDENSING UNIT –

The condensing unit is mounted on

a

slideout base, accessible by removing

the

rear serving side access panel.

The

condenser is of the baretube design.

The

condenser fan motor draws the

air

through the rear access panel, across

the

compressor and discharges back out

the

rear access panel unless the case has

been

Field converted to front air discharge

as

previously discussed in the

Location

section of this manual.

For this reason, if

the case is installed in a counter, provisions

must be made for the release of the

discharge air.

CLEANING THE CONDENSER –

To clean condenser, a soft, nylon

brush

should be used to loosen dirt and

lint.

Then vacuum up the dirt or

blow

condenser out with ahigh-pressure

gas

such as nitrogen. Never use a wire

brush

to clean condenser tubes.

CLEANING EXTERIOR / INTERIOR –

When cleaning the exterior of the

cabinet

use a soft cloth or sponge with water

and

mild detergent. Rinse and wipe dry.

For cleaning the interior of the

product

compartment, abuilt-in drain has

been

provided with astandard hose

fitting

located at the front of the cabinet in

the

base area. Disconnect the

electrical

power and allow cabinet to warm

to

above freezing temperature. Use a

soft

cloth or sponge with a mild detergent

to

wash the interior. Wipe dry

before

restarting the cabinet. Allow the

cabinet

to cool down to proper

temperature

before reloadin g produc t.

SERIAL PLA TE LOC A TION –

One serial plate is located on the interio

r

left wall of the cabinet, and a second

one

in the condensing unit

compartment.

Both contain all pertinent infor

mation

such as model, serial number,

amperage

rating, refrigerant type and charge,

etc.

Specific charges are DCSG/DCCG-4

16

oz.,DCSG/DCCG-8 29 oz., DCSG/DCCG-

12 33 oz., and DCSG/DCCG-16 has

31

oz., all have R-404a. The “D”

models

have the same charge.

TEMPERATURE CONTROL

REPLACEMENT –

The Ranco temperature control is

located

in the compressor compartment.

To

replace, first disconnect power supply

and

remove two screws holding control

dial

plate. Pull capillary tube from

control

well, noting length of tube removed.

Push

new cap tube into well, being careful

not

to kink it, and making certain it

reaches

full depth of well.

7

Replace spade connectors and

reinstall

dial plate and two screws which

hold

control in place.

Operational Data

The following operational data is based on lab tests, and may vary under field

conditions. The conditions shown at the non-recommended high 85°F ambient are shown

for information only and a possible reason for jobsite problems. Note that during August,

2002, the DCC/SG-8 cases changed from semi-hermetic (SH) to hermetic (H) and similarly,

during December, 2003, the DCC/SG-12 cases changed from the semi-hermetic (SH) to

hermetic (H) style compressors which operate under different pressures.

75°F

85°F

Model Compressor

Compressor

Type

Suction

Pressure

Head

Pressure

Suction

Pressure

Head

Pressure

DCC/SG-4

NE2134GK

H

9

230-240

10

260-270

HATB-005E-

DCC/SG-8 &-D

CAA

SH

6

230-240

7

245-255

DCC/SG-8 &-D

T2155GK

H

9

230-240

10

235-245

DCC/SG-12 &-

D

DCC/SG-12 &-

KAGB-005E-

IAA SH 6235-245 7250-260

D

J2212GK

H

10

230-240

11.5

260-270

DCC/SG-16 &-

D

KAAB-007E-

CAA SH 6270-280 7280-290

Load Line Temperature

0 to +10°F

5 to +12°F

TROUBLE SHOOTING CHART

TROUBLE

PROBABLE

CAUSE

SOLUTION

Compressor will not start,

no noise

1. Power disconnected 1. Check service cord for

proper connection

2. Blown fuse or breaker 2. Replace fuse or reset

breaker

3. Defective or broken

wiring

3. Repair or replace

4. Defective overload

4. Replace

5. Defective te mperature 5. Replace control

Compressor will not start

cuts out on overload

1. Low voltage 1. Check voltage at cabinet.

Should be within 5% of

rating

2. Defective compressor 2. Replace

3. Defective relay

3. Replace

8

4. Restriction pinched cap

tube

4. Repair or replace tube

5. Restriction moisture 5. Leak check, replace drier,

evacuate and recharge

6. Inadequate air over

condenser

7. Defective condenser fan

motor

6. Allow at least 24” at front

and back of unit

compartment

7. Replace

TROUBLE

PROBABLE

CAUSE

SOLUTION

High head pressure

1. Cabinet location too warm

1. Relocated cabinet

2. Restricted condenser air

flow

3. Defective condenser fan

motor

4. Air or non-condensable

gases in system

2. Clean condenser or

remove air flow restriction

3. Replace motor

4. Leak check, change drier,

evacuate and recharge

W arm storage temper atures 1. Temperature control not

set properly

1. Reset control

2. Short of refrigerant 2. Leak check, change drier,

evacuate and recharge

3. Cabinet location too warm 3. Relocate cabinet

4. Too much refrigerant 4. Purge system, change

drier, evacuate and recharge

5. Low voltage, compressor

cycling on overload

5. Check voltage at cabinet.

Should be within 5% of

rating

6. Heavy frost on side walls

6. Defrost cabinet

Compressor runs

continu ously, product too

cold

1. Defective control

1. Replace

2. Control s

ensing element

not completely insta

lled in

well

2. Push control sensing

element into well

3. Short on refrigerant 3. Leak check, change drier,

evacuate and recharge

Compressor runs

continu ously, product too

warm

1. Short on refrigerant 1. Leak check, change drier,

evacuate and recharge

2. Inefficient compressor

2. Replace

9

DIPPING USERS GUIDE

The general success of any ice cream dipping department depends to a great ex

tent on the

people within that department. If at all

possible, a single individual should be assigned the

direct responsibility of assuring that proper

operational procedures are being followed.

LOADING

–



Careful thought should be given to the placement of flavors within the cabinet prior to

the opening of the dipping department. Flavors with the highest sugar content (ripple,

maple syrup, and candy) require a lower temperature for dipping than vanilla. Since

temperatures will vary slightly within the cabinet, it is recommended that these flavors

be placed in the corners where maximum cooling effect from two walls can be taken

adv antage of.

STORAGE

–



In order to assure product quality and minimum energy usage, it is important that

proper attention is given to the maintenance of product temperatures prior to placement

in the display freezer. Storage temperatures are generally maintained at –12 degrees F

to –18 degrees F. This allows for long-term storage of ice cream without deterioration.

Dipping te mperatures are generally maintained at +5 degrees F to +9 degrees F, which

allows for rather limited display time before deterioration begins to occur.



Ice cream removed from a delivery truck, walk-in freezer, or storage cabinet should be

placed in the dipping cabinet immediately.



The dipping cabinet is not designed as a hardening cabinet, and will generally only

maintain ice cream at the preset dipping temperature.



If ice cream is allowed to warm up prior

to placement in the dipping cabinet,

crystallization may occur resulting in some loss of product quality.

LIDS

–



To conserve energy and minimize frost accumulation on the cabinet interior walls, the

lids should remain closed until the customer has made his/her choice of flavors, and

should be closed immediately once the customer has been served. Under no

circumstances should the cabinet lids be left open for extended periods of time.

10

TEMPERATURE CONTROL

–



The temperature control is factory set for normal dipping temperatures. If, after a week

or so of operation, it is decided that a higher or lower temperature is required, only a

qualified refrigeration mechanic should adjust the control. Other than the initial

adjustment and possibly a seasonal adjustment, no other setting should be required. If

the cabinet temperature fluctuates to any great extent, a refrigeration mechanic should

be notified. Employees should not be allowed to tamper within the control setting.

LOA D LIMI TS

–

•

A fully loaded cabinet will use less energy and maintain generally more even

temperatures than one that is only partially full. However, care should be taken not to

exceed the load line limits as noted on the interior cabinet walls through the use of wire

racks, stepshelving, or by stacking containers three high.

DIPPING

–



Much of the success of hand dipping and appeal of the stored ice cream to the customer

depends on the training of personnel in proper dipping methods. Periodic scraping of

the container sidewalls and leveling off of the ice cream is essential to avoid discoloration

and drying out of the ice cream. Scraping the container sidewalls and leveling off the ice

cream should be done lightly with the use of a spade. Start with the back of the spade

turned towards the side of the can, working from the top of the can down. Once the

walls are cleared, the top portion of the remaining ice cream should be leveled off, filling

in holes left by previous dipping.

MAINTENANCE

–

•

Proper maintenance of refrigeration equipment can have a dramatic effect on the

equipment’s ability to perform, as well as power consumption and customer reaction to

your dipping operation.



Hussmann equipment is designed so that a minimum amount of maintenance is

necessary. The relatively few items that do require attention should be scheduled for

specific time periods based on prevailing store conditions and cabinet usage.

11

W

ARR

A

NT

Y

–

Please

read

carefully

to

assure

prompt

and

accurate

service

Ordering

Replacement

Parts

–

•

Con

tact

your

nearest

Hussmann

Distributor.

•

Always

specify

model

and

serial

number

of

cab

inet.

•

If correct part number is not known, give aclear description of part itself

and

it s func ti on

in

the

cabinet.

Warranty

Parts

Procedure

–

•

Same

as

items

above

•

Give original installation date of cabinet and, if possible, forward acopy of the

original invoice

or

delivery

receipt.

•

All shipments of in-warranty replacement parts will be invoiced from the factoryuntil

such time as the defective part is returned and proved to be defective by our Quality

Control Department.

Con

tact

your

Hussmann

Distributor

for

instructions

on

returning

in-warranty

parts.

Warranty parts must be returned to the factorywithin 30 days of date of failure to

assure

proper

disposition.

Lack of any of the above information may result in the shipment of the wrong part, or a

delay

in

shipment.

Compressor

Replacement

Procedure

–

Replacement compressors will not be shipped from the Hussmann factory. They

may be obtained from your nearest Copeland Wholesaler.

Your wholesaler will replace, free of charge, any compressor found to be defective within

twelve months of installation, not to exceed twenty months from the date of

manufacture, as determined by the compressor serial number on the compressor serial

plate. For any defective compressor beyond the twelve or twenty month time period, a salvage

value credit will be given too partially offset the invoice for the replacement.

12

M100-2309

WIRING DIAGRAM

GLOVERSVILLE, NY 12078



REV EO # REV DATE REV BY

APPROVED BY EO NUMBER

SCALE

SHEET #

DRAWN BY:

DATE DRAWN :

APPROVED BY:

-

JJH

01/29/2004

-

INCHES

1 OF 1

--

-

-

-

-

-

-

-

TOLERANCES UNLESS OTHERWISE SPECIFIED: FRACTIONAL 1/32"

DECIMAL 0.031" ANGULAR 1° HOLE LOCATION & SPACING 1/64"

22 26

24 28

30 6

23 27

25 29

31 5

CR

S

1

2

S

M

START

CAP.

RELAY

OVERLOAD

COMPRESSOR

MOTOR

COMPRESSOR

TEMPERATURE

CONTROL

CONDENSER

FAN

LAMP

BALLAST

LIGHT

SWITCH

TERMINAL

BLOCK

POWER

SWITCH

POWER

CORD

BLUE

BLUE

RED

RED

BLK

WHT

BLK

BLK

WHT

BLK

GRN

115 VOLT

60 Hz

1 Ph

BLK

WHT

USAGE: DCCG-4

WHT

BLK

CANOPY HEATER

HIGH LIMIT SWITCH