Print Preview - C: emp.aptcache 200251b001 200251b · s9516-br-mma-010 0910-lp-028-6760 description, operation, and maintenance for ship stores refrigeration unit 1298-00-d marlo

FOR OFFICIAL USE ONLY

S9516-BR-MMA-0100910-LP-028-6760

DESCRIPTION, OPERATION, AND MAINTENANCEFOR

SHIP STORES REFRIGERATIONUNIT 1298-00-D

MARLO COIL(MANUAL PREPARED BY SYSTEMS & ELECTRONICS INC.)

N00024-96-C-2100N00024-04-C-2100

DISTRIBUTION STATEMENT D: DISTRIBUTION AUTHORIZED TO DOD AND DOD CONTRACTORS ONLY.CRITICAL TECHNOLOGY OCTOBER 2007. OTHER REQUESTS SHALL BE REFERRED TO COMNAVSEASYSCOM(PMS-450). NO SECONDARY DISTRIBUTION AUTHORIZED WITHOUT WRITTEN APPROVAL OF THEAPPLICABLE NAVSEA PROGRAM MANAGEMENT OFFICE.WARNING. THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMSEXPORT CONTROL ACT (TITLE 22, U.S.C., SEC 2751, ET SEQ.) OR THE EXPORT ADMINISTRATION ACT OF1979, AS AMENDED, TITLE 50, U.S.C., APP. 2401 ET SEQ. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECTTO SEVERE CRIMINAL PENALTIES. DISSEMINATE PER THE PROVISIONS OF OPNAVINST 5510.161.DESTRUCTION NOTICE. DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS ORRECONSTRUCTION OF THE DOCUMENT.PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

16 DECEMBER 2002CHANGE B - 29 OCTOBER 2007



APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR : S9516-BR-MMA-010

TITLE OF MANUAL : Description, Operation, and Maintenance for Ship Stores Refrigeration Unit 1298-00-D

APPROVAL AUTHORITY : NAVSEA PMS450, ltr Ser: 450TLD/1000 dated 16 December 2002.

Contract Number Ship Applicability Qty of ManualsQty of

Equipment Building Yard

N00024-96-C-2100 VIRGINIA(SSN774) Class

* 1 Electric Boat, Groton, CT

REMARKS :

Change A approved by NAVSEA letter Ser 450F6/0681 dated 21 June 2004.

Change B approved by NAVSEA letter Ser 450F6/0939 dated 29 October 2007.

* Quantities distributed in accordance with the applicable class Index of Technical Publications (ITP).

DATE : 16 December 2002

CERTIFICATION: It is hereby certified that S9516-BR-MMA-010 and changes thereto have been provided by contractand approval data shown above.

D. F. Vetelino, ManagerTechnical ServicesGENERAL DYNAMICS/Electric BoatGroton, CT 06340

Mfr: Marlo CoilHigh Ridge, MO, 63049CAGE CODE: 38450


/s/

FOR OFFICIAL USE ONLYS9516-BR-MMA-010

This page intentionally left blank



Record of Alterations

This manual reflects alterations occurring after 16 December 2002 as a result of accomplishment of the following:

CHANGE NO. DEFICIENCY DESCRIPTION

A TMDER 774-04-N023 Paragraph 1.5.1, last sentence, change to description of door heater, add,:...except when chill or freeze room lights are on.”, for clarification.

Table 1-1 and Table 7-4, thermal expansion valve part number correctedfrom “EMCE-22-JC” to “EMCE-23-JC”. Connection size correctedfrom “3/8 in. x 5/8 in. ODF” to “3/8 in x 1/2 in. ODF”.

Table 1-1, Defrost Initiation Timer setting changed from 4 hours to 240minutes, expressed in minutes for consistency.

Table 6-1, Defrost Initiation Timer TD1 setting changed, as above.

Table 6-6, SPH setting changed from “0°F” to “52F”, to correct settingerror discovered during initial unit startup.

B TMDER 774-04-N030 To table 1-2, added “1 set, Refrigeration Charging and Test Kit, MarloCoil 700-000-305, including cylinder adapter, Yellow Jacket 19105,14”x14”x4”, 7 lbs.”

To table 7-1, added “Marlo Coil 700-000-305, Refrigeration Chargingand Test Kit, including cylinder adapter, Yellow Jacket 19105, table1-2”. Both changes reflect new VIRGINIA test kit and adapter.

Also specifies that throughout the manual, sheet designations wereadded, as necessary, to the figure references to identify the appropriatesheets of multi-sheet figures.

TMDER 774-06-N038 For table 6-7, values of three menu selections were revised: InPC from“2 deg F” to “0 deg F”; SPL from “0 deg F” to “-5 deg F”; SPH from “35deg F” to “52 deg F”. All revisions are EB D434 engineering resolutionsto Ship’s Force Discrepancy Record 0142. Also clarifies maintenanceprocedures, updates figure FO-2 in accordance with ERH413-0205A39, A40, A42, and A45, and makes other miscellaneous corrections.Revised Figure 6-17 to add callout for item 8, drain line heater junctionbox.



TABLE OF CONTENTS

Chapter Page1 GENERAL INFORMATION AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . 11.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.3 WARNINGS, CAUTIONS, AND NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.4 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.5 EQUIPMENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.5.1 Chill and Freeze Rooms and Associated Doors. . . . . . . . . . . . . . . . . . . . . . . . 1-21.5.2 Pressure Equalization Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.5.3 Chill and Freeze Room Floor and Ceiling Gratings and Drains. . . . . . . . . . . . . . . . . . 1-21.5.4 Chill and Freeze Room Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31.5.5 Chill and Freeze Room Removable Access Panels. . . . . . . . . . . . . . . . . . . . . . . 1-101.5.6 Cabinet Assembly Access Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.5.7 Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.5.8 Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.5.9 Liquid Receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.5.10 Moisture/Sight-Flow Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.5.11 Chill Water Bypass/Diverter Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.5.12 Water Regulating Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.5.13 Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.5.14 Refrigerant Filter/Dehydrator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.5.15 Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.5.15.1 Thermal Expansion Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.5.15.2 Evaporator Coil Drip Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111.5.15.3 Defrost Initiation Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111.5.15.4 Defrost Cycle Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111.5.15.5 Defrost Termination Thermostat Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111.5.15.6 High Defrost Temperature Thermostat Switch. . . . . . . . . . . . . . . . . . . . . . . . . 1-111.5.16 Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111.5.17 Evaporator Fans and Fan Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111.5.18 Evaporator Fan Outlet Dampers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111.5.19 Evaporator Coil Inlet Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111.5.20 Chill Room Damper Actuator and Damper. . . . . . . . . . . . . . . . . . . . . . . . . . 1-111.5.21 Schrader Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.22 SSRU Room Temperature Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.22.1 Chill Room Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.22.2 Freeze Room Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

iFOR OFFICIAL USE ONLY

FOR OFFICIAL USE ONLYS9516-BR-MMA-010Chapter Page

1.5.22.3 Chill Room Temperature Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.22.4 Freeze Room Temperature Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.23 Refrigeration Unit Safety Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.23.1 Compressor High Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.23.2 Compressor Internal Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.24 Refrigeration Unit Control Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.24.1 Compressor Low Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.24.2 Power Supply Voltage Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.24.3 Condenser Water Flow Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.5.24.4 Anti-Cycle Lockout Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-131.5.24.5 Water Failure On-Delay Relay Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-131.6 REFERENCE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-131.7 EQUIPMENT, ACCESSORIES, AND DOCUMENTS SUPPLIED. . . . . . . . . . . . . . . . 1-13

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2 CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2.1 Control Panel Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2.2 SSRU Valves and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2.3 Operator Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112.3 OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132.3.1 Normal System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132.3.1.1 Operator Turn On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-142.3.1.2 System Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152.3.1.3 Normal System Restart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152.3.2 Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152.3.2.1 Restarting After Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152.3.3 Operating System Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152.3.4 Defrost Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

3 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1.1 Refrigeration Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1.2 Defrost Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.1.2.1 Temperature Termination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.1.2.1.1 Backup Temperature Termination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.1.2.2 Time Termination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.1.3 Pumpdown Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.2 PROPERTIES AND CHARACTERISTICS OF REFRIGERANT HFC-134a. . . . . . . . . . . 3-33.2.1 Inhalation Toxicity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.2.2 Skin and Eye Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.2.3 Combustibility of HFC-134a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

ii Change BFOR OFFICIAL USE ONLY


Chapter Page

3.2.4 Thermal Decomposition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.2.5 Spills or Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.3 FUNCTIONAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.3.1 Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.3.1.1 Compressor Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.3.1.2 Compressor Oil Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.3.1.3 Compressor Oil Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.3.1.4 Compressor Service Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.3.1.5 Compressor Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.3.2 Water Regulating Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.3.3 Chill Water Bypass/Diverter Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.3.4 Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.3.5 Liquid Receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.3.6 Refrigerant Filter/Dehydrator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.3.7 Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.3.8 Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.3.8.1 Evaporator Coil Defrost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.3.9 Control of Air Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.3.9.1 Evaporator Fan and Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.3.9.2 Evaporator Fan Outlet Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.3.9.3 Evaporator Coil Inlet Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.3.9.4 Chill Room Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.3.10 Schrader Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.3.11 Thermal Expansion Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.4 REFRIGERATION UNIT ELECTRICAL CONTROL. . . . . . . . . . . . . . . . . . . . . 3-123.4.1 MODE SELECT Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.4.2 START Pushbutton Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.4.3 PUMPDOWN/STOP Pushbutton Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.4.4 EMERGENCY STOP/RESET Pushbutton Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.4.5 Compressor Low Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.4.6 Compressor High Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.4.7 Condenser Water Flow Switch (Water Failure). . . . . . . . . . . . . . . . . . . . . . . . 3-123.4.8 Water Failure On Delay Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.4.9 Compressor Internal Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.4.9.1 Compressor Internal Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.4.9.2 Compressor Internal Motor Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133.4.10 Compressor Motor Starter Overload Relay. . . . . . . . . . . . . . . . . . . . . . . . . . 3-133.4.11 Fan Motor Overload Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133.4.12 Voltage Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133.4.13 Anti-Cycle Lockout Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

iiiFOR OFFICIAL USE ONLY


3.4.14 Freeze Room Temperature Probe and Thermostat. . . . . . . . . . . . . . . . . . . . . . . 3-133.4.15 Chill Room Temperature Probe and Thermostat. . . . . . . . . . . . . . . . . . . . . . . . 3-133.4.16 Defrost Initiation Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133.4.17 Defrost Cycle Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133.4.18 Defrost Termination Thermostat Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143.4.19 High Defrost Temperature Thermostat Switch. . . . . . . . . . . . . . . . . . . . . . . . . 3-143.4.20 Elapsed Time Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143.5 SSRU OPERATING SEQUENCE AND CONTROLS. . . . . . . . . . . . . . . . . . . . . 3-143.5.1 Function Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143.5.2 System Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143.5.3 Refrigeration Control Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143.5.4 Chill Room Refrigeration Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163.5.5 Pumpdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-173.5.6 Defrost Control and Initiation and Normal Termination. . . . . . . . . . . . . . . . . . . . . 3-173.5.7 Defrost Termination Backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-193.5.8 High Pressure Discharge Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-213.5.9 Water Flow Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-213.5.10 Emergency Stop/Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-223.5.11 Compressor Thermal Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . 3-233.5.12 Power Supply Voltage Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-233.5.13 Fan Motor Thermal Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-233.5.14 Crankcase Heaters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-233.5.15 Chill Room and Freeze Room Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-233.6 CHILL WATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

4 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 ORGANIZATIONAL LEVEL TROUBLESHOOTING PROCEDURES. . . . . . . . . . . . . 5-15.2 CHECKING DAMPER OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95.2.1 Evaporator Fan Outlet Dampers Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 5-95.2.2 Evaporator Coil Inlet Damper Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

6 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.1.1 Tag-Out Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.1.2 Return To Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2SECTION 1. ADJUSTMENTS AND ALIGNMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26.2 MANIFOLD TEST GAGE SETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26.2.1 Installing Manifold Test Gage Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36.2.2 Removing Manifold Test Gage Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36.3 HFC-134a REFRIGERANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

ivFOR OFFICIAL USE ONLY


Chapter Page

6.3.1 Recovery of Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36.3.2 Evacuation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46.3.3 Adding Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46.3.3.1 Adding Refrigerant to an Evacuated Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46.3.3.2 Adding Refrigerant to a Charged Unit Suspected of Being Low On Refrigerant. . . . . . . . . . . 6-56.3.4 Starting a Sealed Scroll Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56.3.5 Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66.4 DEFROST INITIATION TIMER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66.4.1 Testing Timer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66.4.2 Self-Check Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76.4.3 Blue Fluorescent Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96.4.4 Setting Timing Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106.5 DEFROST CYCLE TIMER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126.6 FREEZE ROOM THERMOSTAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126.6.1 Front Panel Key Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126.6.1.1 Key Entry Function Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126.6.2 Primary Menu Selections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-146.6.3 Secondary Menu Selections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-156.6.4 Secure Menu Selections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-166.6.5 Diagnostic Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-196.6.6 Program Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-216.7 CHILL ROOM THERMOSTAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-216.8 WATER FAILURE ON-DELAY RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-226.9 CHILL ROOM AIR DAMPER ACTUATOR. . . . . . . . . . . . . . . . . . . . . . . . . 6-226.10 DEFROST TERMINATION THERMOSTAT SWITCH. . . . . . . . . . . . . . . . . . . . 6-236.10.1 Temperature Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-246.10.2 Capillary and Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-256.11 HIGH DEFROST TEMPERATURE THERMOSTAT SWITCH. . . . . . . . . . . . . . . . . 6-256.11.1 Temperature Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-266.11.2 Capillary and Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-266.12 COMPRESSOR LOW PRESSURE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . 6-266.13 COMPRESSOR HIGH PRESSURE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . 6-286.14 POWER SUPPLY VOLTAGE MONITOR. . . . . . . . . . . . . . . . . . . . . . . . . . 6-306.15 ANTI-CYCLE LOCKOUT TIMER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-326.16 THERMAL EXPANSION VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-336.17 WATER REGULATING VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36SECTION 2. REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-376.18 ACCESS PANEL REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . 6-386.19 CONTROL PANEL REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-386.19.1 Defrost Initiation Timer Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

vFOR OFFICIAL USE ONLY


6.19.2 Defrost Cycle Timer Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-406.19.3 Water Failure On-Delay Relay Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 6-406.19.4 Freeze Room Thermostat Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-416.19.5 Chill Room Thermostat Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-416.19.6 Compressor Low Pressure Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . 6-426.19.7 Compressor High Pressure Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . 6-426.19.8 Power Supply Voltage Monitor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 6-436.19.9 Anti-Cycle Lockout Timer Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-436.19.10 Indicator Lamp Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-446.20 EQUIPMENT CABINET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-446.20.1 Defrost Termination Thermostat Switch Replacement. . . . . . . . . . . . . . . . . . . . . 6-446.20.2 High Defrost Temperature Thermostat Switch Replacement. . . . . . . . . . . . . . . . . . . 6-446.20.3 Solenoid Coil Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-456.20.4 Fan Motor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-466.20.5 Chill Room Air Damper Actuator Replacement. . . . . . . . . . . . . . . . . . . . . . . . 6-496.20.6 Compressor Crankcase Heater Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 6-516.20.7 Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-536.20.8 Isolator Mount Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-556.20.9 Evaporator Coil Heater Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-576.20.10 Drip Pan Heater Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-596.20.11 Drain Line and Trap Heater Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-596.20.12 Water Bypass/Diverter Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 6-606.20.13 Flow Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-636.20.14 Water Regulating Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-636.20.15 Moisture Indicator/Sight Flow Indicator Replacement. . . . . . . . . . . . . . . . . . . . . 6-656.20.16 Refrigerant Component Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-676.20.17 Control Circuit Fuse Checkout and Replacement. . . . . . . . . . . . . . . . . . . . . . . . 6-726.20.18 Isolator Base Assembly Removal and Reinstallation. . . . . . . . . . . . . . . . . . . . . . 6-726.21 DOOR REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-736.21.1 Door Heater Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-736.21.2 Door Hinge Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-736.21.3 Door Latch and Strike Plate Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-756.21.4 Door Gasket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-756.21.5 Door Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-756.22 CHILL AND FREEZE ROOM REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-756.22.1 Bulkhead Batten Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-756.22.2 Floor Grating and Ceiling Grating Replacement. . . . . . . . . . . . . . . . . . . . . . . . 6-776.22.3 Freeze Room Inlet Screen and Evaporator Coil Inlet Damper Replacement. . . . . . . . . . . . 6-776.22.4 Evaporator Fan Outlet Damper Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 6-776.22.5 Floor Drain Plate Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79

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Chapter Page

6.22.6 Light Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79

6.22.7 Light Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79

6.22.8 Chill Room and Freeze Room Caulk Repair. . . . . . . . . . . . . . . . . . . . . . . . . . 6-80

6.22.9 Chill Room and Freeze Room Pressure Equalization Valve (PEV) Replacement. . . . . . . . . . 6-80

7 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 LIST OF MAJOR COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.3 PARTS LISTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.4 LIST OF MANUFACTURERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.2 INSTALLATION DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.3 SITE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.4 REFERENCE PUBLICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.5 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.6 UNPACKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.7 PREPARATION OF FOUNDATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.8 INPUT REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.9 INSTALLATION PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.9.1 Removal of Base Structure Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.9.2 SSRU Interface Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.10 INSTALLATION CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Change B viiFOR OFFICIAL USE ONLY



viii (blank)FOR OFFICIAL USE ONLY


LIST OF ILLUSTRATIONS

Figure Title Page1-1. Ship Stores Refrigeration Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2. Ship Stores Refrigeration Unit Location of Components (Sheet 1 of 6) . . . . . . . . . . . . . . . . . 1-4






2-1. Control Panel Controls and Indicators (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-1. Control Panel Controls and Indicators (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-2. SSRU Controls and Indicators (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8



3-1. Refrigeration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2. Refrigeration Unit Piping (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7



6-1. Defrost Initiation Timer TD1 and Defrost Cycle Timer TD2 . . . . . . . . . . . . . . . . . . . . . 6-7

6-2. Self-Diagnostics Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-3. Defrost Initiation Timer TD1 and Defrost Cycle Timer TD2 Wiring Diagram . . . . . . . . . . . . . . 6-11

6-4. Freeze Room Thermostat (FRT) and Chill Room Thermostat (CRT) . . . . . . . . . . . . . . . . . . 6-14

6-5. Thermostat Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

6-6. Defrost Termination Thermostat Switch and High Defrost Temperature Thermostat Switch . . . . . . . . 6-25

6-7. Compressor Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

6-8. Compressor High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6-9. Power Supply Voltage Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

6-10. Anti-Cycle Lockout Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

6-11. Thermal Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6-12. Water Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

6-13. Cord Grip/Stuffing Box Installation and Cable Clamp Installation . . . . . . . . . . . . . . . . . . . 6-39

6-14. Solenoid Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

6-15. Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48

6-16. Chill Room Air Damper Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

6-17. Compressor Crankcase Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

6-18. Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54

6-19. Isolator Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56

6-20. Evaporator Coil Heater Element and Drip Pan Heater Element Replacement . . . . . . . . . . . . . . 6-58

6-21. Drain Line and Trap Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60

ixFOR OFFICIAL USE ONLY

FOR OFFICIAL USE ONLYS9516-BR-MMA-010Figure Title Page

6-22. Water Bypass/Diverter Valve and Flow Switch Replacement . . . . . . . . . . . . . . . . . . . . . 6-62

6-23. Water Regulating Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

6-24. Moisture Indicator/Sight Flow Indicator Element Replacement . . . . . . . . . . . . . . . . . . . . 6-66

6-25. Refrigerant System Pipe Routing and Component Location (Sheet 1 of 4) . . . . . . . . . . . . . . . 6-68




6-26. Door Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74

6-27. Typical Batten Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76

6-28. Floor and Ceiling Grating Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78

6-29. Floor Drain Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79

7-1. Ship Stores Refrigeration Unit (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-1. Ship Stores Refrigeration Unit (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7-2. Cabinet Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7-2. Cabinet Assembly (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

7-3. Control Panel (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18



7-4. Refrigerant Plant (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7-4. Refrigerant Plant (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7-5. Isolator Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

8-1. SSRU Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 3

FO-1. Ship Stores Refrigeration Unit Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6

FO-2. Ships Stores Refrigeration Unit Electrical Schematic (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 8- 7

FO-2. Ships Stores Refrigeration Unit Electrical Schematic (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 8- 8

FO-3. Base Structure Assembly/Installation Weld Map . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 9

FO-4. SSRU Installation Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

x Change BFOR OFFICIAL USE ONLY


LIST OF TABLES

Number Title Page1-1. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1-2. Equipment, Accessories, and Documents Supplied . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

2-1. Control Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-2. SSRU Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3. Operational Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

3-1. Properties of Saturated HFC-134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

5-1. Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2. High Compressor Discharge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-3. Low Compressor Suction Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-4. High Chill Room Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-5. Low Chill Room Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-6. High Freeze Room Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-7. Low Freeze Room Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-8. High Chill Room Temperature (When Being Used As Freeze Room) . . . . . . . . . . . . . . . . . 5-5

5-9. Low Chill Room Temperature (When Being Used As Freeze Room) . . . . . . . . . . . . . . . . . . 5-5

5-10. Refrigeration Plant Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-11. Defrost Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-12. Abnormal Defrost Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-13. Compressor Short Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-14. Fan Does Not Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-15. Evaporator Coil or Drip Pan Heater Element Fails . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-16. Refrigerator System Noises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

6-1. SSRU Control and Timer Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2. Key Functions and Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-3. Secondary Menu Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-4. Secure Menu Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6-5. Thermostat Diagnostic Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-6. Freeze Room Thermostat (FRT) Programmed Values . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6-7. Chill Room Thermostat (CRT) Programmed Values . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

7-1. Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2. Ship Stores Refrigeration Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-3. Doors and Associated Parts (See Figure 6-26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-4. Cabinet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-5. Fans/Motors and Associated Parts (See Figure 6-15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-6. Chill Room Damper/Actuator and Associated Parts (See Figure 6-16) . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-7. Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-8. Refrigeration Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

xiFOR OFFICIAL USE ONLY

FOR OFFICIAL USE ONLYS9516-BR-MMA-010Number Title Page

7-9. Isolator Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7-10. List of Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

xiiFOR OFFICIAL USE ONLY


SAFETY SUMMARYThe following are general safety precautions that may not be related directly to any particular procedural step and, therefore,may not appear elsewhere in this publication. They are recommended precautions that personnel must understand andapply during many phases of operation and maintenance.The refrigerant selected for this unit is HFC-134a.INHALATION TOXICITY. HFC-134a poses no acute or chronic hazard when it is handled safely and when exposures aremaintained at or below 1,000 ppm. However, inhaling high concentrations of HFC-134a vapor may cause temporary centralnervous system depression with narcosis, lethargy and anesthetic effects. Other effects that may occur include dizziness,a feeling of intoxication and a loss of coordination. Continued breathing of high concentrations of HFC-134a vapors mayproduce cardiac irregularities (cardiac sensitization), unconsciousness and, with gross overexposure, death. If any of theinitial symptoms are experienced, move to fresh air and seek medical attention. Medical attention must be given immediatelyif exposed to high concentrations of HFC-134a. Do not treat with adrenaline (epinephrine) or similar drugs. These drugsmay increase the risk of cardiac arrhythmias and cardiac arrest. If the person is having difficulty breathing, administeroxygen. If breathing has stopped, give artificial respiration.SKIN AND EYE CONTACT. At room temperature, HFC-134a vapors have little or no effect on the skin or eyes. However,in liquid form, HFC-134a can freeze skin or eyes on contact, causing frostbite. Following contact, soak the exposed areain lukewarm water, not cold or hot. If medical treatment cannot begin immediately, apply a light coat of a non-medicatedointment, such as petroleum jelly. If the exposed area is in a location where the presence of the ointment would be awkward,such as on the eye, apply a light bandage. In all cases of frostbite, seek medical attention as soon as possible. Alwayswear protective clothing when there is a risk of exposure to liquid HFC-134a. Where splashing is possible, always weareye protection and a face shield.COMBUSTIBILITY OF HFC-134a. HFC-134a is nonflammable at ambient temperatures and atmospheric pressure.However, tests have shown HFC-134a to be combustible at pressures as low as 5.5 psig at 350°F when mixed with airat concentrations generally greater than 60% air by volume. At lower temperatures, high pressures are required forcombustibility. At ambient temperature, all concentrations of HFC-134a in air are nonflammable at pressures below 15 psig.Combustible mixtures of air and HFC-134a will not form when liquid HFC-134a is pumped into a closed vessel if the initialair pressure in the vessel is limited to one atmosphere absolute and the final pressure is limited to 300 psig. If the initial airpressure is greater than one atmosphere, combustible mixtures may form as the tank is filled. Based on the precedinginformation, observe the following precautions when handling HFC-134a.

a. Equipment should never be leak tested with a pressurized mixture of HFC-134a and air. HFC-134a may be safelypressurized with dry nitrogen.

b. Refrigerant cylinder pressures should not exceed 300 psig.

THERMAL DECOMPOSITION. An open flame (lit cigarette), welding or hot surfaces such as space heaters (Salamandersor other types) will decompose HFC-134a to extremely toxic materials. Purge HFC-134a piping with nitrogen before andwhile using a torch. If a torch is used with HFC-134a in the line and the HFC-134a is leaking through, acids, which are veryirritating to the nose and throat at very low concentrations, will form. It is virtually impossible for a person to voluntarilyremain in an atmosphere where these acid vapors are present in high enough concentrations to cause serious harm. Themedical department shall observe personnel exposed to significant levels of refrigerant decomposition products for immediateor delayed pulmonary edema.SPILLS OR LEAKS. If a large release of vapor occurs, such as from a large spill or leak, the vapors may concentrate near thedeck or low spots and displace the oxygen available for breathing, causing suffocation. Observe the following precautionsshould a refrigerant leak or spill occur:

a. Evacuate all personnel until the area has been ventilated.b. Do not reenter an affected area unless equipped with a self-contained breathing apparatus or unless an area monitor

indicates that the concentration of HFC-134a vapors in the area is below 1,000 ppm.c. Always use a self-contained breathing apparatus or an air-line respirator when entering areas where vapors might

exist. Use the buddy system and a lifeline.d. HFC-134a vapors have a slightly sweet odor that can be difficult to detect. Therefore, frequent leak checks (in

accordance with Planned Maintenance System) are recommended.

SERVICE. Under no circumstances should any person reach into or enter the unit for the purpose of adjusting equipmentexcept in the presence of someone who is capable of rendering aid.

SAFETY-1FOR OFFICIAL USE ONLY


If refrigerant is being charged into or being removed from a system, prohibit nonessential persons from being in or entering thespace while refrigerant transfer is taking place. Always have two people present (two man rule) when working with refrigerantin an enclosed space. The second person can isolate the leaks and should be able to call for help if required.When refrigerant is being transferred by hose or pipe from a remote location, establish telephone communication betweenthe pumping station and the space involved.Do not pressurize a refrigerant system with air. At pressures above atmospheric and with air concentrations greater than 60percent by volume, refrigerant HFC-134a can form combustible mixtures.Before filling a system with refrigerant, carefully check the filling/flushing system and the refrigeration plant for leaks. Apressure drop test with nitrogen will reveal leaks in the system. Test temporary piping and HFC-134a units with 75 psigfor 15 minutes. Test all joints for leakage using soapsuds.Technicians moving refrigerant into or out of the refrigerant envelope of any container or the refrigeration unit itself must becertified in accordance with OPNAVINST 5090.1.CONTACT WITH SKIN OR EYES. Always wear safety goggles, rubber gloves, protective apron and long-sleeved shirtbuttoned at the cuffs when handling refrigerants, hot lubricating oil, and solvents to avoid getting liquid into the eyes and on theskin. Liquid refrigerant can cause injury by freezing moisture in the eyes, solvents can cause eye irritation, and hot oil can burn.If HFC-134a refrigerant accidentally comes in contact with the eyes, avoid rubbing or irritating the eyes and give first aidtreatment immediately by promptly irrigating and washing the eyes gently with water at room temperature for 15 minutes.Take the injured person to the medical officer.If HFC-134a refrigerant comes in contact with the skin, treat the injury as if the skin were frostbitten or frozen. Immediatelyremove clothing that becomes wet with HFC-134a refrigerant.GENERAL OPERATIONAL PRECAUTIONS. Observe the following precautions during system operations:

a. Verify that electrical power is available prior to each start-up.

b. Verify that chill water bypass/diverter valves are in correct positions and that water is flowing.

c. Verify that evaporator fans are free from any obstruction.

d. Verify that all louvers, drains, and gratings in front of evaporator coil and air ducts are free from obstruction.

e. Verify that all ship stores refrigeration unit switches are in the correct position for both the operating systemand the stand-by system.

f. Before starting, stopping, or operating the ship stores refrigeration unit, thoroughly read this manual and follow allprocedures as they are written.

GENERAL MAINTENANCE PRECAUTIONS. Observe the following precautions during maintenance activities:

WARNING

Observe safety precautions as outlined in OPNAVINST 5100.19. Industrial hygiene requirements forrefrigeration system maintenance must be reviewed with the maintenance activity industrial hygienedepartment to determine appropriate engineering controls and/or personal protective equipment.

When working on or near the refrigeration unit use the correct tools in order to prevent displacement orbreakage of refrigerant lines and condenser water piping. Failure to use proper care and precautions couldresult in injury or death to personnel.

a. Before performing maintenance or making any adjustments to the ship stores refrigeration unit, disconnect powersupply and properly attach tag indicating out-of-service condition.

b. If ship stores refrigeration unit is to be out of service for any length of time where temperatures may drop belowfreezing (32°F), drain water from all components and systems that contain water; for example, refrigerationcondensers, water flow switch, and interconnecting piping. After all water has drained, blow through with nitrogento remove any trapped moisture.

c. Before making any adjustments or performing any maintenance on the ship stores refrigeration unit, thoroughly readthis manual and follow all procedures as they are written.



SPECIFIC WARNINGS AND CAUTIONS

WARNING

Before starting the ship stores refrigeration unit always look for OUT-OF-SERVICE tags. If anOUT-OF-SERVICE tag is found, the cause for the OUT-OF-SERVICE shall be corrected beforethe ship stores refrigeration unit is started. An attempt at starting the ship stores refrigeration unitwhile out of service could result in injury or death to personnel.

WARNING

Do not bypass any safety switches under any circumstances. Failure to ensure automatic operation ofthe safety switches could result in equipment damage and injury or death to personnel.

WARNING

The ship stores refrigeration unit is energized by a 440 Vac, 3-phase 60 Hz power supply. Alwaysdisconnect electric power at the main power supply and tag OUT-OF-SERVICE when performingany service. Failure to do so could result in injury or death of personnel.

WARNING

The SSRU consists of two separate independent systems. Whenever one operating system is beingshut down for maintenance the entire SSRU must be tagged OUT-OF-SERVICE before performingany maintenance. Failure to do so could result in injury or death to personnel.

WARNING

The ship stores refrigeration unit is pressurized at all times. When making adjustments or serviceto either the ship stores refrigeration unit or condenser water systems isolate the affected areabeing serviced and release pressure. Failure to follow this procedure could result in injury ordeath of personnel.

WARNING

Prior to performing maintenance, review other WARNINGs and CAUTIONs in the Safety Summary.

WARNING

When making any repair that could result in refrigerant HFC-134a being present in the atmosphere,the space shall be ventilated with fresh air. Be sure ventilation in the space is adequate to keep theconcentration of refrigerant below 1000 parts per million. Ventilation air should be exhausted outsidethe ship. Failure to properly ventilate the space could result in injury or death to personnel.

WARNING

Check for refrigerant vapor presence prior to entering equipment cabinet. A concentration ofrefrigerant vapor can cause suffocation or result in heart failure.



WARNING

Rotating parts can cause death or injury. Do not wipe down or place hands in the vicinity of rotatingparts. Ensure that rotating parts are deenergized and tagged out of service before performingmaintenance on them.

WARNING

Some components within the operating system may be at temperatures greater than 125°F. Chemicalsafety goggles or a full face shield, chemical resistant gloves and chemical resistant long sleeveshirts must be worn when performing any service or maintenance. Contact with unprotected skin canresult in serious burns or injury to personnel.

WARNING

When a maintenance procedure may result in exposure to refrigerant, technicians performing theprocedure must be certified in accordance with OPNAVINST 5090.1.

WARNING

Refrigerant HFC-134a containers are under pressure. Chemical safety goggles or a full-face shieldshall be used whenever handling refrigerant. Wear chemical resistant gloves. Failure to do socould result in injury or death to personnel.

WARNING

Technicians moving refrigerant into or out of the refrigerant envelope of any container or therefrigeration unit itself must be certified in accordance with OPNAVINST 5090.1.

WARNING

Energized electrical equipment is hazardous to personnel. To prevent injury or death, ensure thatonly qualified personnel work on or near energized equipment.

WARNING

Prior to removing any access cover to the refrigeration unit, check for the presence of HFC-134arefrigerant using the SHIPS Central Air Monitoring System (CAMS) or portable electronic leakdetector. A concentration of refrigerant vapor can cause suffocation or result in heart failures.

WARNING

Fan motor mounting assembly weighs approximately 100 lb. Use proper lifting equipment toavoid personnel injury.

WARNING

Compressor and crankcase heater can be very hot and could cause severe burns if not sufficientlycooled. To prevent injury to personnel, exercise care in working near compressor.



WARNING

Isolator with piping and component weigh approximately 660 lbs. Use proper hoisting equipment toavoid personnel injury.

WARNING

Evaporator coil heater elements can be very hot and could cause severe burns if not sufficientlycooled. To prevent injury to personnel, exercise care in working near evaporator coil heaters andallow to cool thoroughly before replacing.

WARNING

Drip pan heater elements can be very hot and could cause severe burns if not sufficiently cooled.To prevent injury to personnel, exercise care in working near drip pan heaters and allow to coolthoroughly before replacing.

WARNING

SSRU weighs approximately 10,000 lbs. Exercise suitable precautions to prevent injury to personnelor damage to equipment when moving and positioning SSRU.

CAUTION

The compressor is not to be started with the system in a vacuum, as would be the case followingsystem evacuation. Ensure the correct amount of refrigerant has been charged into the refrigerationunit.

CAUTION

If the unit has been evacuated, refer to paragraph 6.3 on how to charge the refrigeration unit.

CAUTION

Scroll compressors are directionally dependent; i.e. they will compress in one rotational directiononly. Three-phase scroll compressors will rotate in either direction depending on power phasing. Toprevent reverse rotation each system is provided with a power supply voltage monitor. Verificationof correct rotation can be confirmed by observing the LED on the power supply voltage monitor.The LED indicator glows when all conditions are acceptable. Failure to have correct compressorrotation will result in damage to the equipment.

CAUTION

The compressor crankcase heater must be on for at least 6 hours before starting the SSRU. When thethree-position selector switch is in the OFF position, both crankcase heaters are energized. Failure todo so will result in damage to the compressor.



CAUTION

Dispose of all non-metallic waste parts and products (such as rags contaminated with oil, grease,solvents, or other compounds, or compounds themselves) in accordance with OPNAVINSTP-45-110-96, disposal method 1, or approved maintenance activity requirements and procedures,as applicable.

CAUTION

To prevent equipment damage, maintain a dry nitrogen blanket on the refrigeration circuit wheneverit is open for maintenance.

CAUTION

Relay contacts will transfer during this test.

CAUTION

Return timer to original conditions and replace card before resuming normal operation.

CAUTION

Correct the problems associated with following conditions first before using reset keys. More thanone error could be present. Caution is advised since several items are reset at one time.

CAUTION

Incorrect settings may result in poor performance or equipment damage.

CAUTION

The snap-action of the switch is critical for proper control operation. If the switch does not haveproper snap-action it may operate erratically. To prevent damage to the switch, the screwdriver usedto toggle the switch must be kept out of the switch area. The only point that the switch should bemanually toggled is the bellows lever.

CAUTION

To avoid damage to equipment, do not force adjustment screw beyond stops.

CAUTION




CAUTION


CAUTION

The heater element may be difficult to remove. Ensure the element is defective prior to removal,because excessive force may damage the element.

CAUTION

Ceiling joints shall not be caulked so that moisture can escape if necessary. Repeated freezing andthawing of accumulated moisture could result in frostheaving which could damage panels.




SAFETY-8 (blank)FOR OFFICIAL USE ONLY


CHAPTER 1

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1.1 GENERAL.This chapter includes general information, safety data, and description of the equipment comprising the Ship StoresRefrigeration Unit (SSRU) as well as tabulated reference data.

1.2 SAFETY PRECAUTIONS.Refer to Safety Summary for information on safety precautions.

1.3 WARNINGS, CAUTIONS, AND NOTES.Warnings, Cautions, and Notes are placed in text as necessary to prevent injury to personnel, destruction of equipment, orspecific comments on text or procedures. General safety precautions and warnings are summarized in the Safety Summary.

1.4 INTRODUCTION.The purpose of this technical manual is to provide operational, maintenance and troubleshooting instructions for the ShipStores Refrigeration Unit (SSRU). The scope of this technical manual includes the SSRU and shipboard refrigerated storagespaces. The refrigerated spaces are the chill and freeze rooms.

1.5 EQUIPMENT DESCRIPTION.The equipment described in this technical manual consists of a self-contained ship stores refrigeration unit and refrigeratedshipboard spaces (figure 1-1). The ship stores refrigeration unit consists of two separate refrigeration systems, eachindependently operated. Either system can be used for providing refrigerated air to the chill and freeze rooms. The controlsystem for the ship stores refrigeration unit will not permit simultaneous operation of both refrigeration systems. Only onesystem may operate at any given time, thus providing a back-up feature for maintaining the shipboard spaces at the designtemperature. Both systems have the cooling capacity to maintain the desired space temperatures. The chill room temperaturemay be maintained at either 33°F, +2/-0°F or -2°F, +4/-0°F and the freeze room at -2°F, +4/-0°F.

1-1FOR OFFICIAL USE ONLY


1.5.1 Chill and Freeze Rooms and Associated Doors. The chilled storeroom (chill room, figure 1-2, sheet 1, 2) has aninterior volume of 221 cu-ft. The frozen storeroom (freeze room, 1) has an interior volume of 401 cu-ft. The deck grating tooverhead grating height (stack height) in both storerooms is 5 ft 5 inches.The chill room and freeze room walls are constructed with extruded aluminum both inside and out with 2 inches of 2-lbpolyurethane insulation in-between. The exterior wall seams are welded to avoid the penetration of moisture. The interior wallseams are either riveted or welded. If riveted the seams are caulked to prevent moisture or debris from entering. The bottom 9inches of the interior walls are welded to prevent moisture and debris from entering.The chilled and frozen storeroom deck is constructed with aluminum extrusion on the interior and steel plate on the exteriorwith 2 inches of 2-lb polyurethane insulation in-between. The interior deck seams are welded to prevent moisture anddebris from entering.The chill room and freeze room interior overhead is riveted and the seams are not caulked. This allows the walls to equalizepressure with submarine ambient pressures and to draw out any moisture from within the walls.Both the freeze room and the chill room are accessed through hinged doors (3) with rectangular 18-1/2 x 38 inch openings.The doors are operable from either inside or out. The doors are also provided with an inside safety release (will release evenwhen the door is padlocked), a latch compatible with standard Group II padlocks, and a self-falling hook latch. Heaters (4) areinstalled in the sides, head, and sill of the doorframe at the gasket contact areas to prevent frost accumulation at door gaskets.Door heaters are continuously energized, with no thermostats, except when chill or freeze room lights are on.

1.5.2 Pressure Equalization Valve. Each room contains a pressure equalization valve (figure 1-2, sheet 1, 5). The valvesmaintain a zero pressure differential between the inside and outside of the rooms with minimal heat loss. Pressure equalizationvalves have electric heaters to prevent frost build up. The heaters are continuously energized, with no thermostats installed.

1.5.3 Chill and Freeze Room Floor and Ceiling Gratings and Drains. Both rooms have removable aluminum floorgratings (figure 1-2, sheet 1, 6). The gratings provide ventilation and drainage to facilitate cleaning decks and drains (7).

1-2 Change BFOR OFFICIAL USE ONLY


Each room also contains one-inch stand off battens located on ten-inch centers (not shown) and a ceiling grating (8)to optimize cooling air circulation.

1.5.4 Chill and Freeze Room Lighting. Chill and freeze rooms each contain two bulkhead-mounted incandescentlight fixtures (figure 1-2, sheet 1, 9), located above the ceiling grating. Control switches (10) are installed inside the roomalongside each door. An amber light mounted on the Control Panel (11, details in Chapter 2) indicates when the lights insideeach room are energized.

Change B 1-3FOR OFFICIAL USE ONLY














1.5.5 Chill and Freeze Room Removable Access Panels. Removable access panels (figure 1-2, sheet 1, 12) in theaft and outboard bulkheads provide service access to the ship exterior through the chill and freeze rooms. The freeze roomcontains four bulkhead access panels. The chill room contains two bulkhead access panels.

1.5.6 Cabinet Assembly Access Panels. Removable access panels (figure 1-2, sheet 1, 13) in the chill and freeze roomsand under the Control Panel provide service access to the coil and compressor and other equipment cabinet (14) components.

1.5.7 Compressor. The refrigeration compressor (figure 1-2, sheet 3, 15) is a hermetic scroll type operating on 440 Vac,3-phase, 60-Hz power. The compressor is furnished with a 70-watt crankcase heater, back seating service valves, an oil sumpsight glass and an internal pressure relief valve. The compressor oil heater is an external wrap-around attached directly tothe compressor. The crankcase heater protects the compressor from the accumulation of liquid refrigerant in the oil duringthe off cycle. Accumulated liquid refrigerant can damage the compressor at start-up. When the compressor is stopped,an internal solenoid valve minimizes the shutoff sound, equalizes the pressure across the scroll members, and limits theamount of reverse rotation. Thermal overload protection is provided internal to each compressor motor. The compressoris equipped with discharge and suction service valves for isolation or replacement of the compressor. With the exceptionof the service valves and the crankcase heater, the compressor is not serviceable. The purpose of the compressor is to takea low temperature, low pressure refrigerant gas, Tetrafluoroethane (HFC-134a), compress it into a high temperature, highpressure gas, and deliver it to the condenser.

1.5.8 Condenser. The brazed plate construction condenser (figure 1-2, sheet 3, 16) uses chill water to condense HFC-134arefrigerant from a high pressure, high temperature gas into a high pressure liquid. The condenser is designed for continuousoperation of the ship stores refrigeration unit at condenser water temperatures as high as 100°F. The compressor discharge linehas a pressure connection for the water regulating valve.

1.5.9 Liquid Receiver. The refrigerant receiver (figure 1-2, sheet 3, 17) is welded steel construction. The liquid receiverhas two primary functions. The receiver maintains a liquid seal on the liquid side of the refrigeration circuit under allconditions of rolling and pitching of the ship. With the condenser the liquid receiver provides storage volume for the fulloperating charge of HFC-134a refrigerant with room for expansion.

1.5.10 Moisture/Sight-Flow Indicator. The moisture/sight-flow indicator (figure 1-2, sheet 3, 20) is located in therefrigerant liquid line where it exits the receiver. A large crystal clear sight glass provides a view of the liquid refrigerant.Bubbles may indicate a shortage of refrigerant. A color dot, in the center of the moisture/sight-flow indicator, provides amoisture indication. When the color dot is dark green it indicates a dry moisture-free refrigerant. A bright yellow dot indicatesa wet moisture laden refrigerant.

1.5.11 Chill Water Bypass/Diverter Valves. Three valves are used to control the flow of chill water into the refrigerationunit. The two-way chill water bypass/diverter valve (figure 1-2, sheet 4, 23) supplies or diverts supply water to or aroundPlant #1. Three-way chill water bypass/diverter valve 2 (21) controls water out of Plant #1 and into Plant #2. Two-way chillwater bypass/diverter valve 3 (25) controls water leaving Plant #1 and Plant #2.

1.5.12 Water Regulating Valve. The two water regulating valves (figure 1-2, sheet 3, 19) are located in the chill waterpiping on the entering side of the brazed plate condensers. The three-way regulating valve maintains a constant refrigerantcondensing pressure by passing part of the condenser inlet water around the condenser directly to outlet. The valvesare refrigerant pressure actuated and operate in response to the condensing pressure. The water regulating valve pressuresensing line connects to the shutoff valve (18).

1.5.13 Shutoff Valve. Two shutoff valves (figure 1-2, sheet 3, 18) are located between the compressor discharge lineand the water regulating valve sensing lines. These valves allow refrigerant to be isolated from the sensing line in bothPlant #1 and Plant #2.

1.5.14 Refrigerant Filter/Dehydrator. The refrigerant filter/dehydrator (figure 1-2, sheet 4, 22) is located in the refrigerantliquid line leaving the receiver. The refrigerant filter/dehydrator removes moisture, acids, and particulate matter from therefrigerant. The refrigerant filter/dehydrator is a brazed-in-place, non-serviceable, sealed cartridge.

1.5.15 Evaporator Coil. The evaporator coil (figure 1-2, sheet 5, 26) located in the equipment cabinet (figure 1-2, sheet 1,14) is eight rows deep with dual refrigerant circuits. Each circuit serves one of the two independent refrigeration systems. Theevaporator coil is constructed with copper tubes, aluminum fins, and stainless steel framework. The coil is provided withelectric defrost heaters included within the coil. When defrost occurs, both circuits are defrosted.1.5.15.1 Thermal Expansion Valves. There are two thermostatic expansion valves (figure 1-2, sheet 5, 33) on theevaporator coil, one for each circuit. The valves are direct operating and each valve is actuated by its own thermal element.Each valve is equipped with an external equalizer. The purpose of the thermal expansion valve is to maintain a preset amount



of superheat in the refrigerant leaving the evaporator coils, preventing liquid refrigerant from returning to the compressorwhile still supplying the evaporator with enough refrigerant to satisfy all load conditions.1.5.15.2 Evaporator Coil Drip Pan. The evaporator coil is provided with a drip pan with heaters (figure 1-2, sheet 5, 32)for the collection of condensate during the defrost cycle. Drip pan heaters prevent the formation of ice. The drip pan heatersare energized during the defrost cycle and are deenergized at the conclusion of the defrost cycle. The drip pan also includesboth a drain line and trap. Defrost heaters are provided in both the drain line and the trap. The drain line and trap heaters are onat all times. The evaporator coil defrost heaters and drip pan heater are cycled on and off by the evaporator coil defrost cycle.1.5.15.3 Defrost Initiation Timer. The defrost initiation timer is a microprocessor based long range computing timer.The defrost initiation timer is located on the ship stores refrigeration unit Control Panel (figure 1-2, sheet 1, 11). The defrostinitiation timer counts the accumulated minutes the freeze room thermostat has been closed. When the time interval, which ispreset by the operator, has elapsed, the system will enter the pump down cycle. At the conclusion of the pump down cycle thedefrost cycle will begin. A single defrost initiation timer serves both refrigeration systems.1.5.15.4 Defrost Cycle Timer. The defrost cycle timer is a microprocessor based long range computing timer. The defrostcycle timer is located on the Control Panel (figure 1-2, sheet 1, 11). The defrost cycle timer counts the minutes the defrostcycle has been on. When the defrost time interval preset by the operator has elapsed and neither the defrost terminationthermostat switch nor the high defrost temperature thermostat switch have interrupted the defrost cycle, the defrost cycle timerwill interrupt the defrost cycle and restart the system. The timer serves as a back up for the defrost termination thermostatswitch and the high defrost temperature thermostat switch. One defrost cycle timer serves both refrigeration systems.1.5.15.5 Defrost Termination Thermostat Switch. The defrost termination thermostat switch (figure 1-2, sheet 6, 36) is atemperature actuated single-pole, dual throw switch. The switch acts as the primary device for terminating the defrost cycle.Upon termination of the defrost cycle, and when the evaporator coil has cooled sufficiently to reset the switch, the evaporatorfan starts immediately. If the freeze room thermostat is calling for cooling, the compressor will restart immediately. Theswitch is located inside the equipment cabinet (figure 1-2, sheet 1, 14) on the bulkhead opposite the Control Panel abovethe auxiliary terminal box (figure 1-2, sheet 6, 35) and the switch temperature sensing bulb is located on the evaporator coiltubesheet. One defrost termination thermostat switch serves both refrigeration systems.1.5.15.6 High Defrost Temperature Thermostat Switch. The high defrost temperature thermostat switch (figure1-2, sheet 6, 37) is a temperature actuated, single-pole, dual throw switch and acts as backup to the defrost terminationthermostat switch for terminating the defrost cycle. The switch is located inside the equipment cabinet (figure 1-2, sheet1, 14), above the auxiliary terminal box (figure 1-2, sheet 6, 35) on the bulkhead opposite the Control Panel. The switchtemperature-sensing bulb is located on the evaporator coil tubesheet. One high defrost temperature thermostat switch servesboth refrigeration systems.

1.5.16 Solenoid Valves. Two 120 Vac, 60 Hz, solenoid valves (figure 1-2, sheet 6, 34) located in the equipment cabinetopen and close in response to the control system. The solenoid valve permits the flow of refrigerant when open and preventsthe flow of refrigerant when closed. There is one solenoid valve in each refrigeration system.

1.5.17 Evaporator Fans and Fan Motors. Two eight-blade propeller evaporator fans (figure 1-2, sheet 5, 29) arecontained in the ship stores refrigeration unit equipment cabinet. One fan operates with each refrigeration system. Only onefan is operated at any given time as determined by which system is operating. The non-operating fan is isolated from thesystem by automatic dampers. The operating fan runs continuously except during the defrost cycle. During the defrost cyclethe fan is off. Each evaporator fan has a separate motor connected directly to the fan. The motors operate on 440 Vac,3-phase, 60 Hz power supply and turn at constant speed.

1.5.18 Evaporator Fan Outlet Dampers. Each evaporator fan has a separate gravity operated outlet damper (figure 1-2,sheet 5, 30) located at the top of the equipment cabinet. The damper opens when the fan is operating and closes when thefan is not operating.

1.5.19 Evaporator Coil Inlet Damper. A single gravity type inlet damper (figure 1-2, sheet 5, 31) allows air from the freezeroom and return air from the chill room to enter to the evaporator coil. This damper remains open unless both fans are off.

1.5.20 Chill Room Damper Actuator and Damper. Temperature control of the chill room is maintained through theopening and closing of the chill room damper (figure 1-2, sheet 5, 28) which is controlled by the damper actuator (27) inresponse to the chill room thermostat. The chill room damper controls the amount of cold air supplied to the chill room. Thechill room damper actuator opens and closes the inlet air damper for the chill room. The damper actuator is direct connected tothe operating shaft of the chill room damper. The damper actuator opens when power is applied and remains open until poweris interrupted. The fail-safe spring return feature of the damper actuator will close the damper when power is interrupted.



1.5.21 Schrader Valves. Schrader valves (figure 1-2, sheet 5, 33A) are installed in the suction and discharge lines ofboth systems. The valves are used for attaching the test gauge set for charging and recovering refrigerant, evacuating thesystems, and to set the thermal expansion valve superheat.

1.5.22 SSRU Room Temperature Controls. The ship stores refrigeration unit control system includes chill and freezeroom temperature controls. Once set by the operator, these controls automatically maintain the rooms at design temperatures.Locations of room temperature controls are shown and the operations and functions are further described in Chapter 2.1.5.22.1 Chill Room Thermostat. The chill room thermostat is a microprocessor-based fully programmable thermostatwith two 4-digit LED displays for set point and room temperature. This thermostat is on the ship stores refrigeration unitControl Panel. The thermostat continuously displays the temperature within the chill room. The chill room thermostatmodulates the chill room damper open or closed to maintain space temperature at the set point by regulating air flow from thefreeze room to the chill room. The chill room thermostat does not control compressor operation.1.5.22.2 Freeze Room Thermostat. The freeze room thermostat is a microprocessor-based fully programmablethermostat with two 4-digit LED displays for set point and room temperature. This thermostat is on the ship storesrefrigeration unit Control Panel. The thermostat continuously displays the temperature within the freeze room. The freezeroom thermostat cycles the liquid solenoid valve open and closed which in turn cycles the compressor operation to maintainspace temperature at the set point.1.5.22.3 Chill Room Temperature Probe. The chill room temperature probe senses the air temperature in the chillroom. The connection cable is terminated at the chill room thermostat. The temperature-sensing probe is located inside thechill room at the far left upper corner opposite the door.1.5.22.4 Freeze Room Temperature Probe. The freeze room temperature probe senses the return air temperaturefrom the freeze room. The connection cable is terminated at the freeze room thermostat. The probe is located betweenthe evaporator coil inlet damper and the evaporator coil.

1.5.23 Refrigeration Unit Safety Switches. The ship stores refrigeration unit control system includes operational safetyswitches to prevent operation that would result in damage to the ship stores refrigeration unit and equipment. Locations andoperations of refrigeration unit safety devices are further described in Chapter 2 and Chapter 3.1.5.23.1 Compressor High Pressure Switch. The compressor high pressure switch is a pressure-operated safety devicethat protects the system and personnel from damage or injury resulting from equipment failure caused by high pressure. Thehigh pressure switch is located in the Control Panel. In the event it opens, the system will immediately shut down and theHIGH PRESSURE indicator will light. The high pressure switch must be manually reset after the pressure falls below theset point. The system will lock out when the high pressure switch is opened and only manual system restart is possible.There is a high pressure switch in each refrigeration system.1.5.23.2 Compressor Internal Pressure Relief Valve. The compressor internal pressure relief valve will open at adischarge-to-suction pressure differential pressure of 375 to 450 psi. The valve will automatically reset as the pressure drops.Each compressor has a separate compressor internal relief valve. The internal pressure relief valve is a safety backup in caseof a malfunctioning or isolated compressor high pressure switch.

1.5.24 Refrigeration Unit Control Switches. The ship stores refrigeration unit control system includes several operationalcontrol switches. The purpose of these switches is to monitor operation of the operating system. Locations and operations ofrefrigeration unit control devices are further described in Chapter 2 and Chapter 3.1.5.24.1 Compressor Low Pressure Switch. The compressor low pressure switch will interrupt compressor operationwhen the compressor suction pressure decreases to the cut-out setting and the associated LOW PRESSURE indicator willlight. As the suction pressure rises to the cut-in setting, the switch will reset, the associated LOW PRESSURE indicator willextinguish and compressor restart will occur after the anti-cycle lockout timer has timed out. Switch activation is a normal partof the pumpdown cycle and system operation. Each system has a separate compressor low pressure switch.1.5.24.2 Power Supply Voltage Monitor. The power supply voltage monitor protects the compressors from hazardousline conditions. The power supply voltage monitor is located inside the ship stores refrigeration unit Control Panel. Thevoltage monitor continuously monitors the voltage in each of the three phases and separately senses low voltage, voltageunbalance including phase loss and phase sequence. Protection is also assured during periods of large average voltagefluctuations, or when regenerated voltages are present. The red LED indicator glows when all voltages are acceptable. Thereis a power supply voltage monitor in each refrigeration system.1.5.24.3 Condenser Water Flow Switch. The condenser water flow switch (figure 1-2, sheet 4, 24) prevents therefrigeration system from operating when the flow rate of chill water has dropped to less than the required minimum. Thewater flow switch is located in the chill water return piping. In the event of chill water flow less than the required minimum,the switch will close and energize the water failure on-delay relay timer. A single water flow switch serves both refrigerationsystems.



1.5.24.4 Anti-Cycle Lockout Timer. The anti-cycle lockout timer is a solid state device that prevents short cycling ofthe compressor. The anti-cycle timer is located inside the ship stores refrigeration unit Control Panel. The anti-cycle timerprovides protection from premature cycling of the compressor. When the compressor is turned off, the delay is initiated andprevents restarting until the anti-cycle timer has timed out. There is an anti-cycle lockout timer for each system.1.5.24.5 Water Failure On-Delay Relay Timer. When energized by the condenser water flow switch, the waterfailure on-delay relay located in the Control Panel provides an operator adjustable time delay before the system enters thepump-down cycle. At the end of the delay period the system enters the pump-down cycle. If power to the on-delay relayshould be interrupted before the timing period expires, the timer will reset and the system will continue to operate. One waterfailure on-delay relay serves both refrigeration systems.

1.6 REFERENCE DATA.Reference data for the ship stores refrigeration unit equipment are listed in table 1-1.

1.7 EQUIPMENT, ACCESSORIES, AND DOCUMENTS SUPPLIED.Equipment, accessories, and documents supplied with the ship stores refrigeration unit are listed in table 1-2.

Table 1-1. Reference Data

Component Reference Data Characteristic

Compressor Part numberManufacturerTypeDisplacementMotor HorsepowerVoltageRPMWeightCondensing TemperatureLubricating Oil ChargeLubricating Oil SpecificationLubricating Oil ViscosityRefrigerant Charge (HFC-134a)Suction Service Valve SizeDischarge Service Valve SizeCapacity

ZS38K4ECopeland CorporationScroll13.3 CFM at 3500 rpm5440 Vac, 3Ph, 60 Hz350086 lb70°F64 ozPolyol ester (POE)22 ISO VG at 40°C5 lb +/- 0.5 lbRotalock 7/8 in. ODFRotalock 5/8 in. ODF1 Ton



Table 1-1. Reference Data (Cont.)


Condenser Part NumberManufacturerTypeDry WeightHeat RejectionNominal SurfaceCondensing TemperatureRefrigerant HCF-134a MassFlow RateChill Water Flow RateRefrigerant Pressure DropRefrigerant VolumeRefrigerant Side MaterialNumber of ChannelsRefrigerant SideRefrigerant Inlet ConnectionSizeRefrigerant Outlet ConnectionSizeWater Mass Flow RateWater Pressure DropWater VolumeWater Side MaterialNumber of Channels WaterSideWater Inlet Connection SizeWater Outlet Connection Size

C2AFlatPlate, Inc.Brazed Plate9.5 lb20,400 BTUH6.9 Square Feet70°F3.4 lb/min0-5 gpmNegligible0.0270 ft3Stainless steel95/8 in. ODF5/8 in. ODF0-43.5 lb/min0-10 psi0.030 ft3Stainless steel107/8 in. ODF7/8 in. ODF

Liquid Receiver Part NumberManufacturerTypeDry WeightShell DiameterOverall LengthStorage Capacity, HFC-134aRefrigerant Inlet ConnectionSizeRefrigerant Outlet ConnectionSize

ARL20977A C and R Components (Henry)Vertical32 lb8.625 in.16 in.29 lb5/8 in. ODF5/8 in. ODF





Evaporator Coil Part NumberManufacturerTypeFace AreaDry WeightNumber of CircuitsRefrigerant Passes per CircuitFin Depth per CircuitFin MaterialNumber of FinsFin DepthFin LengthFin ThicknessTube MaterialNumber of Tubes per CircuitTube LengthTube ODTube Wall ThicknessHeat Transfer

1298-31Marlo CoilTube and Fin27 in. x 38 in.260 lb246 in.Aluminum20512 in.27.375 in.0.016 in.Copper3788.7 in.0.625 in.0.035 in.12,000 BTUH

Evaporator Coil DefrostHeaters

Part NumberManufacturerTypeQuantity of Heaters per CircuitHeat Rating

519X-180429IndeecoTubular straight41000 W

Drip Pan Heaters Part NumberManufacturerTypeQuantity of Heaters per CircuitHeat Rating

511X-180428IndeecoU-bend1500 W

Evaporator Fan Part NumberManufacturerTypeMaterialDiameterAir Flow Rate

16-8-3R-PAG-35-ACrowley CompanyPropeller, 8 bladeNylon16 in.2100 cfm

Evaporator Fan Motors Part NumberManufacturerTypeElectric Power SupplyHorsepowerSpeedInsulation ClassFrame SizeDutyEnclosureDesignNavy ServiceAmbientSpecification

MR1035Mil Spec, Inc.Squirrel Cage Induction440 Vac, 3Ph, 60 Hz1 HP1750 rpmClass F56ContinuousSpray tightBA40°CMIL-M-17059





Evaporator Fan OutletDampers

Part NumberManufacturerTypePower SupplyFace AreaNumber of BladesMaterial

3200 17 in. x 17 in.PHL, Inc.PlenumGravity17 in. x 17 in.6Aluminum

Evaporator Coil InletDampers

Part NumberManufacturerTypePower SupplyFace AreaNumber of BladesMaterial

3200 19 in. x 27.23 in.PHL, Inc.Vertical mountGravity19 in. x 27.63 in.8Aluminum

Water Regulating Valve Part NumberManufacturerTypeSizeWeightWater FlowSet PointInlet Connection SizeOutlet Connection SizeBypass Connection SizeMaterial

M700P-50FL-3WMetrex Valve Corp.3-Way diverting1/2 in. NPS10 lb5 gpm70°F (71 psig)1/2 in. NPS 150#, MIL-F-20042D1/2 in. NPS 150#, MIL-F-20042D1/2 in. NPS 150#, MIL-F-20042DBronze

Chill WaterBypass/Diverter Valve(Bypass)

Part NumberManufacturerTypeFlow PatternOptions

1 IN IPS-MN-34-SB(1)-2P0-C0PBM, Inc.180 degree turn, 3 position#6B7-HG-1H-2S-A0-1P

Chill WaterBypass/Diverter Valve(Outlet)



Chill WaterBypass/Diverter Valve(Inlet)



Compressor Oil Heater Part NumberManufacturerTypePower SupplyRating

918-0043-01Copeland CorporationStrap-on440 Vac, 60Hz70 Watt

RefrigeratorFilter/Dehydrator

Part NumberManufacturerTypeSizeMaterial

C-083-SSporlan Valve Co.Flow through3/8 in. ODFSteel with copper sockets





Moisture/Sight FlowIndicator

Part NumberManufacturerTypeSizeMaterial

SA-13SSporlan Valve Co.Flow through3/8 in. ODFBrass

Thermal Expansion Valve Part NumberManufacturerTypeConnection SizeNominal RatingThermal Bulb DimensionsCapillary Tube LengthPort SizeChargeExternal Equalizer Line Size

EMCE-23-JCSporlan Valve Co.EBF3/8 in. x 1/2 in. ODF1 T0.5 in. OD x 3.5 in. long5 ftAType C1/4 in. OD

Solenoid Valve Part NumberManufacturerTypePower SupplyConnection SizeOrifice

E5S 130Sporlan Valve Co.NC120 Vac, 60Hz3/8 in. ODF0.150 in.

Compressor High PressureSafety Switch

Part NumberManufacturerTypeOperating RangeDifferentialContact RatingMaximum Working PressureEnclosurePressure Connection

60-2065Danfoss Automatic ControlsSPDT, manual reset85 to 300 psig, set at 150 psig43 psi, fixed120 Vac: 16 FLA, 96 LRA435 psigNEMA 2, Drip Proof36 in. capillary with 1/4-in. flare nut

Compressor Low PressureSwitch

Part NumberManufacturerTypeOperating RangeDifferential Range & SettingContact RatingMaximum Working PressureEnclosurePressure Connection

60-2063Danfoss Automatic ControlsSPDT, auto reset6 in. Hg to 72 psig, set at 0 psig6 to 32 psid, set at 6 psid120 Vac: 16 FLA, 96 LRA245 psigNEMA 2, Drip Proof36 in. capillary with 1/4-in. flare nut

Condenser Water FlowSwitch

Part NumberManufacturerSwitch TypeSet PointDifferentialContact RatingAmbient Temperature RatingProof PressureWire TerminationConnection Size

FS-200-UE-LW-0.50-V-3.0GPM-AGems Sensor Div. of IMO Ind.Magnetic, NC at no flow3.0 gpm +/-10%+/-10% of Set Point10 Watt at 110 Vac+32°F to +200°F at 200 psi400 psig at 200°F maxLead wire1/2 in. NPS, MIL-F-1183/10 union





Chill Room Thermostat Part NumberManufacturerTypeSet PointSet Point DifferentialInputOutputDisplayAccuracyEnclosure

D85123-0Dwyer Instruments Inc.Microprocessor based33 or -2°F (selectable)2°F or 4°FRTDRelay, SPDT, 10 A at 240 VacTwo 4-digit, 7 segment LED+/- 0.25% of span, +/-1 degreeNEMA-4X, IP65

Freeze Room Thermostat Part NumberManufacturerTypeSet PointSet Point DifferentialInputOutputDisplayAccuracyEnclosure

D85123-0Dwyer Instruments Inc.Microprocessor based-2°F4°FRTDRelay, SPDT, 10A at 240 VacTwo 4-digit, 7 segment LED+/- 0.25% of span, +/-1 degreeNEMA-4X, IP65

Freeze Room TemperatureProbe

Part NumberManufacturerType

56422-1231Dwyer Instruments Inc.RTD

Chill Room TemperatureProbe


56422-1231Dwyer Instruments Inc.RTD

Doorframe Heater Part NumberManufacturerPower Supply

BY-18Jamison Door Company125V, 145W, 1.2A

Power Supply VoltageMonitor

Part NumberManufacturerTypeLine Voltage Operating RangeVoltage DetectionLow Voltage TripTrip Voltage UnbalanceBetween PhasesTrip DelayPhase Reversal Response TimeOutput

RLM911SSAC Inc.Solid State400 to 480 Vac at 60 HzDelay trip, auto reset88 to 92% of line voltage2 to 6%, adjustable2 to 20 seconds adjustable (set at 2 seconds)100 ms, auto resetSPDT relay, 8 A at 240 Vac

Anti-Cycle Lockout Timer Part NumberManufacturerTypeInputOutput, Minimum LoadOutput, Maximum LoadInitiate Time DelaySetting, Lockout TimeFor Total Lockout Time

TL120A5TSSAC Inc.Solid state120 Vac40 mA0.5A, 10A IR8 ms5 minute, fixed120 Vac for 15 seconds





Defrost Initiation Timer Part NumberManufacturerTypeDisplayRangeTime SettingRepeat AccuracyReset TimeCycle Progress DisplayLoad RelayRelay TypeRelay Contact Rating

365A300Q30PXAutomatic Timing & ControlsMicroprocessorFour mode digital, on-delay0.01 seconds to 999 hoursSelectable (set at 240 minutes)+/- 10 ms on all settings60 ms, on power failure3 digit, blue vacuum fluorescent1 instantaneous, 1 delayedDPDT, form C7 A at 120 Vac

Defrost Cycle Timer Part NumberManufacturerTypeDisplayRangeTime SettingRepeat AccuracyReset TimeCycle Progress DisplayLoad RelayRelay TypeRelay Contact Rating

365A300Q30PXAutomatic Timing & ControlsMicroprocessorFour mode digital, on-delay0.01 seconds to 999 hoursSelectable (set at 15 minute)+/- 10 ms on all settings60 ms, on power failure3 digit, blue vacuum fluorescent1 instantaneous, 1 delayedDPDT, form C7 A at 120 Vac

Defrost TerminationThermostat Switch

Part NumberManufacturerTypeRangeDifferential Range & SettingSwitch Cut-Out SettingSwitch ActionContact Rating

060-100Ranco North AmericaTemperature actuated-35 to 95°F4 to 50°F; set at 10°F+40°FSPDT24 FLA at 120 Vac

High Defrost TemperatureThermostat Switch

Part NumberManufacturerTypeRangeDifferential Range & SettingSwitch Cut-Out SettingSwitch ActionContact Rating

060-100Ranco North AmericaTemperature actuated-35 to 95°F4 to 50°F; set at 40°F+95°FSPDT24 A at 120 Vac

Pressure EqualizationValve

Part NumberManufacturerElectric HeaterMaterialLengthInside DiameterMounting Flange Diameter

1830Kason120 VacAluminum4 in.3.5 in.5-3/32 in.





Chill Room DamperActuator

Part NumberManufacturerPower SupplyPower ConsumptionAngle of RotationTorqueDirection of RotationPower Failure Operation (failsafe)

LF120-SBelimo Aircontrols Inc.120 VacRunning 5.5W, holding 3.5W95 degrees max adjustable35 in-lb, constantReversible, cw/ccwSpring return

Water Failure On-DelayRelay Timer

Part NumberSupplierTypeTime Delay AdjustmentRangeSwitch Setting

2A562GraingerSolid state timing, on-delayPotentiometer3 to 60 secondsSelectable (set at 45 seconds)

Compressor Starter Part NumberManufacturerNEMATypeNumber of PolesHolding CoilContact Rating

8536-SBO2V02SSquare DSize OOpen magnetic3-NO, with 1-NO, 1-NC auxiliary120 Vac18 A at 440 Vac

Compressor StarterThermal Overload Unit


B17-5Square DMelting Alloy

Fan Starter Part NumberManufacturerNEMATypeNumber of PolesHolding CoilContact Rating

8502-SAO12V02SSquare DSize OOOpen magnetic3-NO, with 1-NO auxiliary120 Vac9 A at 440 Vac

Defrost Heater Starter Part NumberManufacturerNEMATypeNumber of PolesHolding CoilContact Rating

8502-SBO2V02SSquare DSize OOpen magnetic3-NO, with 1-NO, 1-NC auxiliary120 Vac18 A at 440 Vac

Control Relay Part NumberManufacturerNEMATypeNumber of PolesHolding Coil

8501-X040Square DA600Open magnetic4120 Vac

Contact Cartridge Part NumberManufacturerType

XC1Square DStandard (reversible NO/NC)

Contact Cartridge Part NumberManufacturerType

XC2Square DOverlapping (reversible NO/NC)





Control Transformer Part NumberManufacturerPrimarySecondaryRatingProtectionRegulation

9070-TF350D1Square D440 Vac120 Vac350 VAFusing, primary and secondaryInrush, 1894 VA at 20% PF and 95% secondary voltage

Mode Selector Switch Part NumberManufacturerStyleTypeOperator FunctionEnvironmental ProtectionNumber of Contact BlocksContact Rating

800H-JR2KD7BBMMRockwell Automation (formerly Allen Bradley)3-position, non-illuminatedNEMA, 4, 4x, 13Maintain contactCorrosion resistant410 A at 120 Vac

Start Pushbutton Switch Part NumberManufacturerStyleTypeOperator Button StyleOperator Button ColorContactsEnvironmental ProtectionNumber of Contact BlocksContact Rating

9001-SKR24GH5Square DMomentary contact, non-illumNEMA 4, 4x, 13Mushroom head 1-3/8 in. dia.Green1-NOCorrosion resistant110 A at 120 Vac

Emergency Stop/ResetPushbutton Switch

Part NumberManufacturerStyleTypeOperator Button StyleOperator Button ColorContactsEnvironmental ProtectionNumber of Contact BlocksContact Rating

9001-SKR2BH6Square DMomentary contact, non-illumNEMA, 4, 4x, 13Extended guardBlack1-NCCorrosion resistant110 A at 120 Vac

Pumpdown/StopPushbutton Switch

Part NumberManufacturerStyleTypeOperator Button StyleOperator Button ColorContactsEnvironmental ProtectionNumber of Contact BlocksContact Rating

9001-SKR3YH5Square DMomentary contact, non-illumNEMA 4, 4x, 13Extended guardYellow1-NOCorrosion resistant110 A at 120 Vac





Indicator LightIlluminated

Part NumberManufacturerStyleTypeOperator Button StyleDome ColorsEnvironmental ProtectionContact Rating

9001-SKT1Square DPush-to-testNEMA 4, 4x, 13Plastic domeGreen, red, blue, white, amberCorrosion resistant10 A at 120 Vac

Indicator LightIlluminated (Flashing)


9001-SKTF1Square DPush-to-testNEMA 4, 4x, 13Plastic domeRedCorrosion resistant10 A at 120 Vac

Indicator LightIlluminated


9001-SKT5Square DPush-to-testNEMA 4, 4x, 13Plastic domeGreenCorrosion resistant10 A at 440 Vac

Elapsed Time Meter Part NumberManufacturerRangeTypePower

635KCramer Inc.0 to 99999 HrsNon-resettable120 Vac

Freeze Room Design LoadInterior Volume

0.31 Ton401 ft3

Chill Room Design LoadInterior Volume

0.44 Ton221 ft3

Control Station Box (ForChill Room and FreezeRoom Light Control)

Part NumberManufacturerTypeControlsLabel PlateNumber of Contact Blocks

PWB-4Killark Electric Manufacturing Co.NEMA 1, #2ER702-Position Selector SwitchON/OFF2 (One NC, one NO)

Table 1-2. Equipment, Accessories, and Documents Supplied

Quantity NomenclatureCID

Number Dimensions (In.)Weight and Volume

(Lb/Cu Ft)

1 Ship Stores RefrigerationUnit

1298-00-D 222 L/120.5 W/80.7 H 10,185/932

1 set Drawings -- -- --

1 set Technical Manuals S9516-BR-MMA-010 -- --



Table 1-2. Equipment, Accessories, and Documents Supplied (Cont.)

Quantity NomenclatureCID

Number Dimensions (In.)Weight and Volume

(Lb/Cu Ft)

1 set Manifold Test gage set,HFC-134a, includingdiaphragm valves and colorcoded hoses

Imperial EastmanDiv. Catalog Number631-CKP

14 L/8 W/6 H 5/0.39

1 set Refrigeration Charging andTest Kit including cylinderadapter

Marlo Coil 700-000-305Yellow Jacket 19105

14”x14”x4” 7 lbs




1-24 (blank)FOR OFFICIAL USE ONLY


CHAPTER 2

OPERATION

2.1 INTRODUCTION.The nominal 1.0 ton Ship Stores Refrigeration Unit (SSRU) is designed to maintain the freeze room at -2°F, +4/-0 °F and thechill room at either 33°F +2/-0°F or -2°F+4/-0°F. Tetrafluoroethane (HFC-134a) refrigerant is circulated through the system.The refrigerant liquid absorbs heat in the evaporator coil as it cools the chill and freeze rooms and rejects heat to the chillwater circulating through the condenser. The SSRU consists of two independent refrigeration systems.

NOTEOperating instructions for this equipment may also be contained in the Ship Systems Manual(SSM). In this case the operating instructions in the SSM take precedence over the operatinginstructions in this manual.

2.2 CONTROLS AND INDICATORS.Operator controls and indicators consist of manual and automatic switches, relays, timers, meters, voltage monitors, indicatorlights, thermostats, refrigeration controls, refrigeration valves and chill water valves.

2.2.1 Control Panel Controls and Indicators. Table 2-1 and figure 2-1 describe the control panel controls and indicators.Specific settings and adjustments are further described in Chapter 6.

2.2.2 SSRU Valves and Indicators. Table 2-2 and figure 2-2 describe the SSRU valves, control mechanisms, andindicators.







Table 2-1. Control Panel Controls and Indicators

Control or Indicator Function

CHILL ROOM THERMOSTAT (CRT) (figure 2-1, sheet1, 1)

Fully programmable, microprocessor based control with two4-digit light emitting diode (LED) displays for set pointand °F and °C chill room temperature. Input is from chillroom temperature probe. Refer to Chapter 6 for operatoradjustment procedure.

FREEZE ROOM THERMOSTAT (FRT) (23) Fully programmable, microprocessor based control with two4-digit LED displays for set point and °F and °C freeze roomtemperature. Input is from freeze room temperature probe.Refer to Chapter 6 for operator adjustment procedure.

MODE SELECT switch (2) Three-position rotary switch (SW1), selects SSRU systemto place in operation.

PLANT #1 Applies power to refrigeration Plant #1 compressor andcomponents.

PLANT #2 Applies power to refrigeration Plant #2 compressor andcomponents.

OFF Deenergizes Plant #1 and Plant #2.

START switch (26) Pushbutton switch (PB1). Normally open switch.Momentary closure starts refrigeration plant selected byoperator.

PUMPDOWN/STOP switch (25) Pushbutton switch (PB2). Normally open switch.Momentary closure begins pump down cycle to evacuaterefrigerant from the evaporator coil to receiver and condenserbefore system is stopped.

EMERGENCY STOP/RESET switch (24) Pushbutton switch (PB3). Normally closed switch.Momentary opening brings operation of system to immediatestop. Also operates as control system reset in event ofsystem shut down by safety control device.

POWER ON indicator (7) White light indicates power is available to SSRU.

DEFROST indicator (8) Blue push-to-test light indicates defrost cycle is on.

WATER FAILURE/PUMPDOWN indicator (9) Red push-to-test light indicates condenser water flow fallsbelow minimum required flow in one of two refrigerationplants or PUMPDOWN/STOP switch is pressed. Indicatorremains lit until EMERGENCY STOP/RESET switch ispressed.

HIGH DEFROST TEMPERATURE indicator (11) Red push-to-test light indicates high defrost temperaturethermostat (HTT) is closed.

FAN #1 indicator (5)FAN #2 indicator (3)

Green push-to-test light indicates evaporator fan for Plant#1 or Plant #2 is operating.

COMPRESSOR #1 indicator (6)COMPRESSOR #2 indicator (4)

Green push-to-test light indicates compressor motor forPlant #1 or Plant #2 is operating.

LOW COMPRESSOR #1 indicator (10)LOW COMPRESSOR #2 indicator (12)

Amber push-to-test light indicates low compressor suctionfor Plant #1 or Plant #2. Indicator is controlled by input fromcompressor 1 low pressure switch (LP1) (35) or compressor2 low pressure switch (LP2) (38).



Table 2-1. Control Panel Controls and Indicators (Cont.)


HIGH PRESSURE indicator (14) Red push-to-test light flashes to indicate high dischargepressure in Plant #1 or Plant #2 compressor. Indicator iscontrolled by inputs from compressor 1 high pressure switch(HP1) (34) and compressor 2 high pressure switch (HP2)(39).

PLANT RUN TIME elapsed time meter (13) Elapsed time meter (ET3) indicates total operating time ofControl Panel.

COMPRESSOR #1 RUN TIME elapsed time meter (16) Elapsed time meter (ET1) indicates total operating time ofrefrigeration Plant #1.

COMPRESSOR #2 RUN TIME elapsed time meter (15) Elapsed time meter (ET2) indicates total operating time ofrefrigeration Plant #2.

CRANKCASE HEATER #1 indicator (17) Green push-to-test light indicates compressor motorcrankcase oil heater for Plant #1 is energized.

CRANKCASE HEATER #2 indicator (18) Green push-to-test light indicates compressor motorcrankcase oil heater for Plant #2 is energized.

FREEZE ROOM LIGHTS indicator (19) Amber push-to-test light indicates lights in freeze room areenergized.

CHILL ROOM LIGHTS indicator (20) Amber push-to-test light indicates lights in chill room areenergized.

DEFROST INITIATION TIMER (21) Digital, microprocessor control rest timer (TD1) initiatedby freeze room thermostat (FRT) counts the accumulatedminutes that thermostat is energized and initiates defrost.Operator set to control duration of cooling cycles. Refer toChapter 6 for operator adjustment procedure.

DEFROST CYCLE TIMER (22) Digital, microprocessor control reset timer (TD2) energizedat initiation of defrost cycle to terminate defrost. Refer toChapter 6 for operator adjustment procedure.

Fan Interlock Control Relay CR1 (figure 2-1, sheet 2, 28) Relay controls power to evaporator fan motors for bothsystems. Delays fan start up following defrost.

Pumpdown Holding Control Relay CR2 (27) Relay initiates pumpdown in event of low water flow failurefor both systems.

Low Voltage Relay CR3 (51) Relay provides low voltage protection.

Low Pressure Relay CR4 (Plant #1) (50) Integral to pumpdown and defrost cycles for refrigerationPlant #1.

Low Pressure Relay CR5 (Plant #2) (49) Integral to pumpdown and defrost cycles for refrigerationPlant #2.

Water Failure On Delay Relay MM1 (48) Energized when condenser water flow switch (H2O) (waterfailure) closes. Contacts close after operator adjustable delaywhich events nuisance trips.

Anti-Cycle Lockout Timer 1MM1 (36)Anti-Cycle Lockout Timer 2MM1 (37)

Provide protection against short cycling of compressor 1or compressor 2. Lockout delay initiated at end of eachoperation to prevent restarting compressor for 5 minutes.



Table 2-1. Control Panel Controls and Indicators (Cont.)


Power Supply Voltage Monitor 1MM2 (30)Power Supply Voltage Monitor 2MM2 (32)

Protects compressor motor for Plant #1 or Plant #2 fromhazardous line conditions or improper phase sequence.Monitors power voltage and phase balance. LED glows whenoutput relay is energized and conditions are satisfactory. Onfault condition compressor operation is interrupted.

Compressor 1 Low Pressure Switch LP1 (35)Compressor 2 Low Pressure Switch LP2 (38)

Interrupts system operation when compressor 1 or 2 suctionpressure decreases to the switch set point less differential.Automatic reset on pressure rise to set point.

Compressor 1 High Pressure Switch HP1 (34)Compressor 2 High Pressure Switch HP2 (39)

Interrupts system operation when compressor 1 or 2discharge pressure reaches the switch set point. Switchmust be reset manually by pressing green button on switchhousing.

Compressor 1 Starter 1MS1 (45)Compressor 2 Starter 2MS1 (43)

Magnetic control electrical starter for compressor 1 orcompressor 2 motor. Overload reset with red handle (seefigure 2-1, sheet 2).

Fan 1 Starter 1MS2 (47)Fan 2 Starter 2MS2 (46)

Magnetic contact electrical starter for fan 1 or fan 2 motor.

Defrost Heater Starter HS (40) Magnetic contact electrical contacter for defrost heaterelements.

Control Transformer No. 1 (TR1) (44) Supplies 110 Vac, 60 Hz power to controls when PLANT#1 is selected.

Control Transformer No. 2 (TR2) (42) Supplies 110 Vac, 60 Hz power to controls when PLANT#2 is selected.

Control Transformer No. 3 (TR3) (41) Supplies 110 Vac, 3-phase, 60 Hz power to freeze and chillroom overhead lights, door and pressure equalization valveheaters, freeze room indicator light, chill room indicatorlight, and drain line and trap heater.

Table 2-2. SSRU Controls and Indicators


Water Regulating Valve (figure 2-2, Sheet 1, 1)Water Regulating Valve (7)

Regulates flow of water to condenser to maintain condensingpressure.

Chill Water Bypass/Diverter Valve 1 (Inlet) (3) Manually operated chill water valve controls entry of coolingwater into SSRU. The position for the chill water inlet valveunder various operating conditions and repair is shown infigure 2-2, Sheet 3.

Chill Water Bypass/Diverter Valve 3 (Outlet) (5) Manually operated chill water valve controls exit of coolingwater from SSRU. The position for the chill water outletvalve under various operating conditions and repair is shownin figure 2-2, Sheet 3.

Chill Water Bypass/Diverter Valve 2 (8) Manually operated chill water valve controls direction ofcooling water in SSRU. The position for the chill waterbypass valve under various operating conditions and repairis shown in figure 2-2, Sheet 3.



Table 2-2. SSRU Controls and Indicators (Cont.)


Condenser Water Flow Switch (H2O) (4) NO magnetically operated flow switch closes whencondenser water flow falls below 3.0 gpm. Water failureon-delay relay MM1 will be energized to allow operatoradjustable delay before pumpdown cycle begins.

Rotalock Valve (Compressor Suction) (figure 2-2, Sheet 2, 9)Rotalock Valve (Compressor Suction) (12)

Manually operated valve controls entry of refrigerant intocompressor. Used to isolate compressor. Open but notbackseated except for repair or for prolonged shutdown.

Rotalock Valve (Compressor Discharge) (10)Rotalock Valve (Compressor Discharge) (13)

Manually operated valve controls exit of refrigerant fromcompressor. Used to isolate compressor. Open but notbackseated except for repair or for prolonged shutdown.

Shutoff Valve (11)Shutoff Valve (14)

Control flow of refrigerant to capillary sensing line of waterregulating valves (1) and (7) respectively. Open except forregulating valve repair.

Moisture/Sight Flow Indicator (15)Moisture/Sight Flow Indicator (16)

Sight glass shows liquid refrigerant as it exits receiver.Bubbles may indicate shortage of refrigerant or restriction inliquid line. Color dot in center of indicator shows moisturecontent. Dry, moisture free refrigerant shows dark green dot.Bright yellow dot indicates wet, moisture-laden refrigerant.

Crankcase Oil Level Sight Glass (17)Crankcase Oil Level Sight Glass (18)

Sight glass shows level of compressor crankcase oil incompressor sump for Plant #1 or Plant #2 compressor.







B C

A

2

B

CA3

B

CA 1

UNIT #2 UNIT #1

RSS UNITWATER BY-PASS/DIVERTER VALVE

WATER INWATER OUT

MARLO COIL P.O. BOX 171 HIGH RIDGE MO. 63049CAGE 38450

WATER BY-PASS/

DIVERTER VALVE NO. POSITION

NORMAL OPERATION

123

123

123

WATER FLOW TOUNIT #1 - ONLY

WATER FLOW TOUNIT #2 - ONLY

C B

C B

B C

C B

C A

A C

C A

A B

B C

WATER BY-PASS/DIVERTER VALVE NO. 1

48-015-560

UNIT #1 NORMAL/UNIT #2


48-015-562

NORMAL/UNIT #1 UNIT #2


48-015-561

UNIT #1UNIT #2NORMAL

06581:0503Figure 2-2. SSRU Controls and Indicators (Sheet 3)

MARLO



2.2.3 Operator Controls and Indicators. Table 2-3 lists the various controls and indicators for the SSRU and provides thestate of each item for normal operating conditions, pumpdown, emergency stop, defrost, and repair.

Table 2-3. Operational Controls and Indicators

Normal Operation Position or Reading for Operating System

Name Plant #1 Plant #2 PumpdownEmergency

Stop Defrost Repair

Refrigeration Valves

Compressor Discharge Open1 Open1 Open1 Open1 Open1 Shut

Compressor Suction Open1 Open1 Open1 Open1 Open1 Shut

Water Regulating PressureShut Off

Open Open Open Open Open Shut

Solenoid Valve Automatic Automatic Automatic Automatic Automatic Automatic

Evaporator Coil TXV Automatic Automatic Automatic Automatic Automatic Automatic

LP Schrader Valve #1 Closed Closed Closed Closed Closed Open

LP Schrader Valve #2 Closed Closed Closed Closed Closed Open

HP Schrader Valve #1 Closed Closed Closed Closed Closed Open

HP Schrader Valve #2 Closed Closed Closed Closed Closed Open

Chill Water Valves

Water Regulating Automatic Automatic Automatic Automatic Automatic Automatic

By-Pass/Diverter Valve #1(Inlet) (Manual)(figure 2-2, Sheet 3)

C→B C→B C→B C→B C→B figure 2-2, Sheet 32

By-Pass/Diverter Valve #2(Outlet) (Manual)(figure 2-2, Sheet 3)

C→B C→B C→B C→B C→B figure 2-2, Sheet 32

By-Pass/Diverter Valve #3(Manual)(figure 2-2, Sheet 3)

B→C B→C B→C B→C B→C figure 2-2, Sheet 32

Miscellaneous

Freeze Room Equalization Automatic Automatic Automatic Automatic Automatic Automatic

Chill Room Equalization Automatic Automatic Automatic Automatic Automatic Automatic

Switches

Compressor High Pressure Automatic Automatic Automatic Automatic Automatic Manual reset

Compressor Low Pressure Automatic Automatic Automatic Automatic Automatic N/A

Condenser Water Failure Automatic Automatic Automatic Automatic Automatic N/A

Defrost Termination Automatic Automatic Automatic Automatic Automatic N/A

Compressor Motor Overload Automatic Automatic Automatic Automatic Automatic Manual reset

Fan Motor Overload Automatic Automatic Automatic Automatic Automatic Automatic

Manual Switches

Selector rotary switch PLANT #1 PLANT #2 PLANT #1 orPLANT #2

PLANT #1 orPLANT #2

PLANT #1 orPLANT #2

OFF

START pushbutton switch Closed Closed Open Open Open Open



Table 2-3. Operational Controls and Indicators (Cont.)



Stop Defrost Repair

PUMPDOWN/STOPpushbutton switch

Open Open Closed Open Open Open

EMERGENCYSTOP/RESETpushbutton switch

Closed Closed Closed Open Closed Closed

Compressor motor overloadreset (Manual reset)

Closed Closed Closed Closed Closed Closed

Fan motor overloadreset

Automatic Automatic Automatic Automatic Automatic Automatic

Operational Control

Power Supply VoltageMonitor


Water Failure On-DelayRelay


Anti-Cycle LockoutTimer


Chill Room Thermostat Automatic Automatic Automatic Automatic Automatic Automatic

Freeze Room Thermostat Automatic Automatic Automatic Automatic Automatic Automatic

Chill Room AirDamper Actuator


Defrost Control

Defrost Initiation Timer Automatic Automatic Automatic Automatic Automatic Automatic

Defrost Cycle Timer Automatic Automatic Automatic Automatic Automatic Automatic

Defrost TerminationThermostat Switch


High Defrost TemperatureThermostat Switch


Indicator Lights Automatic Automatic Automatic Automatic Automatic Press-to-test

POWER ON (white) On On On On On Off

DEFROST (blue) Off Off Off Off On Off

WATERFAILURE/PUMPDOWN(red)

Enabled Enabled On Off Off Off

COMPRESSOR #1(with PLANT #1 selected)(green)

Enabled Off Off Off Off Off

COMPRESSOR #2(with PLANT #2 selected)(green)

Off Enabled Off Off Off Off

FAN #1 (withPLANT #1 selected) (green)

Enabled Off Off Off Off Off



Table 2-3. Operational Controls and Indicators (Cont.)



Stop Defrost Repair

FAN #2 (withPLANT #2 selected) (green)

Off Enabled Off Off Off Off

CRANKCASE HEATER #1with PLANT #1 selected(green)

Enabled On On On On Off

CRANKCASE HEATER #2with PLANT #2 selected(green)

On Enabled On On On Off

HIGH DEFROSTTEMPERATURE

Off Off Off Off Enabled Off

LOW COMPRESSOR 1SUCTION PRESSURE(with PLANT #1 selected)(amber)

Enabled Enabled On Off On Off

LOW COMPRESSOR 2SUCTION PRESSURE(with PLANT #2 selected)(amber)

Enabled Enabled On Off On Off

HIGH COMPRESSORDISCHARGE PRESSURE(with PLANT #1 orPLANT #2 selected)(flashing red)

Enabled Enabled Off Off Off Off

Moisture/Sight FlowIndicator

Green Green Green Green Green Green

1. Compressor suction and discharge Rotalock valves are open but not backseated for these conditions.

2. In the event of a chilled water leak from a water regulating valve or plant piping, the leak is isolated and operation is maintained on the oppositeunit. Refer to figure 2-2, sheet 3, for valve position.

2.3 OPERATING PROCEDURES.The ship stores refrigeration unit consists of two independent refrigeration systems. Either system is capable of maintainingthe chill room and freeze room temperatures at design conditions. Each system consists of a compressor, condenser,receiver, evaporator coil, evaporator fan and all controls necessary for operation. It is not possible to operate both systemssimultaneously. One feature common to both systems is the evaporator coil defrost cycle. When defrost occurs the cooling coilin both systems goes through the defrost cycle. Operating procedures are required for normal operation, emergency stopping,system rotation, system defrost, and system repair. Controls and indicators are described in figure 2-1 and figure 2-2 and table2-1 and table 2-2. The switch and valve settings for various modes of operation are shown in table 2-3 and figure 2-2. Whenperforming these procedures, proceed to the next step if a normal indication occurs. If an abnormal indication is observed,perform corrective action before proceeding to the next step. When a normal operating system is to be shut down for anyreason, other than an emergency, the operator should always put the operating system through the pumpdown cycle. This willassure that when it is restarted the system is in the proper condition. A system that has been on stand-by and is to be put inservice must be activated through the normal start procedure. There are conditions in which a system may be operated in anemergency situation. These procedures are included in the following paragraphs. Various maintenance situations will requirethat a system be shut down. Procedures for this situation are found in the following paragraphs.

2.3.1 Normal System Operation. One person can operate the SSRU. To perform normal SSRU operation, proceed asfollows:



WARNING

Before starting the ship stores refrigeration unit always look for OUT-OF-SERVICE tags. If anOUT-OF-SERVICE tag is found, the cause for the OUT-OF-SERVICE shall be corrected before the shipstores refrigeration unit is started. An attempt at starting the ship stores refrigeration unit while out ofservice could result in injury or death to personnel.Do not bypass any safety switches under any circumstances. Failure to ensure automatic operation of thesafety switches could result in equipment damage and injury or death to personnel.

CAUTION

The compressor is not to be started with the system in a vacuum, as would be the case followingsystem evacuation. Ensure the correct amount of refrigerant has been charged into the refrigerationunit.

CAUTION

If the unit has been evacuated, refer to paragraph 6.3 on how to charge the refrigeration unit.

a. Verify that 440 Vac, 3-phase, 60 Hz power is provided to the Control Panel.b. On control panel, select the refrigeration plant to be placed in operation by moving the three-position mode selector

switch from OFF to PLANT #1 or PLANT #2 as desired. Observe POWER ON (white) indicator is lit.

CAUTION

Scroll compressors are directionally dependent; i.e. they will compress in one rotational directiononly. Three-phase scroll compressors will rotate in either direction depending on power phasing. Toprevent reverse rotation each system is provided with a power supply voltage monitor. Verificationof correct rotation can be confirmed by observing the LED on the power supply voltage monitor.The LED indicator glows when all conditions are acceptable. Failure to have correct compressorrotation will result in damage to the equipment.

c. Verify that condenser water is flowing through the SSRU. Low flow will be indicated by WATERFAILURE/PUMPDOWN (red) indicator.

CAUTION

The compressor crankcase heater must be on for at least 6 hours before starting the SSRU. When thethree-position selector switch is in the OFF position, both crankcase heaters are energized. Failure todo so will result in damage to the compressor.

d. Verify that the compressor suction and discharge service valves on the compressor are open and the compressorCRANKCASE HEATER (green) oil heater indicator lights have been on for at least 6 hours.

2.3.1.1 Operator Turn On. To start the SSRU, proceed as follows:

a. On Control Panel, press EMERGENCY STOP/RESET.b. Press START.c. Observe CRANKCASE HEATER (green) indicator for operating system goes off.d. Observe CRANKCASE HEATER (green) indicator for nonoperating system remains lit.e. Observe FAN (green) indicator and COMPRESSOR (green) indicator for operating system are on. For initial startup

with refrigerated spaces above 32°F temperature, the fan may be delayed.



2.3.1.2 System Stop. To stop the SSRU, proceed as follows:

a. On Control Panel, press PUMPDOWN/STOP.

b. Observe FAN (green) indicator and COMPRESSOR (green) indicator for operating system are on until pumpdowncycle is complete.

c. When pumpdown cycle is complete, observe FAN (green) indicator and COMPRESSOR (green) indicator foroperating system are off. LOW PRESSURE (amber) indicator will light.

d. Observe POWER ON (white) indicator remains lit.

e. Verify that both CRANKCASE HEATER (green) indicators are lit.

2.3.1.3 Normal System Restart. Before a system can be re-started, the anti-cycle lockout timer must time out. Torestart system, proceed as follows:

a. Wait until anti-cycle lockout timer (1MM1/2MM1) has timed out (minimum 5 minutes).

b. Perform system start procedure per paragraph 2.3.1.1.

2.3.2 Emergency Stop. To bring an operating system to an immediate emergency stop, press EMERGENCYSTOP/RESET. All indicator lights except CRANKCASE HEATER lights and POWER ON lights go out.2.3.2.1 Restarting After Emergency Stop. To restart after emergency stop, proceed as follows:

a. Allow anti-cycle lockout timer (1MM1/2MM1) to time out for minimum 5 minute timeout.

b. Restart the system per paragraph 2.3.1.1.

2.3.3 Operating System Rotation. Operating system rotation (switching from one compressor and plant to the other) isrecommended as a method of maintaining equal use on both systems. To rotate from the operating system to the stand-bysystem, proceed as follows:

a. Perform system stop per paragraph 2.3.1.2.

b. When operating system has stopped, move mode selector switch on Control Panel to either PLANT #1 or PLANT#2 to select system to be placed in operation.

c. Press EMERGENCY STOP/RESET.

d. Perform system start per paragraph 2.3.1.1.

2.3.4 Defrost Cycle. The defrost cycle is a fully automatic process cycle. The time interval between defrost cycles isset by the operator (approximately 4 hours). The normal duration of the defrost cycle is approximately 15 minutes. Uponinitiation of the defrost cycle, the liquid solenoid closes, the compressor shuts off on low pressure and the fan motor turnsoff. At that time, the defrost heaters energize.

a. To initiate manual defrost, set DEFROST INITIATION TIMER to 0, 0, 0.

b. Time interval between defrost cycles is dependent on duty cycle of compressor. If the compressor operatescontinuously, defrost cycles will occur more frequently. Inspect coil frequently to select defrost cycle accordingto rate of frost accumulation.






CHAPTER 3

FUNCTIONAL DESCRIPTION

3.1 INTRODUCTION.Refrigeration is the process whereby heat is extracted by refrigerant at low temperature and pressure, and is rejected at ahigher temperature and pressure. This process is used to maintain a given space at a desired temperature. The spaces beingmaintained are the chill and freeze rooms. The temperatures in these two spaces are 33°F, +2/-0°F or -2°F, +4/-0 °F in the chillroom, and -2°F, +4/-0 °F in the freeze room. The refrigerant used in this system is Tetrafluorethane or HFC-134a. This is thefluid to which heat is added in the refrigerated spaces and later rejected to the circulating chill water flowing through thecondenser. Normal chill water (condenser water) temperature range is between 44°F and 60°F. In emergency conditions thecondenser water temperature may rise to 100°F, and the refrigeration unit will continue to operate. At elevated condenserwater temperatures the chill and freeze room temperatures may be higher than the temperatures mentioned above.

3.1.1 Refrigeration Cycle. A basic refrigeration cycle is shown in figure 3-1. Starting at the compressor, the refrigerationcycle proceeds as follows. The compressor draws in a continuous flow of low temperature, low pressure superheatedrefrigerant gas from the evaporator coil. The compressor takes this stream of gas and compresses it to a high pressure, hightemperature gas, and delivers it to the condenser. In the condenser the stream of refrigerant gas is condensed into a liquid.This is accomplished by lowering the gas temperature, and in the process, rejecting heat to the condenser chill water. As therefrigerant exits the condenser, the liquid is a high temperature, high pressure saturated liquid. This liquid is delivered tothe receiver and subsequently to the evaporator coil. At the entrance to the evaporator coil a metering device called athermal expansion valve (TXV) changes the flow of refrigerant from a high temperature, high pressure liquid to a lowtemperature, low pressure liquid.



LIQUID

GASEVAPORATION COIL

CONDENSER

RECEIVERCOMPRESSOR

HIGH SIDE

LOW SIDE

TXV

06460:0503

Figure 3-1. Refrigeration Cycle

As shown in figure 3-1, the refrigerant cycles through the system. The system is divided into a high and low side withthe compressor and TXV as division points. From the TXV the refrigerant travels through the evaporator coil, then backthrough the suction line to the compressor. This part of the system is at the low pressure required by the evaporator coil, andthe pressure will be the same from the expansion valve through to the compressor, except for the pressure drop necessaryto move the refrigerant through the piping. This is the low pressure side (low side) of the system. The pressure on the low



side is sometimes called the back pressure or suction pressure. The compressor takes the low pressure gas and builds it toa pressure high enough to condense. The compressor discharge line, condenser, receiver and liquid line are all at highpressure in the high side of the system. In reality the compressor crankcase contains low pressure vapor; however the entirecompressor is considered part of the high side.

3.1.2 Defrost Cycle. The purpose of the defrost cycle is to remove accumulated frost from the evaporator coil. This isaccomplished by electrically heating the coil, melting the frost, and draining away the liquid water condensate. Properoperation of the defrost cycle requires periodic operator inspection of the evaporator coil surface. Adjustments to the time andtemperature set points of the various controls may be necessary to suit shipboard conditions. The defrost cycle is time initiatedby defrost initiation timer TD1 and temperature terminated by defrost termination thermostat switch DTT. The defrost cycle isterminated by the high defrost temperature thermostat switch HTT if the defrost termination thermostat switch fails. Thedefrost cycle timer TD2 will terminate the defrost cycle if the high defrost temperature thermostat switch fails. On initiation ofdefrost, defrost initiation timer TD1 closes the liquid solenoid valve and allows the system to pump down. When both systemsare in low pressure, the defrost heater contactor closes and energizes the heating elements, the defrost cycle timer clock, andthe blue DEFROST indicator. While DEFROST is lighted, the compressors and fans are prevented from operating.3.1.2.1 Temperature Termination. When the evaporator coil reaches the set point temperature of defrost terminationthermostat DTT, fan interlock relay CR1 and the power supply to TD1 and TD2 are deenergized and their contacts reset,deenergizing the heater contactor. Because the freeze room thermostat resistance temperature detector (RTD) is trapped withinthe evaporator coil section by the evaporator coil inlet damper, it will call for cooling. When the evaporator coil surfacetemperature drops to the DTT set point minus the differential, DTT will reset and energize CR1 to bring the fan on line. Thedelay on action of the fan prevents warm condensate from being blown into the refrigerated spaces.3.1.2.1.1 Backup Temperature Termination. Failure of defrost termination thermostat DTT through loss of thermal bulbcharge would result in the DTT never rising to the set point. Such a condition could result in overheating of the evaporatorcoil. Should DTT fail to terminate defrost, high defrost temperature thermostat HTT will terminate defrost on rise to the setpoint. When the evaporator coil surface temperature drops to the HTT set point minus the differential, HTT will reset andenergize CR1 to bring the fan on line.3.1.2.2 Time Termination. If defrost termination thermostat DTT and high defrost temperature thermostat HTT fail toterminate defrost within the defrost cycle timer TD2 setting, TD2 will terminate defrost. Upon time termination of defrost,CR1 will be locked out by the alarm relay contact of freeze room thermostat FRT. When the temperature display of FRT dropsbelow the alarm high set point, CR1 will be released and the fan will be energized.

3.1.3 Pumpdown Cycle. The purpose of the pumpdown cycle is to remove the refrigerant from the evaporator coil inpreparation for compressor shut down. It is necessary to remove refrigerant from the evaporator coil on shut down inorder to prevent slugging the compressor with liquid refrigerant on subsequent restart. Removal of refrigerant from theevaporator coil is also required as part of the defrost cycle to prevent a high pressure condition which could result fromheating liquid refrigerant.

3.2 PROPERTIES AND CHARACTERISTICS OF REFRIGERANT HFC-134a.The chemical formula for HFC-134a (Tetrafluoroethane) is CF3CH2F. Hydrofluorocarbons (HFC) contain only hydrogen,fluorine, and carbon atoms. They contain no chlorine atoms and therefore will not cause ozone depletion. Table 3-1 definestemperature/temperature properties of saturated HFC-134a.

3.2.1 Inhalation Toxicity. HFC-134a poses no acute or chronic hazard when it is handled safely and when exposures aremaintained at or below 1,000 ppm. However, inhaling high concentrations of HFC-134a vapor may cause temporary centralnervous system depression with narcosis, lethargy and anesthetic effects. For more details, see the Safety Summary at thebeginning of this manual.

3.2.2 Skin and Eye Contact. At room temperature, HFC-134a vapors have little or no effect on the skin or eyes.However, in liquid form, HFC-134a can freeze skin or eyes on contact, causing frostbite. For more details, see the SafetySummary at the beginning of this manual.

3.2.3 Combustibility of HFC-134a. HFC-134a is nonflammable at ambient temperatures and atmospheric pressure. Formore details, see the Safety Summary at the beginning of this manual.

3.2.4 Thermal Decomposition. An open flame (lit cigarette), welding or hot surfaces such as space heaters (Salamandersor other types) will decompose halogen refrigerants and solvents to extremely toxic materials. For more details, see theSafety Summary at the beginning of this manual.



3.2.5 Spills or Leaks. If a large release of vapor occurs, such as from a large spill or leak, the vapors may concentratenear the deck or low spots and displace the oxygen available for breathing, causing suffocation. For more details, see theSafety Summary at the beginning of this manual.

3.3 FUNCTIONAL DESCRIPTION.The ship’s stores refrigeration unit consists of two independent refrigeration plants. Either plant is capable of maintaining thechill room and freeze room temperatures at design conditions. Each plant consists of a compressor, condenser, liquid receiver,cooling coil, evaporator fan and all controls necessary for operation. It is not possible to operate both plants simultaneously.One feature common to both plants is the evaporator coil defrost cycle. When defrost occurs the cooling coil in both plantsgoes through the defrost cycle. The refrigeration unit has a nominal capacity of 1.0 ton of refrigeration under normal operatingconditions. The controls system is designed to provide automatic operation, and will cycle off under light load conditions.Detailed reference data for the components in the refrigeration unit are provided in table 1-1. Equipment description isprovided in Chapter 1 and the operation of the controls and instruments discussed in this chapter are described in Chapter 2. Adetailed functional description of the refrigeration unit equipment is provided in the following paragraphs. Figure 3-1 showsthe refrigeration cycle and is augmented by the illustration of the refrigeration unit in figure 3-2 and the hydraulic schematic(figure FO-1). Figure 3-2 indexes the major components of each plant separately.

Table 3-1. Properties of Saturated HFC-134a

PressureVolumecu ft/lb

Densitylb/cu ft

EnthalpyBtu/lb

EntropyBtu/lb °F

Temp°F PSIA PSIG

LiquidVf

VaporVg

LiquidI/vf

VaporI/vg

Liquidhf

Vaporhg

LiquidSf

VaporSg

Temp°F

-40-38-36-34-32

7.4297.8728.3368.8229.331

14.7*13.7*12.7*11.8*10.8*

.01132

.01135

.01137

.01140

.01143

5.7825.4765.1904.9214.669

88.3288.1287 .9287.7387.53

0.17300.18260.19270.20320.2142

0.000.591.191.792.38

97.0597.3597.6597.9598.25

00.0011410.0028170.0042190.005616

0.23120.23090.23050.23010.2298

-40-38-36-34-32

-30-28-26-24-22

9.86210.4211.0011.6012.24

9.8*8.6*7.4*6.2*5.0*

.01145

.01148

.01150

.01153

.01156

4.4334.2104.0013.8053.619

87.3387.1286.9286.7286.52

0.22560.23750.24990.26280.2763

2.983.584.184.785.39

98.5598.8599.1599.4599.75

0.0070100.0083990.0097840.011170.01254

0.22940.22910.22880.22850.2282

-30-28-26-24-22

-20-18-16-14-12

12.8913.5814.3015.0415.82

3.6*2.2*0.1*0.341.12

.01159

.01161

.01164

.01167

.01170

3.4453.2813.1262.9802.842

86.3286.1185.9185.7085.50

0.29030.30480.31990.33560.3519

5.996.607.207.818.42

100.05100.35100.65100.95101.24

0.013290.015290.016650.018010.01937

0.22790.22760.22730.22700.2267

-20-18-16-14-12

-10-8-6-4-2

16.6317.4718.3419.2420.19

1.932.773.644.545.49

.01172

.01175

.01178

.01181

.01184

2.7122.5882.4722.3622.257

85.2985.0884.8884.6784.46

0.36880.38630.40450.42340.4430

9.039.6410.2510.8611.48

101.54101.84103.13102.43102.72

0.020730.022080.023430.024770.02611

0.22650.22620.22600.22570.2255

-10-8-6-4-2

02468

21.1622.1823.2324.3225.45

6.467.488.539.6210.75

.01187

.01190

.01193

.01196

.01199

2.1592.0651.9761.8921.812

84.2584.0483.8283.6183.40

0.46330.48420.50600.52850.5518

12.0912.7113.3313.9514.57

103.02103.31103.60103.89104.19

0.024750.028780.030120.031450.03277

0.22530.22500.22480.22460.2244

02468

1012141618

26.6227.8329.0830.3831.72

11.9213.1314.3815.6817.02

.01202

.01205

.01208

.01212

.01215

1.7361.6641.5961.5311.469

83.1882.9782.7582.5482.32

0.57590.60080.62660.65320.6807

15.1915.8216.4417.0717.70

104.48104.76105.05105.34105.63

0.034090.035410.036730.038040.03935

0.22420.22400.22380.22360.2234

1012141618



Table 3-1. Properties of Saturated HFC-134a (Cont.)


Densitylb/cu ft

EnthalpyBtu/lb

EntropyBtu/lb °F

Temp°F PSIA PSIG

LiquidVf

VaporVg

LiquidI/vf

VaporI/vg

Liquidhf

Vaporhg

LiquidSf

VaporSg

Temp°F

2022242628

33.1134.5436.0337.5639.14

18.4119.8421.3322.8624.44

.01218

.01221

.01225

.01228

.01231

1.4101.3541.3011.2501.201

82.1081.8881.6681.4381.21

0.70920.73850.76890.80020.8325

18.3318.9619.5920.2220.86

105.91106.20106.48106.76107.05

0.040660.041970.043270.044570.04587

0.22330.22310.22290.22280.2226

2022242628

3032343638

40.7742.4544.1945.9847.82

26.0727.7529.4931.2833.12

.01235

.01238

.01242

.01245

.01249

1.1551.1111.0691.0280.9901

80.9980.7680.5380.3180.08

0.56580.90020.93570.97231.010

21.4922.1322.7723.4224.06

107.33107.61107.88108.16108.44

0.047170.048460.049750.051040.05233

0.22250.22250.22220.22200.2219

3032343638

4042444648

49.7251.6853.7055.7857.92

35.0236.9839.0041.0843.22

.01252

.01256

.01260

.01263

.01267

0.95340.91830.88470.85260.8219

79.8579.6179.3879.1578.91

1.0491.0891.1301.1731.217

24.7025.3526.0026.6527.30

108.71108.99109.26109.53109.80

0.053610.054890.056170.057450.05873

0.22170.22160.22150.22140.2212

4042444648

5052545658

60.1262.3864.7167.1069.56

45.4247.6850.0152.4054.86

.01271

.01275

.01279

.01283

.01287

0.79520.76440.73740.71150.6868

78.6778.4378.1977.9577.71

1.2621.3081.3561.4051.456

27.9528.6129.2629.9230.58

110.07110.33110.60110.86111.12

0.060000.061270.062540.063810.06508

0.22110.22100.22090.22080.2207

5052545658

6062646668

72.0974.6877.3580.0982.90

57.3959.9862.6565.3968.20

.01291

.01295

.01299

.01303

.01308

0.66300.64020.61830.59730.5771

77.4677.2276.9776.7276.47

1.5081.5621.6171.6741.733

31.2531.9132.5833.2433.92

111.38111.64111.90112.15112.40

0.066350.067610.068870.070130.07139

0.22050.22040.22030.22020.2201

6062646668

7072747678

85.7988.7591.7994.9098.10

71.0974.0577.0980.2083.40

.01312

.01317

.01321

.01326

.01330

0.55770.53910.52120.50400.4875

76.2175.9675.7075.4475.18

1.7931.8551.9191.9842.051

34.5935.2635.9436.6237.30

112.65112.90113.15113.40113.67

0.072650.073910.075160.076420.07767

0.22000.21990.21980.21980.2197

7072747678

8082848688

101.4104.7108.2111.7115.3

86.7090.0093.5097.00100.6

.01335

.01340

.01344

.01349

.01354

0.47150.45620.44140.42720.4135

74.9174.6574.3874.1173.84

2.1212.1922.2652.3412.418

37.9838.6639.3540.0440.73

113.88114.12114.36114.59114.82

0.078920.080180.081430.082680.08393

0.21960.21950.21940.21930.2192

8082848688

9092949698

119.0122.8126.7130.6134.7

104.3108.1112.1115.9120.0

.01359

.01364

.01370

.01375

.01380

0.40040.38760.37540.36360.3522

73.5773.2973.0172.7372.44

2.4982.5802.6642.7512.840

41.4342.1342.8243.5344.23

115.05115.28115.50115.72115.94

0.085180.086420.087670.088920.09017

0.21910.21900.21890.21880.2188

9092949698

100102104106108

138.8143.1147.4151.9156.4

124.1128.4132.7137.2141.7

.01386

.01391

.01397

.01403

.01409

0.34110.33050.32030.31040.3008

72.1671.8771.5771.2870.98

2.9313.0253.1223.2223.325

44.9445.6546.3647.0847.79

116.16116.37116.58116.79116.99

0.091410.092660.093910.095150.09640

0.21870.21860.21850.21840.2183

100102104106108



Table 3-1. Properties of Saturated HFC-134a (Cont.)


Densitylb/cu ft

EnthalpyBtu/lb

EntropyBtu/lb °F

Temp°F PSIA PSIG

LiquidVf

VaporVg

LiquidI/vf

VaporI/vg

Liquidhf

Vaporhg

LiquidSf

VaporSg

Temp°F

110112114116118

161.1165.8170.6175.6180.7

146.4151.1155.9160.9166.0

.01415

.01421

.01427

.01434

.01440

0.29150.28260.27400.26560.2575

70.6870.3770.0669.7569.44

3.4303.5393.6503.7653.883

48.5249.2449.9750.7051.43

117.19117.39117.58117.77117.96

0.097650.098890.100100.101400.10260

0.21820.21810.21800.21790.2178

110112114116118

120122124126

185.8191.1196.5202.2

171.1176.4181.8187.5

.01447

.01454

.01460

.01468

0.24970.24210.23480.2277

69.1268.8068.4768.14

4.0054.1304.2604.393

52.1752.9153.6554.40

118.14118.32118.49118.66

0.103900.105100.106400.10760

0.21770.21760.21750.2174

120122124126

*Indicates pressure in inches of mercury vacuum.









3.3.1 Compressor. The compressor draws refrigerant gas from the low side of the system, as shown in figure 3-1 andfigure FO-1, and delivers it to the high side of the system. Upon leaving the compressor the superheated gas enters thecondenser where it is condensed to a saturated liquid. The compressor is a scroll compressor. A scroll compressor consists oftwo identical spiral scrolls assembled at a phase difference of 180 degrees. Each scroll is bound on one side to a flat plate. Onescroll is stationary and the other moves in an orbit around the shaft center of the motor at an amplitude equal to the orbit radius.The two scrolls make contact at several points and form a series of pockets. During suction, vapor enters the space between thetwo scrolls. With each successive revolution of the motor shaft the volume of the suction pocket is reduced and the compressionprocess is complete when the refrigerant gas is compressed to its maximum pressure. During discharge, the trapped gaspockets open to the discharge port. The volume of the gas pockets is reduced to zero and the trapped gas is forced into thedischarge line. The sequence of suction, compression and discharge occurs simultaneously in the two trapped gas pockets.3.3.1.1 Compressor Protection. The compressor is provided with an internal pressure relief valve and the compressormotor is provided with an internal motor overload to protect the compressor from excessive pressure and motor overload.3.3.1.2 Compressor Oil Management. Unlike semi-hermetic compressors, scroll compressors do not have an external oilpump with the customary oil pressure safety controls. Therefore, there is no inherent compressor protection against loss of oil.As a result, immediately after system start-up, the oil reservoir level will fluctuate until equilibrium is reached.3.3.1.3 Compressor Oil Heater. The compressor oil heater is used to prevent liquid refrigerant from being absorbed bythe oil and causing foaming of the oil at start-up. The heater is attached to the outside of the compressor and is energizedwhenever the compressor is off. If the system has been off for a period of time, and the oil heater has not been on, the heatershould be energized for at least 6 hours before starting the compressor. Excessive liquid refrigerant in the oil can cause damagewhen starting the compressor. The heater prevents absorption of refrigerant into the oil during shutdown or when a plant is instandby. This in turn prevents oil from migrating from the crankcase during startup.3.3.1.4 Compressor Service Valves. The hermetic compressor is not serviceable. Suction and discharge Rotalock valves(figure 3-2, sheet 2, 13 through 16) are attached to the compressor shell for system servicing, compressor isolation, andinstrumentation hook-up.For this application, the Rotalock valves valve positions are defined as follows:

• Closed - No flow through the valve, but the pressure switch senses compressor pressure.

• Open - Flow through the valve and pressure switch senses compressor pressure. (The valve is opened by fullybackseating the valve, then turning the handle back a quarter to one half turn).

• Backseated - Flow through the valve, but pressure switch does not sense compressor pressure.

3.3.1.5 Compressor Rotation. The compressor is directional dependent, i.e. it will compress in one rotational directiononly. Three phase scroll compressors will rotate in either direction depending on power phasing. There is a 50/50 chance thatthe initial phasing will be incorrect, therefore a power supply voltage monitor is included in the control system. This monitorwill prevent the compressor from operating if any power supply problems exist. To minimize the shutoff sound and equalizethe pressures across the scroll compressor members, an internal solenoid valve is incorporated into the compressor. Thislimits the amount of reverse rotation at shutdown and thereby improves reliability.

3.3.2 Water Regulating Valve. The 3-way water regulating valve (figure 3-2, sheet 1, 1 and 11) is used to control thevolume of water flowing through the condenser and bypass the remainder of the water to the chill water return piping. Theflow is controlled in order to maintain a constant refrigerant condensing temperature. The valve contains a bellows opposed byan adjustable spring. The bellows is connected to the high side of the refrigerant system via a capillary controlled by theshut off valve (figure 3-2, sheet 1 and sheet 2, 8 and 17, respectively). Refrigerant pressure operates the valve mechanism sothat water is supplied as needed to maintain the desired condensing temperature. As the condensing pressure rises, the valvecondenser port opens to allow a greater flow of water through the condenser. As the condensing pressure falls, the valvecondenser port closes to decrease flow through the condenser.

3.3.3 Chill Water Bypass/Diverter Valves. Three hand-operated chill water valves (figure 3-2, sheet 1, 4, 6, and 12) areused to isolate water regulating valves (1 and 11) and condensers (3 and 9) if one should leak. The position for each chill watervalve under various operating conditions and repair is shown in Chapter 2 (figure 2-2).

3.3.4 Condenser. The brazed plate refrigeration condenser (figure 3-2, sheet 1, 3 and 9) is designed especially forrefrigeration application. The condenser consists of stainless steel plates copper brazed together at high temperature providinga leak-tight rugged lightweight assembly. Chill water flow must be provided before the refrigeration unit is started andmaintained any time the plant is in operation. Chilled water flow to the unit is 5+/- 0.5 GPM. The water flow throughthe condenser varies to maintain the condensing pressure.



3.3.5 Liquid Receiver. The liquid receiver (figure 3-2, sheet 1, 5 and 7) serves as a reservoir for refrigerant when thecirculation rate is lower at light load and maintains a liquid seal at the outlet under conditions of rolling and pitching. Inaddition, the receiver acts as a storage space for the refrigerant charge when the system is pumped down.

3.3.6 Refrigerant Filter/Dehydrator. The refrigerant filter/dehydrator (figure 3-2, sheet 2, 18 and 19) is located in theliquid line leaving the receiver. The filter collects particulate matter in the refrigerant stream, and the dehydrator contains adehydrating agent for moisture removal.

3.3.7 Solenoid Valves. The 120 Vac, 60 Hz, solenoid valves (figure 3-2, sheet 3, 30 and 31) in the refrigerant highpressure side open and close in response to the control system. The solenoid valves permit the flow of refrigerant when openand prevent the flow of refrigerant when closed. There is one solenoid valve in each refrigeration system. When the solenoidvalve closes the compressor will continue to operate until the low pressure safety switch opens. When this occurs, the systemwill stop. At this point the HFC-134a refrigerant charge has been removed from the evaporator and collected in the receiver,condenser, and liquid line. The solenoid valves operate in response to freeze room thermostat FRT, PUMPDOWN/STOPpushbutton PB2, EMERGENCY STOP/RESET pushbutton PB3, and DEFROST INITIATION TIMER TD1.

3.3.8 Evaporator Coil. Liquid refrigerant is evaporated in the evaporator coil (figure 3-2, sheet 3, 21). The singleevaporator coil consists of two independent circuits, each circuit serving one of the two systems. Entering liquid refrigerant isexpanded by the TXV (22 and 23) and heat is absorbed from room air in evaporating the liquid refrigerant. Each evaporatorcoil circuit has the cooling capacity to maintain the chill and freeze rooms at the design temperature when the refrigerationplant is supplied with 5 gpm 44° F to 60° F chill water. Only one evaporator coil circuit may be operated at a time and bothsystems cannot operate simultaneously. The two independent circuits in the evaporator coil are located side by side betweenthe same tubesheets. During the defrost cycle, both evaporator coils circuits are defrosted.3.3.8.1 Evaporator Coil Defrost. An evaporator coil operating at a temperature below 32°F will collect frost. When frostis formed provision must be made to eliminate it. If this is not done the frost builds in thickness and acts as an insulator on thecoil surface and will reduce, if not prevent, air circulation in the chill and freeze rooms. The evaporator coil and drip panare provided with automatically controlled electric defrost. The defrost cycle is time initiated and temperature terminated.A timer terminates the defrost cycle in the event of failure of the temperature termination. During defrost evaporator coilheaters (figure 3-2, sheet 3, 27) melt frost that accumulates on the coil to form water. This water drains off the coil andcollects in the evaporator coil drip pan (29). The drip pan has electric heaters that prevent the condensate from freezing.The bottom of the drip pan has an outlet to carry off the water. This outlet has both a trap to prevent the infiltration of airand an electric heater to prevent freezing. The electric heater in the trap is energized at all times. Consequently, the waterin the trap is always liquid, permitting immediate drainage when the defrost cycle is initiated. The electric heaters in thecoil drip pan are energized only during the defrost cycle.

3.3.9 Control of Air Movement. During the refrigeration cycle, air is continuously circulated to the freeze room when therefrigeration unit is operating. Air is circulated to the chill room by opening and closing the chill room damper (figure 3-2,sheet 3, 25) as determined by the chill room thermostat.3.3.9.1 Evaporator Fan and Motor. The evaporator fan (figure 3-2, sheet 3, 24) circulates the cold air leaving theevaporator coil through the chill and freeze rooms. There are two evaporator fans in the refrigeration unit, one fan foreach plant. The fans are direct drive and turn at constant speed. The evaporator fans are off during the defrost cycle. Theevaporator fan motors are directly coupled to the evaporator fans. The evaporator fan motor turns at constant speed of 1750rpm at rated 440 Vac, 3-phase 60 Hz power.3.3.9.2 Evaporator Fan Outlet Damper. There are two evaporator fan outlet dampers (figure 3-2, sheet 3, 26) one foreach evaporator fan. The damper is gravity operated and is open when the fan is operating and closed when the fan isnot operating. When closed, the damper prevents short cycling of air through the non-operating fan. Both evaporator fandampers are closed during the defrost cycle. This traps heat in the evaporator coil section of the equipment cabinet andprevents temperature override to the rooms.3.3.9.3 Evaporator Coil Inlet Damper. The evaporator coil inlet damper (figure 3-2, sheet 3, 28) is located at the inlet tothe evaporator coil from the freeze room. The damper is closed by gravity and remains open when airflow is present.3.3.9.4 Chill Room Damper. The chill room damper (figure 3-2, sheet 3, 25) is an electrically controlled motor operateddamper that controls the flow of air into the chill room. The chill room air damper actuator is directly coupled to the chillroom inlet air damper. The damper is open as long as power is supplied to the refrigeration unit and chill room thermostat CRTcalls for cooling. The chill room damper actuator has a spring return for fail-safe operation and positive close-off.

3.3.10 Schrader Valves. Schrader valves (figure 3-2, sheet 3, 32) are installed in the suction and discharge lines of bothsystems. The valves are used for attaching the test gauge set for charging and recovering refrigerant, evacuating the systems,and to set thermal expansion valve superheat.



3.3.11 Thermal Expansion Valves. There are two thermostatic expansion valves (figure 3-2, sheet 3, 22 and 23) on theevaporator coil, one for each circuit. The thermal expansion valves maintain a preset amount of superheat in the refrigerantleaving the evaporator coils, preventing liquid refrigerant from returning to the compressor while still supplying the evaporatorwith enough refrigerant to satisfy all load conditions.

3.4 REFRIGERATION UNIT ELECTRICAL CONTROL.The following paragraphs describe the function and interactions of the refrigeration unit electrical controls shown in figureFO-1 (hydraulic schematic) and figure FO-2 (electrical schematic). Operator use of these electrical controls and the operationlocations of controls and associated indicator lights are described in Chapter 2 and Chapter 6.

3.4.1 MODE SELECT Switch. MODE SELECT switch SW1 is a three-position rotary switch. (PLANT #1, OFF andPLANT #2) designed to select the system that will be put in operation. The non-operating system will be in a stand-bycondition. The operator must select the system to be put into operation prior to start-up.

3.4.2 START Pushbutton Switch. START pushbutton switch PB1 is a normally open momentary contact switch locatedon the refrigeration unit Control Panel. A momentary closure of this switch will start the system selected by the operator andenergize the associated evaporator fan motor.

3.4.3 PUMPDOWN/STOP Pushbutton Switch. PUMPDOWN/STOP pushbutton switch PB2 is a normally openmomentary contact switch. This is the primary switch used to stop the operating system. A momentary closure of this switchwill bring on the pump-down cycle whereby the refrigerant is evacuated from the system and stored in the liquid receiverand condenser prior to the system stopping.

3.4.4 EMERGENCY STOP/RESET Pushbutton Switch. EMERGENCY STOP/RESET pushbutton switch PB3 is anormally closed momentary contact switch located on the refrigeration unit Control Panel. A momentary opening of thisswitch will bring the operating system to an immediate stop. This switch also functions as a control system reset device in theevent of system shutdown by a safety control.

3.4.5 Compressor Low Pressure Switch. The compressor low pressure switch LP1/LP2 is a single-pole, double-throw(SPDT) pressure actuated switch that will interrupt compressor operation when the compressor suction pressure decreases tothe cut-out setting (-6 psig (8.7 psia)). The amber Low Pressure indicator will illuminate. As the suction pressure rises to thecut-in setting (0 psig) , the switch will reset and the Low Pressure indicator will extinguish. Compressor restart will occurafter the anti-cycle lockout timer 1MM1/2MM1 has timed out. Switch activation is a normal part of the pumpdown cycle.Each system has a separate compressor low pressure switch.

3.4.6 Compressor High Pressure Switch. The compressor high pressure switch HP1/HP2 is a SPDT pressure actuatedswitch that will interrupt compressor operation when the compressor discharge pressure reaches the cut-out setting (150psig). The red High Pressure Indicator will illuminate. When the discharge pressure decreases below the cut-in setting of107 psig, the switch must be manually reset and the High Pressure indicator will extinguish. Pressing the green button onthe switch housing and then pressing EMERGENCY STOP/RESET switch PB3 followed by pressing the START switchcan restart the system, provided that the anti-cycle lockout timer 1MM1/2MM1 has timed out. Each system has a separatecompressor high pressure safety switch.

3.4.7 Condenser Water Flow Switch (Water Failure). The condenser water flow switch (Water Failure) (H2O) is anormally open magnetically operated flow switch. When the condenser water flow rate falls below 3.0 gpm the magneticswitch will close and water failure on-delay relay MM1 is energized. The Water Failure/Pumpdown indicator will illuminate.One condenser water flow switch serves both systems.

3.4.8 Water Failure On Delay Relay. Water failure on delay relay MM1 is located inside the refrigeration unit ControlPanel. This relay has an on-delay feature. When the condenser water flow switch (H2O) closes, it energizes this relay. Thecontacts do not close immediately but close after an operator adjustable 45-second delay. This brief delay provides time forthe condenser water flow to resume before the system is placed in the pumpdown cycle and prevents nuisance trips. Onewater failure on-delay relay serves both systems. The system can be restarted after the anti-cycle lockout timer 1MM1/2MM1has timed out. Pressing the EMERGENCY STOP/RESET switch followed by pressing START switch PB1 on the ControlPanel can restart the system. If condenser water flow returns to acceptable limits before the on-delay relay has timed out, therelay will reset and the system will continue to operate.

3.4.9 Compressor Internal Protection.3.4.9.1 Compressor Internal Pressure Relief Valve. The compressor internal pressure relief valve will open at adischarge-to-suction pressure differential pressure of 375 to 450 psi. The valve will automatically reset as the pressure drops.



Each compressor has a separate compressor internal relief valve. The internal pressure relief valve is a safety backup in caseof a malfunctioning or isolated compressor high pressure switch.3.4.9.2 Compressor Internal Motor Overload. A compressor motor overload is internal to each compressor. In the eventof a motor overload, the contacts will open at a motor temperature of 275°F +/- 9°F and the compressor will come to animmediate stop. The overload relay will automatically reset as the compressor cools to a motor temperature of 141°F +/- 9°F.The compressor may be restarted after the anti-cycle lockout timer 1MM1/2MM1 has timed out by pressing the START switchPB1 on the Control Panel. Each compressor motor has a separate compressor motor overload.

3.4.10 Compressor Motor Starter Overload Relay. The overload relay on the compressor motor starter 1MS1/2MS1,located in the Control Panel, electrically opens the starter and stops the compressor in the event of overload. The relay containsthe compressor starter thermal overload unit. The thermal overload unit melts to open the control circuit and stop the system.Upon cooling, the unit reforms to restore the control circuit. The relay must be reset manually with its red handle to restart thecompressor. Each compressor motor starter has its overload relay mounted on it.

3.4.11 Fan Motor Overload Switch. The fan motor overload thermal switch is built into the fan motor windings andwired in series with the holding relay. In the event of a motor overload the switch will open and the system will come to animmediate stop. The overload will automatically reset as the motor cools. The system may be started after the anti-cyclelockout timer 1MM1/2MM1 has timed out. See paragraph 2.3.1.3. Each fan motor has a separate fan motor overload switch.

3.4.12 Voltage Monitor. The power supply voltage monitor 1MM2/2MM2 protects the compressor from hazardous lineconditions. When all voltages are acceptable and the phase sequence is correct the output relay is energized and the LED willglow. Low voltage and voltage unbalance must be sensed for a continuous trip delay period before the relay and LED aredeenergized. The compressor will come to an immediate stop if a fault is detected. Energization is automatic upon correctionof the fault condition. The output relay will not energize if a fault condition is sensed as power is applied. Providing thepower supply problem has been corrected and the anti-cycle lockout timer 1MM1/2MM1 has timed out, the compressor willrestart automatically. Each system has a separate power supply voltage monitor.

3.4.13 Anti-Cycle Lockout Timer. The anti-cycle lockout timer 1MM1/2MM1 is a solid state device located inside therefrigeration unit Control Panel. The lockout timer provides protection against compressor short cycling. At the end of eachoperation the lockout delay is initiated which prevents restarting the compressor for a period of 5 minutes. This lockout featurealso occurs with momentary loss of power. There is a separate anti-cycle lockout timer for each system. There is no visibleindicator that the anti-cycle lockout timer has been activated.

3.4.14 Freeze Room Temperature Probe and Thermostat. The freeze room temperature probe is an RTD (P392)located in the return air stream from the freeze room. This device provides the input signal to the freeze room thermostatFRT for maintaining freeze room temperature. The freeze room thermostat is fully programmable, microprocessor based,with two 4-digit LED displays for set point (figure 6-3, 3) and freeze room temperature (2). Output is through a SPDTrelay that cycles liquid solenoids on and off.

3.4.15 Chill Room Temperature Probe and Thermostat. The chill room temperature probe is an RTD (P392) located inthe far upper left corner of the chill room. The RTD provides the input signal to the chill room thermostat CRT for maintainingchill room temperature. The chill room thermostat is located in the refrigeration unit Control Panel. The thermostat is fullyprogrammable, microprocessor based, with two 4-digit LED displays for set point (figure 6-3, 3) and chill room temperature(2). Input is from the chill room temperature probe. Output is through a SPDT relay that cycles the chill room damper onand off to control air flow.

3.4.16 Defrost Initiation Timer. Defrost initiation timer TD1 is a digital, microprocessor based indicating reset timer. Twodouble-pole double-throw relays provide instantaneous and delayed outputs. The defrost initiation timer clock is energizedby closure of freeze room thermostat FRT. The timer counts the accumulated minutes that the FRT calls for cooling. Whenthe defrost initiation timer has timed out, it will deenergize the liquid line solenoid valve to force the solenoid valve closed;and the system will pump down and enter the defrost cycle. The defrost initiation timer is located inside the refrigerationunit Control Panel. The defrost initiation timer has a default setting of 240 minutes but should be reset by the operatoras determined by operational requirements.

3.4.17 Defrost Cycle Timer. Defrost cycle timer TD2 is a digital, microprocessor based indicating reset timer. Twodouble-pole double-throw relays provide instantaneous and delayed outputs. The defrost cycle timer clock is energized uponinitiation of the defrost cycle that was brought on by defrost initiation timer TD1. Once energized, the electric defrost heatersare started and the evaporator coil is defrosted. When the defrost cycle timer has timed out, it will terminate the defrost cycle,provided neither defrost termination thermostat DTT nor high defrost temperature thermostat HTT have already terminated thedefrost cycle. The defrost cycle timer has a default setting of 15 minutes, but should be reset by the operator as determined by



operational requirements. If it is necessary to adjust the defrost cycle due to excessive frost build-up, it is recommended thatthe frequency of defrost cycles be increased by adjusting TD1, rather than adjusting TD2 to lengthen the duration of the cycle.

3.4.18 Defrost Termination Thermostat Switch. Defrost termination thermostat DTT switch is a temperature operatedSPDT switch that closes when the evaporator coil surface temperature (defrost temperature) reaches the switch set point (40°F). Upon closure, the defrost cycle is terminated. The switch opens at 30° F.

3.4.19 High Defrost Temperature Thermostat Switch. The high defrost temperature thermostat HTT switch is atemperature operated SPDT switch that closes when the evaporator coil surface temperature reaches the switch set point (95°F). When HTT closes, the defrost cycle is terminated. The switch opens at 55° F.

3.4.20 Elapsed Time Meter. There are three elapsed time meters on the refrigeration unit Control Panel. One meter showsthe cumulative plant operating hours (ET3). The other two meters show the cumulative compressor operating hours for eachsystem (ET1 for compressor #1 and ET2 for compressor #2). There are separate elapsed time meters for each compressor.

3.5 SSRU OPERATING SEQUENCE AND CONTROLS.(Refer to figure FO-2 for electrical sequence). The SSRU operates to maintain space temperatures in the freeze room andthe chill room. Cooling is provided by two independent refrigeration plants, Plant 1 and Plant 2. Reference designators forcomponents of these two plants begin with 1 or 2 respectively in figure FO-2. The following paragraphs discuss the SSRUoperating sequence.

3.5.1 Function Overview. Space temperatures are maintained by cycling the refrigerant solenoid valve 1SOV1 or 2SOV1controlled by freeze room thermostat FRT and a damper controlled by chill room thermostat CRT. Electric defrost of theevaporator coil is time initiated by defrost initiation timer TD1 and temperature terminated by defrost termination thermostatDTT with temperature backup termination provided by high defrost temperature thermostat HTT and time backup terminationprovided by defrost cycle timer TD2.

3.5.2 System Redundancy. Redundancy is permitted by the use of manual selector switch SW1. The operator can chooseto operate the SSRU on Plant #1 or Plant #2. It is not possible to operate both plants simultaneously. Selector switch SW1transfers the action of freeze room thermostat FRT to the requisite plant refrigerant solenoid valve 1SOV1 or 2SOV1 andthe action of START pushbutton PB1 to the requisite fan. Selector switch SW1 also transfers the load of the control circuitto the requisite control transformer. A failure in any portion of one plant does not affect the operability of the other. In theevent of failure of one plant, the operator simply selects the other. Redundancy is provided for the compressors, fans, controltransformer and refrigerant solenoids. Redundancy is not provided for the defrost or pumpdown portions of the control circuit.

3.5.3 Refrigeration Control Circuit. The control circuit is energized when the while POWER ON indicator is lit. Thecontrol circuit is energized when MODE SELECT switch SW1 is turned to either PLANT #1 or PLANT #2. This energizesfreeze room thermostat FRT, and chill room thermostat CRT. The fan for the selected plant energizes when START button PB1is pressed. A holding relay CR3 maintains the circuit until MODE SELECT switch SW1 is turned to OFF, EMERGENCYSTOP/RESET pushbutton PB3 is pressed, or the plant pumps down after PUMPDOWN/STOP pushbutton PB2 is pressed.When freeze room thermostat FRT calls for cooling, refrigerant solenoid valve 1SOV1 or 2SOV1 is energized and theevaporator coil is supplied with refrigerant. The compressor operates on the action of low pressure switch LP1 or LP2. Whenthe low pressure condition is relieved, the compressor energizes provided anti-recycle timer 1MM1/2MM1 has timed out.When freeze room thermostat FRT is satisfied, the refrigerant solenoid valve is deenergized. When a low pressure conditionis achieved, the compressor deenergizes. By the action of selector switch SW1, only one refrigerant solenoid valve can beenergized at a time. Therefore, only one compressor can be operated at a time. Automatic pumpdown of the idle plant ispermitted by the low-pressure switch. This is necessary to prevent liquid refrigerant accumulation in the idle evaporator,particularly for defrost, as some liquid refrigerant can be expected to migrate over time.The sequence of events when starting plant (Plant #1/Plant #2) from a shut down condition is as follows (refer to figure FO-2):

Given that:- High Pressure switch (HP1/HP2) below setpoint (150 psig)- Water Failure switch satisfied (H2O) (greater than 3 GPM)- Freeze Room Temperature (FRT) not satisfied (2º F or above)

• Move Selector switch (SW1) to Plant #1 or Plant #2

• If Plant #1 is selected then SW1-1, SW1-3, SW1-5 and SW1-7 become closed contacts.




• Push the Emergency Stop/Reset switch (PB3)

• Freeze Room Temperature (FRT) and Chill Room Temperature (CRT) energized

• Fan Interlock Control Relay (CR1) energized

• Push the Start switch (PB1)

• CR3 energizes

• CR3-1 contact closes

• Elapsed Timer ET3 energizes

• Solenoid Valve (ISOV1/2SOV1) opens

• Voltage Monitor 1MM2/2MM2 satisfied

• Low Pressure switch (LP1/LP2) resets (0 psig)

• Low Pressure light on control panel de-energizes

• 5 Minute Anti-cycle Timer (1MM1/2MM1) times out (5 minutes since last stop)

• Compressor starts (1MS1/2MS1) (1M1/2M1)

• 1MS1/2MS1-1 contact opens

• Compressor light on control panel energizes

• Elapsed Timer (ET1/ET2) energizes

• Crank Case Heater (CCH1/CCH2) de-energizes

• Crank Case Heater light on control panel de-energizes- When Defrost Termination Thermostat (DTT) senses temperature below 30 º F (DTT breaks defrost on rise to 40º

F, enables fan and TD1 on fall to 30º F):

• Defrost Initiation Timer (TD1) Power Supply (PS) energizes

• Defrost Cycle Timer (TD2) Power Supply (PS) energizes

• Fan starts (1MS2/2MS2) (1M2/2M2)

• Fan light on control panel energizes- When Freeze Room Temperature (FRT) is satisfied (-2º F):

• Solenoid Valve (1SOV1/2SOV1) closes

• Low Pressure switch (LP1/LP2) activates (-6 psig)

• Relay (CR4/CR5) energizes

• Compressor (1MS1/2MS1) (1M1/2M1) stops

• Compressor light on control panel de-energizes

• 5 Minute Anti-cycle Timer (1MM1/2MM1) starts timing

• Crank Case Heater (CCH1/CCH2) energizes

• Crank Case Heater light on control panel energizes

The sequence of events when switching from one plant (Plant #1/Plant #2) to another with the freeze room temperaturesatisfied from a shut down condition is as follows (refer to figure FO-2). (The sequence of events when switching plantoperation with freeze room temperature not satisfied is the same as the above sequence for starting a unit from shutdown):



Given that:- High Pressure switch (HP1/HP2) below setpoint (150 psig)- Water Failure switch satisfied (H2O) (greater than 3 GPM)- Freeze Room Temperature (FRT) satisfied (below 2º F)- Solenoid Valve (1SOV1/2SOV1) remains closed- Low Pressure switch (LP1/PL2) remains activated (-6 - 0 psig)- Low Pressure light remains energized- Relay (CR4/CR5) remains energized- Crank Case Heater (CCH1/CCH2) remains energized- Crank case heater light on control panel remains energized- Initiate manual pumpdown of the operating unit per paragraph 3.5.5. Wait for pumpdown to complete

• Move Selector switch (SW1) to Plant #1 or Plant #2



• Push the Emergency Stop/Reset switch (PB3)

• Defrost Initiation Timer (TD1) Power Supply (PS) energizes (TD1 CLK waits for signal)

• TD1 (11) closes

• Defrost Cycle Timer (TD2) Power Supply (PS) energizes (TD2 CLK waits for signal)

• Freeze Room Temperature (FRT) and Chill Room Temperature (CRT) energized

• Fan Interlock Control Relay (CR1) energized

• CR1-1 closes

• Push the Start switch (PB1)

• CR3 energizes

• CR3-1 contact closes

• Elapsed Timer ET3 energizes


• Fan light on control panel energizes

• Voltage Monitor 1MM2/2MM2 satisfied


• Operation continues as shown for normal start up above

3.5.4 Chill Room Refrigeration Control. When chill room thermostat CRT calls for cooling, the chill room damper isopened to allow for cold air from the freeze room to be circulated by the continuously operating evaporator fan to the chillroom. When chill room thermostat CRT is satisfied, the chill room damper is closed. Chill room temperature is maintained bycycling the damper under control of chill room thermostat CRT.The sequence of events for the chilled room refrigeration control function is as follows (refer to figure FO-2):

• Chilled Room Thermostat (CRT) not satisfied (35º F)• Chilled Room Damper Motor (DM) energizes, actuator opens chilled room damper



• Chilled Room Thermostat (CRT) is satisfied (33º F)• Chilled Room Damper Motor (DM) de-energizes, actuator closes chilled room damper

3.5.5 Pumpdown. Pumpdown is manually initiated by pressing PUMPDOWN/STOP pushbutton PB2 and automaticallyinitiated on the action of water flow switch (H2O) (Water Failure switch). A holding relay maintains contact until the cycle iscompleted. During pumpdown the refrigerant solenoid valve is deenergized. This forces the compressor to pull a vacuum onthe evaporator coil until deenergized by low pressure switch LP1 or LP2. When low pressure is achieved, the control circuit islocked out and a holding relay maintains the WATER FAILURE/PUMPDOWN indicator light.The sequence of events for manual pump down (Plant #1/Plant #2) is as follows (refer to figure FO-2):

• Push the Pumpdown/Stop button

• Relay CR2 energizes

• WaterFailure/Pumpdown light on control panel energizes

• Solenoid valve (1SOV1/2SOV1) closes

• Defrost Initiation Timer (TD1) stops timing


• Low Pressure light on control panel energizes

• 5 Minute Anti-cycle Timer (1MM1/2MM1) starts counting


• Compressor (1M1/2M1) stops

• Compressor light on the control panel de-energizes



• Fan (1M2/2M2) stops

• Fan light on control panel de-energizes

3.5.6 Defrost Control and Initiation and Normal Termination. Electric defrost of the evaporator coil is initiated by theaction of defrost initiation timer TD1. This timer is user adjustable. When the setting of defrost initiation timer TD1 has beenreached, defrost is initiated. The defrost heater consists of 12 elements inserted into dummy tubes in the evaporator coil andthree u-bend heater elements placed beneath the drain pan.Defrost is normally terminated by the action of defrost termination thermostat DTT. This thermostat is wired to deenergizedefrost heater starter HS and lock out the fan when the evaporator coil reaches the set point temperature. When the evaporatorcoil has cooled sufficiently to reset DTT, the fan lock out is released. This terminates defrost on temperature and prevents thefan from immediately energizing and blowing warm moist air into the refrigerated spaces.The sequence of events for automatic defrost initiation (Plant #1/Plant #2), DTT terminated, is as follows (refer to figure FO-2).

Given that:- High Pressure switch (HP1/HP2) below setpoint (150 psig)- Water Failure switch satisfied (H2O) (greater than 3 GPM)- Freeze Room Temperature (FRT) not satisfied (2º F or above)

• Defrost Initiation Timer (TD1 CLK) times up to setpoint (4 hours or as adjusted)

• TD1 (D1) opens

• TD1 (D2) closes

• Solenoid valve (1SOV1/2SOV1) closes




• Low Pressure light on control panel energizes

• Compressor (1MS1/2MS1) (1M1/2M1) stops

• Compressor light on control panel de-energizes

• Anti-cycle Timer (1MM1/2MM1) starts counting



• Elapsed Timer Meter (ET1/ET2) de-energizes


• CR4-1/CR5-1 opens

• CR4-2/CR5-2 closes

• Defrost Cycle Timer (TD2 CLK) energizes and begins to count up

• Defrost Heaters (HS) start

• Defrost Light on control panel energizes

• HS-2 closes

• HS-1 opens

• Fan Stops (1MS2/2MS2) (1M2/2M2)

• Relay CR1 energizes

• Fan light on control panel de-energizes

• Defrost Termination Thermostat (DTT) satisfied (40º F)

• Defrost Termination Thermostat (DTT) switch/contact opens

• CR-1 de-energizes. CR1-1 opens

• Defrost Heater Starter (HS) de-energizes

• Defrost Heaters terminate

• HS-2 contact opens

• HS-1 contact closes

• Defrost light on control panel de-energizes

• Defrost Initiation Timer (TD1) Power Supply (PS) de-energizes

• TD1 CLK resets

• Defrost Cycle Timer (TD2) Power Supply (PS) de-energizes

• TD2 CLK resets

• Solenoid valve (1SOV1/2SOV1) opens



• Relay (CR4/CR5) de-energizes

• CR4-1/CR5-1 close

• CR4-2/CR5-2 open- Given that 5 Minute Anti-cycle Timer (1MM1/2MM1) times out (5 minutes since last stop):





• 1MS1-1/2MS1-1 contacts open


• Crank Case Heater light on control panel de-energizes

• Defrost Termination Thermostat (DTT) resets (30º F)

• Defrost Cycle Timer (TD2) Power Supply (PS) energized

• Defrost Initiation Timer (TD1) Power Supply (PS) energized

• Defrost Initiation Timer (TD1) Starts Counting

• Freeze Room Temperature (FRT) and Chill Room Temperature (CRT) energizes

• Fan Interlock Control Relay (CR1) energizes

• CR1-1 closes



3.5.7 Defrost Termination Backup. Defrost termination is backed up by the action of defrost cycle timer TD2. Thistimer is user adjustable. If the defrost cycle time reaches the set point time of defrost cycle timer TD2, the defrost cycle isimmediately terminated. Termination of defrost on time backup may be an indication of a malfunctioning defrost terminationthermostat DTT, or insufficient time allowed to melt accumulated frost.

a. The sequence of events for defrost back-up termination, TD2, FRT-A satisfied, is as follows (refer to figure FO-2):

Given that:- Water Failure switch (H2O) satisfied (greater than 3 GPM)- High Pressure switch (HP1/HP2) below setpoint (150 psig)- Freeze Room Temperature secondary setpoint (FRT-A) satisfied, less than 52º F

• Defrost Cycle Timer (TD2) times out (15 minutes or as adjusted), as shown on control panel


• Defrost light on control panel de-energizes



• Freeze Room Temperature (FRT) not satisfied (2º F or above)

• Solenoid valve (1SOV1/2SOV1) opens

• Defrost Initiation Timer (TD1) times up from zero










b. The sequence of events for defrost back-up termination, TD2, Freeze Room Temperature secondary setpoint(FRT-A) not satisfied, is as follows (refer to figure FO-2):

Given that:- Water Failure switch (H2O) satisfied (greater than 3 GPM)- High Pressure switch (HP1/HP2) below setpoint (150 psig)- Freeze Room Temperature secondary setpoint (FRT-A) not satisfied, 52º F or higher

• Defrost Cycle Timer (TD2) starts counting

• Defrost Cycle Timer (TD2) times out (15 minutes or as adjusted), as shown on control panel


• Defrost light on control panel de-energized

• Freeze Room Temperature (FRT) not satisfied (2º F or above)

• Relay CR1 is de-energized

• Defrost Initiation Timer (TD1) Power Supply (PS) de-energizes

• Solenoid Valve opens (1SOV1/2SOV1)








• Freeze Room Temperature secondary setpoint satisfied (FRT-A), 50º F or lower

• Relay CR1 is energized

• Defrost Cycle Timer (TD2) Power Supply (PS) de-energizes

• Defrost Initiation Timer (TD1) Power Supply (PS) energizes

• Defrost Cycle Timer (TD2) Power Supply (PS) energizes



• Defrost Initiation Timer (TD1) times up from zero

c. High defrost temperature thermostat HTT provides backup to defrost cycle timer TD2. If the evaporator coiltemperature exceeds the set point of high defrost temperature thermostat HTT, the defrost cycle is immediatelyterminated. A light on the Control Panel indicates that a high defrost temperature condition is present. Thisthermostat will automatically reset when the evaporator coil cools. The sequence of events for defrost back-uptermination, High Temperature Thermostat (HTT) (Plant #1/Plant #2), is as follows (refer to figure FO-2):

• Defrost Cycle Timer (TD2) times up from zero• High Pressure Thermostat switch (HTT) activates (95º F)• High Defrost Temperature light on control panel energizes• Defrost Heaters terminate



• Defrost Initiation Timer (TD1) Power Supply (PS) de-energizes• Defrost Cycle Timer (TD2) Power Supply (PS) de-energizes• Defrost light on control panel de-energizes• High Pressure switch (HP1/HP2) below setpoint (150 psig)• Water Failure switch (H2O) satisfied (greater than 3 GPM)• Freeze Room Temperature (FRT) not satisfied (2º F or above)• Solenoid valve (1SOV1/2SOV1) opens• Low Pressure Switch (LP1/LP2) resets (0 psig)• Low pressure light on control panel de-energizes• 5 Minute Anti-cycle Timer (1MM1/2MM1) times out (5 minutes since last stop)• Compressor starts (1MS1/2MS1) (1M1/2M1)• Compressor light on control panel energizes• Crank Case Heater (CCH1/CCH2) de-energizes• Crank Case Heater light on control panel de-energizes• High Temperature Thermostat (HTT) resets (55º F)• Defrost Initiation Timer (TD1) starts counting• Fan starts (1MS2/2MS2) (1M2/2M2)• Fan light on control panel energizes

3.5.8 High Pressure Discharge Circuit. High compressor discharge pressure is indicated by the action of high pressureswitch HP1 or HP2 and the illumination of the Control Panel HIGH PRESSURE indicator. The control circuit is immediatelydeenergized during a high pressure condition. High pressure switches HP1 and HP2 must be manually reset.The sequence of events during a high pressure discharge condition (Plant #1/Plant #2) is as follows (refer to figure FO-2):

• Compressor Discharge Pressure exceeds 150 psig• Compressor High Pressure switch (HP1/HP2) activates• High Pressure light on control panel energizes• Compressor (1MS1/2MS1) (1M1/2M1) stops• Compressor light on control panel de-energizes• Crank Case Heater (CCH1/CCH2) energizes• Crank Case Heater light on control panel energizes• Discharge Pressure drops below 107 psig• Operator manually resets Compressor High Pressure switch (HP1/HP2)• High Pressure light on control panel de-energizes

3.5.9 Water Flow Failure. Water flow switch H2O (Water Failure switch) provides protection to the operating plant in theevent of low flow of cooling water to the condenser. Manually adjustable timer (MM1) prevents nuisance trips on water flowswitch H2O. Water flow failure automatically initiates the pumpdown cycle. When pumpdown is automatically initiated onloss of flow, the system may trip on high pressure before pumpdown is complete.The sequence of events during a water flow failure condition (Plant #1/Plant #2) is as follows (refer to figure FO-2):



• Water Flow drops below 3 GPM• Water Failure Timer (MM1) starts counting (set at 45 seconds or as adjusted)• Water Flow remains below 3 GPM for 45 seconds or as adjusted• Water Failure Timer times out• Water Failure/Pumpdown light energizes• Relay CR2 energizes• Solenoid Valve (1SOV1/2SOV1) closes• Low Pressure Switch (LP1/LP2) activates (-6 psig)• Low pressure light on control panel energizes• Relay CR4/CR5 energizes• Anti-cycle Timer (1MM1/2MM1) starts counting• Compressor (1M1/2M1) stops• Compressor Light on control panel de-energizes• Crank Case Heater (CCH1/CCH2) energizes• Crank Case Heater light on control panel energizes• Fan (1M2/2M2) stops• Fan light on control panel de-energizes• Once water flow resumes to 3 GPM or greater the normal start-up can be resumed manually.

3.5.10 Emergency Stop/Reset. EMERGENCY STOP/RESET pushbutton PB3 is normally used to reset the controlcircuit in the event that pumpdown has occurred. It may also be used to stop the compressor, fans, and defrost cycleimmediately in the event of an emergency.

a. The sequence of events for an emergency stop during normal cooling mode (Plant #1/Plant #2) is as follows(refer to figure FO-2):

• Operator manually pushes Emergency Stop/Reset switch (PB3)• Compressor stops (1M1/2M1)• Compressor light on control panel de-energizes• Fan stops (1M2/2M2)• Relay CR1 energizes• Fan light on control panel de-energizes• Solenoid Valve (1SOV1/2SOV1) closes• Chill Room Damper (DM) closes (if opened)• 5 Minute Anti-cycle Timer (1MM1/2MM) starts timing• Crank Case Heater (CCH1/CCH2) energizes• Crank Case Heater light on control panel energizes• Defrost Initiation Timer (TD1) resets to zero• Restart in accordance with normal start-up.

b. The sequence of events for an emergency stop during defrost mode (Plant #1/Plant #2) is as follows (referto figure FO-2):



• Operator manually Pushes Emergency Stop/Reset switch (PB3)• Defrost Heaters (HS) de-activate• Defrost light on control panel de-activates• Defrost Initiation Timer (TD1) and Time Termination Timer (TD2) reset to zero• Restart in accordance with normal start-up. The unit will start-up in normal cooling mode. Defrost can be initiated

manually once DTT has reset (30º F).

3.5.11 Compressor Thermal Overload Protection. The compressors are provided with motor starter overload relays thatcontain manually resettable thermal overloads. In the event that the overload is tripped, the operator may reset the starter bypressing the red handle internal to the Control Panel. Indication of compressor overload is not provided on the Control Panel.

3.5.12 Power Supply Voltage Monitor. Power supply voltage monitor 1MM2 or 2MM2 protects each compressor fromincorrect phasing, phase unbalance, and loss of phase. The phase monitors are factory set for the optimum power linecondition sensitivity. Shipboard power line conditions may necessitate changes to these settings in order to prevent nuisancetripping. An LED mounted to the phase monitor provides GO/NOGO indication.

3.5.13 Fan Motor Thermal Protection. The fans are provided with thermal overload switches located internal to the fanmotor. These overloads are not manually resettable, and indication of overload is not provided on the Control Panel. The fanoverloads automatically reset when the motor windings have cooled.The sequence of events triggered by the fan motor thermal protection function (Plant #1/Plant #2) is as follows (refer tofigure FO-2):

• Fan Motor overload• Relay CR3 is de-energized• Fan Motor (1M2/2M2) stops• Fan light on control panel de-energizes• Solenoid Valve (1SOV1/2SOV1) closes• Compressor (1M1/2M1) stops• Compressor light on control panel de-energizes• Crank Case Heater (CCH1/CCH2) energizes• Crank Case Heater light on control panel energizes• Chilled Room Damper (DM) shuts (if open)

The fan overloads are internal to the fan motor windings and cannot be manually reset. The fan motor overloads will resetautomatically when the motor has cooled. Switching to the standby unit is recommended.This same sequence of events occurs after a compressor motor overload. The compressor starter has a manually resettablethermal overload relay. Pressing the red handle will reset the overload. This should not be attempted until the cause of theoverload has been determined and corrected.

3.5.14 Crankcase Heaters. Crankcase heaters CCH are provided with each compressor and are energized when thecompressor is off. CRANKCASE HEATER #1 and CRANKCASE HEATER #2 indicator lights on the Control Panelenergize when the crankcase heaters are energized.

3.5.15 Chill Room and Freeze Room Circuits. Control transformer TR3 powers the chill room and freeze room lights,door heaters, and vent heaters. The chill room and freeze room lights are operated by switches provided inside each room(in control station boxes, figure 7-1, 14). Door and vent heaters in each room are switched with the room lights such thatboth cannot be on simultaneously. Indication that the lights are energized is provided on the Control Panel by CHILLROOM LIGHTS and FREEZE ROOM LIGHTS indicators.



3.6 CHILL WATER.The refrigeration plant requires chilled water to be supplied from the ship. Chilled water to the supply connection passesthrough a series of manual valves, and refrigerant actuated 3-way water regulating valves (figure FO-1). In normal operation,the water regulating valves direct water to the condensers as needed. In the event of a leak in the condenser or water regulatingvalve, the manual valves may be aligned to isolate the leaky plant while allowing normal operation of the remaining plantuntil repairs can be made. Refer to the diagrams shown in figure 2-2, sheet 3.



CHAPTER 4

SCHEDULED MAINTENANCE

4.1 INTRODUCTION.Planned Maintenance to be conducted by Organizational (O-level) personnel (Ship’s Force) will be scheduled and performedin accordance with the Planned Maintenance System (PMS). Planned Maintenance beyond Organizational level capabilitywill be performed by either an Intermediate Maintenance Activity (IMA, I-level) or a Depot (D-level) activity and will bescheduled and performed in accordance with the Class Maintenance Plan for this component/system.






CHAPTER 5

TROUBLESHOOTING

5.1 ORGANIZATIONAL LEVEL TROUBLESHOOTING PROCEDURES.This chapter contains information that will assist the operator in troubleshooting the ship stores refrigeration unit in order toidentify, locate, and correct faults in the refrigeration plant, plant components and chill room and freeze room. This chapteralso contains guidance for diagnostic analyses of possible trouble situations where malfunction, fault, or failure of theequipment or related equipment could render the refrigeration plant inoperative or unable to perform its intended function.This chapter will direct the operator to observe test gages, meters, fuses, circuit breakers, indicator lights, valves and otheravailable indicators to locate and identify faults.

Table 5-1. Troubleshooting Procedure

Description of ProblemReference

Table Symptom

Abnormal Operating Temperatures andPressures

High Compressor Discharge Pressure 5-2 Flashing red indicator on Control Panel

Low Compressor Suction Pressure 5-3 Amber indicator lights on Control Panel for operating plant

High Chill Room Temperature 5-4 Chill room temperature above 35°F

Low Chill Room Temperature 5-5 Chill room temperature below 33°F

High Freeze Room Temperature 5-6 Freeze room temperature above 2°F

Low Freeze Room Temperature 5-7 Freeze room temperature below -2°F

High Chill Room Temperature(When Being Used As Freeze Room)

5-8 Chill room temperature above 2°F

Low Chill Room Temperature(When Being Used as Freeze Room)

5-9 Chill room temperature below -2°F

Refrigeration Plant Will Not Start 5-10 Refrigeration plant does not start when start button isdepressed.

Abnormal Operation

Defrost Will Not Start 5-11 Heavy frost build-up on evaporator coil

Abnormal Defrost Termination 5-12 HIGH DEFROST TEMP indicator lights but plantterminated by defrost cycle timer TD2.

Compressor Short Cycles 5-13 Compressor frequent stopping and starting

Fan Does Not Run 5-14 Plant #1 or Plant #2 in cooling mode but FAN indicatordoes not light

Evaporator Coil or Drip Pan HeaterElement Fails

5-15 Excessive coil icing or blown SSRU main fuse

Abnormal Noises

Compressor Noises 5-16 Vibration, knocking, or squealing sounds



Table 5-1. Troubleshooting Procedure (Cont.)

Description of ProblemReference

Table Symptom

Refrigeration System Noises 5-16 Vibrating tubing

Chill Water Piping Noises 5-16 Vibrating piping or water hammer

Evaporator Fan Noises 5-16 Motor bearing failure, or fan out of balance

Control Relay or Motor StarterContact Chatter

5-16 Low power supply voltage, or faulty holding coil

Table 5-2. High Compressor Discharge Pressure

Possible Cause Corrective Actiona. Compressor discharge service valve closed. a. Open compressor discharge service valve.

b. Interruption of condenser water flow. b. Return condenser water flow to normal.

(1) Open shut off valves.

(2) Inspect adjustment of water regulating valve perparagraph 6.17.

(3) Verify proper valve position of the chill waterbypass valve per figure 2-2, sheet 3.

(4) Remove obstruction or start shipboard circulatingpump.

c. Incorrect compressor high pressure discharge switchsetting.

c. Adjust compressor high pressure discharge switchHP1/HP2 per paragraph 6.13. If required, replace perparagraph 6.19.7.

d. Chilled water temperature above 100 degrees. d. Ensure correct operation of shipboard chilled water.e. Condenser failure. e. Replace condenser per paragraph 6.20.16.

f. Obstruction in compressor discharge piping. f. Remove discharge piping per paragraph 6.20.16. Inspectpiping for obstructions and remove if any are found.Reinstall piping per paragraph 6.20.16.

g. Presence of air and non-condensable gases. g. Remove air and non-condensable gases.

(1) Leak test and identify any leaks per paragraph 6.3.5.

(2) Recover refrigerant per paragraph 6.3.1 andevacuate unit per paragraph 6.3.2.

(3) Repair leaks if any had been located in step (1).

(4) Leak test per paragraph 6.3.5.

(5) Evacuate the unit per paragraph 6.3.2.

(6) Recharge refrigerant per paragraph 6.3.3.



Table 5-3. Low Compressor Suction Pressure

Possible Cause Corrective Actiona. Insufficient refrigerant charge. a. Check for bubbles in moisture sight/flow indicator. Add

HFC-134a as necessary per paragraph 6.3.3.

b. Excessive amount of superheat. b. Examine thermal bulb for proper placement. Check thermalexpansion valve superheat per paragraph 6.16.

c. Compressor suction service valve closed. c. Open valve fully.

d. d. Corrective action as follows:Obstruction in liquid line as noted by asignificant temperature difference between theinlet and outlet lines of the solenoid valve. (1) Replace the solenoid coil per paragraph 6.20.3 or replace

entire solenoid valve per paragraph 6.20.3 and paragraph6.20.16.

(2) Remove the liquid line per paragraph 6.20.1. Inspect thepiping for obstructions and remove if any are found.Replace the piping per paragraph 6.20.1.

Table 5-4. High Chill Room Temperature

Possible Cause Corrective Actiona. Chill room thermostat set at incorrect temperature. a. Verify chill room thermostat operation and temperature

setting per paragraph 6.7.

b. Insufficient air flow. b. Increase air flow.(1) Remove obstruction from cooling coil and dampers.(2) Remove obstruction from return air grills.(3) Rearrange product for proper air distribution.(4) Verify proper operation of fans per table 5-14.

(5) Verify correct operation of evaporator fan outletdampers per paragraph 5.2.1.

(6) Verify correct operation of evaporator coil inletdampers per paragraph 5.2.1.

(7) Verify operation of chill room damper per paragraph6.9.

c. Fan motor overloaded. c. Refer to table 5-14.d. Evaporator coil frosted over. d. Verify operation of defrost initiation timer per paragraph 6.4

and defrost cycle timer per paragraph 6.5.e. System not operating. e. Start refrigeration system per paragraph 2.3.1 and paragraph

2.3.1.1.

f. Power failure or low voltage. f. Verify power supply voltage monitor operation perparagraph 6.14.

g. Compressor failure. g. Remove and replace compressor per paragraph 6.20.7.



Table 5-5. Low Chill Room Temperature

Possible Cause Corrective Actiona. Chill room thermostat at incorrect temperature

setting.a. Reset chill room thermostat to correct setting per

paragraph 6.7.

b. Temperature probe not sensing proper temperature. b. Remove probe, clean surface of probe and relocate asnecessary.

c. Chill room air damper actuator not in properposition.

c. Verify proper damper operation.

(1) Verify air damper actuator operation per paragraph6.9.

(2) Remove obstruction if it exists.

Table 5-6. High Freeze Room Temperature

Possible Cause Corrective Actiona. Freeze room thermostat set at incorrect temperature. a. Check thermostat operation and temperature setting per

paragraph 6.6.

b. Insufficient air flow. b. Increase air flow.

(1) Remove obstruction from cooling coil anddampers.

(2) Remove obstruction from return air grills.

(3) Rearrange product for proper air distribution.

(4) Verify proper operation of fans per table 5-14.



c. System not operating. c. Start refrigeration system per paragraph 2.3.1 andparagraph 2.3.1.1.

d. Power failure or low voltage. d. Verify power supply voltage monitor operation perparagraph 6.14.

e. Compressor failure. e. Remove and replace compressor per paragraph 6.20.7.

f. Liquid refrigerant entering compressor. f. Prevent liquid refrigerant from returning to compressor.

(1) Return suction gas contains too much liquidrefrigerant.

(1) Check for proper thermal expansion valve bulblocation, insulation, and surface contact.

(2) Check thermal expansion valve superheat perparagraph 6.16.

Table 5-7. Low Freeze Room Temperature

Possible Cause Corrective Actiona. Freeze room thermostat at incorrect temperature

setting.a. Reset thermostat setting per paragraph 6.6.



Table 5-7. Low Freeze Room Temperature (Cont.)

Possible Cause Corrective Action

b. Thermostat probe not sensing proper airtemperature.

b. Remove probe, clean surface and relocate as necessary.

c. Freeze room thermostat not operating correctly. c. Replace freeze room thermostat per paragraph 6.19.4.

Table 5-8. High Chill Room Temperature (When Being Used As Freeze Room)

Possible Cause Corrective Actiona. Chill room thermostat set at incorrect temperature. a. Check chill room thermostat operation and temperature

setting per paragraph 6.7.

b. Chill room thermostat not operating correctly. b. Replace chill room thermostat per paragraph 6.19.5.c. Insufficient air flow. c. Increase air flow.

(1) Remove obstruction from cooling coil anddampers.

(2) Remove obstruction from return air grills.

(3) Rearrange product for proper air distribution.

(4) Verify proper operation of fans per table 5-14.



d. Fan motor overloaded. d. Refer to table 5-14.e. System not operating. e. Start refrigeration system per paragraph 2.3.1 and

paragraph 2.3.1.1.

f. Power failure or low voltage. f. Restore power.

(1) Check power supply voltage monitor per paragraph6.14.

g. Compressor failure. g. Remove and replace compressor per paragraph 6.20.7.

h. Liquid refrigerant entering compressor. h. Prevent liquid refrigerant from returning to compressor.

(1) Return suction gas contains too much liquidrefrigerant.

(1) Check for proper thermal expansion valve bulblocation, insulation, and surface contact.

(2) Check thermal expansion valve superheat perparagraph 6.16.

i. Evaporator coil frosted over. i. Verify operation of defrost initiation timer per paragraph6.4 and defrost cycle timer per paragraph 6.5.

Table 5-9. Low Chill Room Temperature (When Being Used As Freeze Room)

Possible Cause Corrective Actiona. Chill room thermostat at incorrect temperature

setting.a. Reset thermostat setting per paragraph 6.7.



Table 5-9. Low Chill Room Temperature (When Being Used As Freeze Room) (Cont.)


b. Thermostat probe not sensing correct air. b. Remove probe, clean surface, and relocate as necessary.c. Chill room damper not closing. c. Very chill room damper operation per paragraph 6.9.

Table 5-10. Refrigeration Plant Will Not Start

Possible Cause Corrective Actiona. Mode selector switch in wrong position. a. Verify position of mode selector switch set to PLANT #1

or PLANT #2 as desired.

b. Low voltage, improper power phasing or powerfailure.

b. Check power supply voltage monitor. If LED is not on,power supply problem exists and must be corrected perparagraph 6.14.

c. Compressor motor starter overload. c. Reset compressor motor starter overload.

(1) Chill or Freeze room entrance door open. (1) Close entrance door, check door seals for tightness.

(2) Scroll flanks in sealed position. (2) Momentarily power compressor in the reversedirection per paragraph 6.3.4.

(3) Internal pressure relief valve open. (3) Allow approximately 5 to 10 minutes for internalcompressor pressure to equalize.

d. Evaporator fan motor overload. d. The evaporator fan motor overload will automatically resetin approximately 30 minutes as the fan motor cools. Theplant may be restarted after the internal overload resetsand the anti-cycle lockout timer has timed out or the otherplant may be started immediately.

e. Control system fuse burn out. e. Test control fuses for continuity. Replace blown fuse.

f. Insufficient condenser water flow. f. Return condenser water flow to normal.

(1) Open shut off valves.

(2) Verify adjustment of water regulating valves perparagraph 6.17.

g. Anti-recycle timer not completely timed out. g. Wait for timer to time out.h. Refrigeration plant protection switch not reset. h. Inspect compressor low pressure switches LP1/LP2 and

compressor high pressure switches HP1/HP2 for properfunction and setting per paragraph 6.12 and paragraph6.13.

i. System is in defrost cycle. i. Wait for completion of defrost cycle.j. Control system not reset. j. Press EMERGENCY STOP/RESET switch.



Table 5-10. Refrigeration Plant Will Not Start (Cont.)


k. Main power fuse blown. k. Troubleshoot electrical power.(1) Troubleshoot shorted defrost heater element per

table 5-15.

(2) Troubleshoot for shorted wiring between fan motorstarter 1MS2 and 2MS2 and wiring to fan motorsper figure FO-2.

l. Compressor failure. l. Remove and replace compressor per paragraph 6.20.7.

Table 5-11. Defrost Will Not Start

Possible Cause Corrective Actiona. No electric power. a. Verify power supply voltage monitor is functioning per

paragraph 6.14.

b. Electric defrost heater will not start. b. Verify evaporator heater (defrost heater) operation and, ifrequired, replace heater. Refer to paragraph 6.20.9.

c. Control circuit fuse failure. c. Verify fuse continuity and replace if required perparagraph 6.20.17.

d. Defrost initiation timer not operating correctly. d. Verify timer functioning correctly.

(1) Verify setting. Timer is adjustable per paragraph6.4.

Table 5-12. Abnormal Defrost Termination

Possible Cause Corrective Actiona. Defrost termination thermostat DTT malfunctions

or is improperly set.a. Inspect and adjust or repair defrost termination thermostat

DTT per paragraph 6.10.

b. High defrost temperature thermostat HTTmalfunctions or is improperly set.

b. Inspect and adjust or repair high defrost temperaturethermostat HTT per paragraph 6.11.

c. Defrost cycle timer TD2 malfunctions or isimproperly set.

c. Inspect and adjust or repair defrost cycle timer TD2 perparagraph 6.5.

d. Evaporator coil iced. d. Inspect coil and troubleshoot heater elements per table5-15.

Table 5-13. Compressor Short Cycles

Possible Cause Corrective Actiona. Anti-cycle lockout timer failed. a. Verify operation of anti-cycle lockout timer 1MM1/2MM1

per paragraph 6.15.



Table 5-14. Fan Does Not Run

Possible Cause Corrective Actiona. Fan motor overheated. a. Allow fan motor to cool.

(1) The evaporator fan motor overload willautomatically reset in approximately 30 minutesas the fan motor cools. The plant may be restartedafter the internal overload resets and the anti-cyclelockout timer has timed out or the other plant maybe started immediately.

(2) Check for frost or ice on cooling coil surface.

(3) Verify proper position and operation of chillroom damper position and actuator operation perparagraph 6.20.5.

b. Fan rotor is locked. b. Remove ice, product, or other obstruction from fan blades.c. Motor is single-phasing. c. Troubleshoot and repair electrical wiring per figure FO-2.

d. Fan motor bearing failed. d. Replace motor per paragraph 6.20.4.e. Open wiring in motor. e. Replace motor per paragraph 6.20.4.

Table 5-15. Evaporator Coil or Drip Pan Heater Element Fails

Possible Cause Corrective Actiona. Heater element failed. a. Verify continuity and function of element.

(1) Secure power to SSRU and tag OUT OF SERVICEper paragraph 6.1.1.

(2) Remove upper equipment cabinet access panellocated inside Control Panel (evaporator coilaccess) per paragraph 6.18.

(3) Using a digital multimeter (DMM), verifycontinuity across the heater element leads.

(4) Verify insulation resistance by performing a 500VDC insulation resistance test between the heaterelement leads and housing (ground) to be greaterthan 10MΩ.

(5) If readings in step (3) or (4) are less than stipulated,replace evaporator coil heater element perparagraph 6.20.9 or drip pan heater element perparagraph 6.20.10.



Table 5-16. Refrigerator System Noises

Possible Cause Corrective Actiona. Compressor mounting hardware loose. a. Tighten fasteners holding compressor in place.

b. Liquid refrigerant entering through suction line. b. Check thermostatic expansion valve superheat perparagraph 6.16.

c. Refrigerant overcharge. c. Remove all refrigerant, evacuate and recharge perparagraph 6.3.

d. Loose, broken or damaged tubing support. d. Repair as necessary.e. Air trapped inside chill water system. e. Increase water velocity by temporarily adjusting chill

water hand valves and regulating valve. Return valvesto their original position when noise disappears.

f. Fan out of balance. f. Clean fan blades with solution of mild detergent andwater.

g. Fan damper blades loose. g. Inspect damper blades and tighten as needed.

h. Fan motor bearing failure. h. Replace fan motor assembly per paragraph 6.20.4.

i. Low voltage. i. Verify power supply monitor 1MM2/2MM2 for properoperation per paragraph 6.14.

j. Failed holding coil. j. Remove and replace relay per paragraph 6.19.

k. Loose wire connection on holding relay. k. Tighten wire terminal connections on holding coils.

5.2 CHECKING DAMPER OPERATION.

5.2.1 Evaporator Fan Outlet Dampers Inspection. Each evaporator fan has an outlet damper. The outlet damper shouldbe closed when the fan is not operating and open when the fan is operating. Inspect dampers for proper position both when thefan is on and when the fan is off and during defrost when both dampers are closed.

5.2.2 Evaporator Coil Inlet Damper Inspection. The evaporator coil inlet dampers are located in the freeze room returnair opening to the evaporator coil. The damper opens when either fan is operating and closes during defrost, or when bothplants are off. Inspect the dampers for proper position both when the fan is on and when the fan is off and during defrost.Inspect for frost or ice accumulation on damper and coil surfaces.






CHAPTER 6

CORRECTIVE MAINTENANCE

6.1 INTRODUCTION.Provided the equipment is operated in accordance with the instructions given in this manual, it will be dependable and requireonly a minimum of maintenance. To maintain Ship Stores Refrigeration Unit (SSRU) properly and to service it correctly,become familiar with the recommended practices and fundamental operations set forth in this chapter. The maintenanceprocedures set forth in this chapter are divided into two sections: Section 1, Adjustments and Alignments, and Section 2,Repair. Also included in this chapter are supporting illustrations and data. Table 6-1 contains default settings for SSRUcontrols and timers that are required in this chapter.

Table 6-1. SSRU Control and Timer Default Settings

Control Default Setting

Defrost Initiation Timer TD1 240 minutes

Chill Room Thermostat CRT Refer to table 6-7 for programming details.

Freeze Room Thermostat FRT Refer to table 6-6 for programming details.

Defrost Cycle Timer TD2 15 minutes

Anti-Cycle Lockout Timer 1MM1/2MM1 5 minutes

Power Supply Voltage Monitor 1MM2/2MM2 LINE VOLTS: 440VOLTAGE LINE BALANCE: 2%TRIP DELAY: 2 seconds

Water Failure On Delay Relay MM1 45 seconds

Condenser Water Flow Switch H2O 3.0 gpm

Defrost Termination Thermostat DTT Primary: 40°Differential: 10°

High Defrost Temperature Thermostat HTT Primary: 95°Differential 40°

Compressor High Pressure Switch HP1/HP2 150 psigDifferential: 43 psig fixed

Compressor Low Pressure Switch LP1/LP2 Primary: 0 psigDifferential: 6 psid

Water Regulating Valve 70°F (71 psig)

6.1.1 Tag-Out Procedure. Some maintenance on the SSRU will require it being tagged OUT OF SERVICE. To preparethe refrigeration plant for OUT OF SERVICE condition, proceed as follows:



WARNING

The ship stores refrigeration unit is energized by a 440 Vac, 3-phase, 60 Hz power supply. Alwaysdisconnect electric power at the main power supply and tag OUT-OF-SERVICE when performing anyservice. Failure to do so could result in injury or death of personnel.The SSRU consists of two separate independent systems. Whenever one operating system is being shutdown for maintenance, the entire SSRU must be tagged OUT-OF-SERVICE before performing anymaintenance. Failure to do so could result in injury or death to personnel.The ship stores refrigeration unit is pressurized at all times. When making adjustments or service to eitherthe ship stores refrigeration unit or condenser water systems, isolate the affected area being serviced andrelease pressure. Failure to follow this procedure could result in injury or death of personnel.Prior to performing maintenance, review other WARNINGs and CAUTIONs in the Safety Summary.

a. Disconnect electric power at the main power supply to the SSRU.b. On Control Panel, set mode selector switch to OFF.c. Tag refrigeration plant OUT OF SERVICE.

6.1.2 Return To Service. After maintenance has been completed, the refrigeration plant may be returned to service.Proceed as follows:

a. Remove OUT OF SERVICE tag.b. Restore ship’s power to the SSRU.c. Start the system per paragraph 2.3.1.3.

SECTION 1. ADJUSTMENTS AND ALIGNMENTS

WARNING

When making any repair that could result in refrigerant HFC-134a being present in the atmosphere, thespace shall be ventilated with fresh air. Be sure ventilation in the space is adequate to keep the concentrationof refrigerant below 1000 parts per million. Ventilation air should be exhausted outside the ship. Failure toproperly ventilate the space could result in injury or death to personnel.Check for refrigerant vapor presence prior to entering equipment cabinet. A concentration of refrigerantvapor can cause suffocation or result in heart failure.Rotating parts can cause death or injury. Do not wipe down or place hands in the vicinity of rotating parts.Ensure that rotating parts are deenergized and tagged out of service before performing maintenance on them.Some components within the operating system may be at temperatures greater than 125°F. Chemical safetygoggles or a full face shield, chemical resistant gloves and chemical resistant long sleeve shirts must beworn when performing any service or maintenance. Contact with unprotected skin can result in seriousburns or injury to personnel.

CAUTION


6.2 MANIFOLD TEST GAGE SETS.The installation and removal of manifold test gage sets are discussed in the following paragraphs.



6.2.1 Installing Manifold Test Gage Sets. To install manifold test gage set (see table 1-2), proceed as follows:

WARNING


a. Tag the SSRU out of service (paragraph 6.1.1).b. Remove equipment cabinet upper access panel in chill room per paragraph 6.18.c. Close all hand valves on the manifold test gage set.d. Remove the 1/4-inch flare pressure connection on the suction pressure and high pressure test ports (schrader

valves). Connect the manifold test gage set to the schrader valves. Refer to figure 6-25, sheet 1 and sheet 4,for location of schrader valves.

6.2.2 Removing Manifold Test Gage Sets. To remove manifold test gage set (see table 1-2), proceed as follows:

WARNING


a. Prior to removing the manifold test gage set, leak test the unit per paragraph 6.3.5.b. Close all hand valves on the manifold test gage set.c. Disconnect the manifold test gage from the suction pressure and high pressure test ports (schrader valves). Reinstall

the 1/4-inch flare pressure connections on the schrader valves.d. Open all hand valves on the manifold test gage set.e. Reinstall equipment cabinet upper access panel in chill room per paragraph 6.18.

6.3 HFC-134a REFRIGERANT.The following paragraphs discuss recovery of refrigerant, evacuation, and adding refrigerant.

WARNING

Refrigerant HFC-134a containers are under pressure. Chemical safety goggles or a full-face shieldshall be used whenever handling refrigerant. Wear chemical resistant gloves. Failure to do socould result in injury or death to personnel.

6.3.1 Recovery of Refrigerant. Refrigerant must be recovered from the system before any hot-work such as brazingis performed. Only qualified refrigeration technicians shall perform maintenance on the plant. To recover refrigerantproceed as follows.

WARNING


a. Tag the SSRU out of service (paragraph 6.1.1).b. Install manifold test gage per paragraph 6.2.1.c. Connect a refrigerant recovery unit to the manifold test gage set installed on the suction and discharge lines

using charge-saver type hose.d. Follow manufacturer’s instructions for the refrigerant recovery unit to recover the refrigerant charge. Total system

charge to be removed is approximately 5 lbs +/- 0.5 lb.



e. Remove the refrigerant recovered from the manifold test gage set.

6.3.2 Evacuation. Evacuation is necessary if the system has become contaminated with air or excessive moisture.Evacuation shall be performed after all system refrigerant has been recovered.

WARNING


CAUTION


a. Recover the refrigerant in the system (paragraph 6.3.1).b. Tag the SSRU out of service (paragraph 6.1.1).c. The shore facility is to provide and install vacuum refrigerant hoses capable of holding a vacuum onto the low

pressure and high pressure side schrader valves.d. The shore facility is to provide and attach a vacuum pump and absolute pressure gage (or vacuum thermopile

indicator) to the refrigerant hoses.e. Operate vacuum pump until at least 5000 microns (5mm Hg absolute) is achieved.f. Valve off vacuum pump and allow pressure to stand for one hour. If vacuum does not rise above 8000 microns(8mm

Hg absolute), the system is sufficiently evacuated.g. If vacuum rises above 8000 microns (8mm Hg absolute), repeat step e. and step f.

6.3.3 Adding Refrigerant. Refrigerant is to be HFC-134a. Refrigerant must not be vented to the ship’s atmosphere. Thefollowing procedure does not identify specific maintenance equipment except by type and use. Exercise extreme caution toavoid personal injury from rotating fan blades or electrical shock (see precautions in Safety Summary).

WARNING


NOTEThe correct refrigerant charge is approximately 5 pounds of refrigerant +/- 1/2 pound. The unit willoperate outside the refrigerant charge tolerance but may not perform efficiently. If a low chargeis suspected, it is recommended to switch over to the stand by unit and then remove the entirerefrigerant charge from the suspected unit and then charge the unit with the recommended 5 pounds+/- 1/2 pound of refrigerant. If conditions do not warrant this then refrigerant can be added to thesuspected unit without removing the existing charge.

6.3.3.1 Adding Refrigerant to an Evacuated Unit. To add refrigerant to an evacuated unit, proceed as follows.

a. Ensure that the unit has been evacuated per paragraph 6.3.2.b. Install manifold test gage set per 6.2.1.c. The shore facility is to provide a dial-a-charge assembly to connect between the refrigerant HFC-134a charging

bottle vapor connection and the manifold test gage set for accurate refrigerant charging.d. Set the dial-a-charge assembly to add five pounds of refrigerant.e. Slowly open the manifold test gage set, dial-a-charge assembly, and bottle valves to allow refrigerant to enter the unit.f. When the dial-a-charge assembly indicates that 5 +/- 1/2 pounds of refrigerant have been added to the unit, close the

manifold test gage set, dial-a-charge assembly, and refrigerant bottle valves.



g. Remove the dial-a-charge assembly, refrigerant charging bottle, and the manifold test gage set per paragraph 6.2.2.h. Return the SSRU to service (paragraph 6.1.2).

6.3.3.2 Adding Refrigerant to a Charged Unit Suspected of Being Low On Refrigerant. To add refrigerant to acharged unit suspected of being low on refrigerant, perform the following:

a. Ensure that there are no leaks using an electronic leak detector.b. If there are leaks, remove refrigerant per paragraph 6.3.1, evacuate unit per paragraph 6.3.2, repair leaks and then

add the correct refrigerant charge per paragraph 6.3.3.1.

NOTEIf no leaks are evident, additional refrigerant is to be added in approximately 1/2 pound increments,if possible. This is to avoid the possibility of overcharging the unit. Overcharging the unit can beevident by a cold or frosted compressor and poor unit performance during operation. If a scale is notavailable that reads in 1/2 pound or 1 pound increments then care must be given to controlling theamount of refrigerant at the refrigerant bottle valve or manifold gage test valve.

c. Tag the SSRU out of service (paragraph 6.1.1).d. Install manifold test gage set per 6.2.1. The shore facility is to provide a dial-a-charge charging assembly to connect

between the refrigerant HFC-134a charging bottle vapor connection and the manifold test gage set for accuraterefrigerant charging. If charging is required while at sea and an accurate means of measuring charge is not available,connect the refrigerant bottle vapor connection directly to the manifold test gage set.

e. Set the dial-a-charge assembly to add 1/2 to 1 pound of refrigerant. If charging is required at sea without thedial-a-charge assembly, operator judgement will have to be exercised to allow only a small amount (approximately1/2 to 1 pound) of refrigerant to enter the unit.

f. Slowly open the manifold test gage set, dial-a-charge assembly, and bottle valves to allow refrigerant to enter the unit.g. When the dial-a-charge assembly indicates that approximately 1/2 to 1 pound of refrigerant has been added to

the unit, close the manifold test gage set, dial-a-charge assembly, and refrigerant bottle valves. If charging isrequired at sea without the dial-a-charge assembly, operator judgement will have to be exercised to determine thatapproximately 1/2 to 1 pound of refrigerant has entered the unit.

h. Tag in electrical power to the unit. Operate the unit to verify the correct refrigerant charge. A correct chargeis indicated as follows:

1. A minimum amount of bubbles are seen in the sight flow indicator.2. Superheat in the evaporator is 8-15°F per paragraph 6.16.3. The compressor does not feel cold to the touch. There is no frost on compressor.

i. Monitor the refrigerant sight glass on the unit for the reduction in the amount of bubbles. Also monitor thecompressor for frost or for the compressor becoming cold to the touch. If unit operation indicates an insufficientcharge, continue adding refrigerant per step e. through step g. above.

j. Remove the manifold test gage set per paragraph 6.2.2.k. Return the SSRU to service (paragraph 6.1.2).

6.3.4 Starting a Sealed Scroll Compressor. If the scroll compressor fails to start as a result of a suspected sealing actioncaused by uneven charging, proceed as follows:

WARNING


a. Tag the SSRU out of service (paragraph 6.1.1).b. Open Control Panel and tag and reverse two compressor starter load side leads at bottom of 1MS1 or 1MS2

per figure FO-2, sheet 2.



c. Return the SSRU to service (paragraph 6.1.2).

d. Momentarily (1 to 2 seconds) power the compressor in the reverse direction by manually closing the starter. Thisaction will free the scroll flanks and allow for normal operation.

e. Tag the SSRU out of service (paragraph 6.1.1).

f. Return the compressor starter leads to their original location.

g. Close Control Panel.

h. Return the SSRU to service (paragraph 6.1.2).

6.3.5 Leak Test.

WARNING


a. Ensure manifold test gage set is installed per paragraph 6.2.1.

b. Attach an HFC-134a bottle to the charging hose, open manifold and bottle valves and charge unit to a pressureof 10 psig.

c. Close manifold and bottle valves. Remove HFC-134a bottle from the charging hose.

d. Attach a dry nitrogen bottle equipped with a 275 psi relief valve to the charging hose. Open manifold and bottlevalves and slowly introduce sufficient dry nitrogen to raise the pressure to 250 psig.

e. Close manifold and bottle valves. Remove HFC-134a bottle from the charging hose. Hold pressure for not less than30 minutes. Using an electronic leak detector, verify that all joints and valves remain leak-free.

f. If leaks are detected, locate them, remove refrigerant, and repair. Repeat steps b. through e. until no leaks are present.

g. Remove the manifold test gage set per paragraph 6.2.2.

h. Evacuate the unit per paragraph 6.3.2.

6.4 DEFROST INITIATION TIMER.

WARNING


The defrost initiation timer TD1 (figure 6-1 and figure 6-3) is a digital, microprocessor based, indicating reset timer withon-delay start. Two DPDT relays provide instantaneous and delayed outputs while combinations of the two will give intervalor pulse mode operation. Time is derived from power line frequency (60 Hz) and reset occurs when power is interrupted.The set point can be any three-digit value of seconds, minutes or hour between 0.01 and 999. The timing units window(figure 6-1, 6) displays the units that have been set for the displays. The three-digit preset (figure 6-1, 3) is set with adefault value of 240 minutes (table 6-1), so that the blue fluorescent display (figure 6-1, 4) of the internal clock is in wholeminutes. The set point should be adjusted if frost accumulation warrants more frequent defrosting. The defrost initiationtimer is not repairable and must be replaced if it malfunctions. Before replacing the timer per paragraph 6.19.1, performself-check diagnostics per paragraph 6.4.2.

6.4.1 Testing Timer Operation. As soon as power is applied to terminals No. 1 and No. 2 of the timer (figure 6-3), theinstantaneous relay is energized and changes the position of its associated contacts (8-6-7 and 9-14-10). The timer then looksfor terminal No. 15 (the clock terminal) to receive power. When terminal No. 15 is powered, the internal clock circuit isenabled and the timer starts to time. When the internal clock time equals the time set on the front face, the delayed relayenergizes and changes the position of its associated contacts (3-4-5 and 13-11-12).



2 4 0

9 74

5

6

73

1

* 2 * 2

06461:0503

Figure 6-1. Defrost Initiation Timer TD1 and Defrost Cycle Timer TD2

* DECIMAL POINTS NOT VISIBLE WITH DEFAULT SETTINGS

NOTE: NUMBERS DISPLAYEDARE TYPICAL FOR DEFROSTINITIATION TIMER

LEGEND:1. TIME OUT SYMBOL2. DECIMAL POINT WINDOW3. THREE DIGIT PRESET4. THREE DIGIT DISPLAY5. TIMING BAR6. TIME UNITS WINDOW7. DIGIT SET KNOBS (REMOVABLE)

6.4.2 Self-Check Diagnostics. The timer can be checked whenever there is any doubt that it is functioning properly. Aself-check procedure is listed on a card permanently installed in the timer. This card folds out for convenient viewing asthe self-check is performed. The card is accessed by removing the two screws securing the front cover plate and removingthe cover plate. The only external wiring required for the self-check procedure is that L1 be connected to terminals No. 1



and No. 15, and L2 be on terminal No. 2 (figure 6-3). The internal program wire for display modes should be placed onthe fifth pin (test).The following is the procedure included on the fold out card (reformatted for technical manual purposes):

CAUTION

Relay contacts will transfer during this test.

NOTEConnect L1 voltage to 1 and 15 with L2 to terminal 2.

NOTEIn the following procedure the timer is operating properly if all displays appear as indicated.

a. Clock and Relay Logic Test:(1) Program timer as follows: Set for any timing mode, 50 or 60 Hz, hours and 999 range.

(2) Rotate the right set point switch to 1 and lug in timer; timing bar (right) should blink once per second.

(3) Rotate all set point switches to 0; the “∇” display should appear (left) and timing bar should blink rapidly. Atthis time all normally open (N.O.) contacts should be closed.

b. Set point switch and display test:(1) Program timer for DOWN & STOP, rotate set point switches to 111 and plug in timer.

(2) Beginning at right, turn each set point switch slowly clockwise through each of its ten positions; in each case,display should agree with switch position except most significant zero which is blanked.

c. Decimal Point, Range Switch and 50/60 Hz Test:

NOTEThe symbol “∇” in display is not a fault in this test.

(1) Program timer for TEST and plug in.

(2) Rotate left set point switch; display should correspond with the shape indicated in figure 6-2 for each switchposition and timer condition shown.

d. Microcomputer Chip Test.

NOTEThe symbol “∇” in display is not a fault in this test.

NOTEDecimal point in display indicates an error.

(1) Internal Flag Test: Continue test as follows with left set point switch. See figure 6-2 for correct display.

(2) Ram Test: Continue test as shown in figure 6-2 with left set point switch.

CAUTION

Return timer to original conditions and replace card before resuming normal operation.



1

1

1

11

1

2

2

2

3

60 Hz Sec

60 Hz Min

60 Hz Hrs

50 Hz Sec

50 Hz Min

50 Hz Hrs

9.99

99.9

999.0

(Not used forself test;disregard.)

LEFT SWITCHPOSITION

TIMERCONDITIONS

CORRECT DISPLAY

DECIMAL POINT, RANGE SWITCH,AND 50/60 HZ TEST

LEFT SWITCHPOSITION

CORRECT DISPLAY

4,5,6

7,8

9

CORRECT DISPLAYLEFT SWITCHPOSITION

0

INTERNAL FLAG TEST

RAM TEST

Figure 6-2. Self-Diagnostics Displays

06623:0503

6.4.3 Blue Fluorescent Display. A high intensity blue fluorescent display (figure 6-1) consists of three digits and decimalpoint (4) (when decimal is set in tenths or hundredths position). Also there is a blinking timing bar (5) and a special timeout symbol (1). The timing bar appears to the right of the digits and blinks once every second during timing. The timingbar shows quickly that the timer is actively timing especially when the digits do not change rapidly as in the hours ranges.



When the delay relay is energized at time-out, a triangular time-out symbol appears to the left of the digits. The timing barblinks noticeably faster at time out.

6.4.4 Setting Timing Switches. The three digits (figure 6-1, 3) are white on a black background and are set with the rotaryswitch knobs located beneath each digit. These knobs can be rotated in either direction, clockwise (cw) or counterclockwise(ccw), and they are pull removable, if digit set security is desired. When the timer is in either time down mode, changingone or more digits during timing will instantly be reflected by an equivalent change in the timer display. In either time upmode, changing digits immediately changes the time-out set point. Setting all three digits to zero will cause instant time-out inany display mode.



8 6 7 9 14 10

PS

1 2

POWERSUPPLY

INSTANTANEOUS CONTACTSL1 TO POWER SUPPLYL2 (COMMON)

3 4 5 13 11 12

CLKCLOCK

1516

L1 TO CLOCKDELAYED CONTACTS

PS

CLK

12

34 6 16

155

1413

1211

910

87

TERMINAL WIRING

Figure 6-3. Defrost Initiation Timer TD1 and Defrost Cycle Timer TD2 Wiring Diagram

06462:0503



6.5 DEFROST CYCLE TIMER.

WARNING


Defrost cycle timer TD2 function is the same as defrost initiation timer TD1 described in paragraph 6.4, except that ittimes the duration of the defrost cycle. The three digit preset (figure 6-1, 3) is set with a default value of 15 minutes (table6-1), so that the blue fluorescent display (4) of the internal clock is in whole minutes. The set point may be adjusted iffrost accumulation warrants a longer defrost period. The operation, diagnostics display and setting methods are identical.Replace TD2 per paragraph 6.19.2.

6.6 FREEZE ROOM THERMOSTAT.

WARNING


Freeze room thermostat FRT (figure 6-4) is microprocessor based. The thermostat is fully programmable with two 4-digit lightemitting diode (LED) displays for set point (figure 6-4, 3) and room temperature (2). Input is received from an RTD andoutput controls the opening and closing of the liquid solenoid valve. The freeze room thermostat is not repairable and must bereplaced if it malfunctions. If an error message occurs in the controller display, verify the problem in accordance with table6-5. If unit operation indicates a problem with the thermostat, reprogram it to the values shown in table 6-6 per paragraph 6.6.1through 6.6.5. If the thermostat is unable to be reprogrammed or if it is preprogrammed to the values of table 6-6 and the unitsdo not operate to maintain the rooms at the correct temperatures, then the thermostat requires replacement per paragraph 6.19.4.

6.6.1 Front Panel Key Functions. The front panel of freeze room thermostat FRT is shown in figure 6-4. The operatorshould become familiar with the key functions and menu items before making any changes to the controller. The set pointlamp (1) is illuminated when the temperature being sensed is between the set point and the differential. The temperaturedisplay (figure 6-4, 2) shows the actual room temperature read by the RTD. The set point display (3) shows the temperaturethat has been set for the thermostat to maintain. The secondary temperature set point lamp (6) illuminates when the secondarytemperature set point is reached and automatically extinguishes when the temperature drops approximately 2 degrees fromthe alarm set point.6.6.1.1 Key Entry Function Definitions. Key functions for individual keys and for simultaneous entries are defined intable 6-2. In addition to these control functions, the thermostat has the following operating characteristics:

a. If no key is pressed for a period of 30 seconds when in the Primary Menu or Secondary Menu, the display will returnto HOME position displaying the temperature value.

b. If no key is pressed for a period of 1 minute when in the Secure Menu, the display will return to HOME positiondisplaying the temperature value.

c. To move to the Primary Menu quickly from any other menu, press the Up Arrow and Enter keys followed bypressing the Index and Down Arrow keys.

Table 6-2. Key Functions and Selections

Key Selection Definition/Function Action/Remarks

Index (5, figure 6-3) Advances the display to the next menuitem.

Advances the display to the next menu item. May alsobe used in conjunction with other keys as noted below.(See table 6-5 for error message clarification.)

Up Arrow (4) Increments a value, changes a menuitem, or selects the item to off.

Maximum value obtainable is 9999 or 999.9 (as limitedby the set points of table 6-6).

Down Arrow (9) Decrements a value, changes a menuitem, or selects the item to off.

Minimum value obtainable is -1999 or -199.9 (aslimited by the set points of table 6-6).



Table 6-2. Key Functions and Selections (Cont.)

Key Selection Definition/Function Action/Remarks

Enter (10) Store the value of the item changed. Ifnot pressed, the previously stored valueof item will be retained.

Display will flash once when ENTER is pressed. (Seetable 6-5 for error message clarification.)

Simultaneous Entry Key Functions

Up Arrow and Enter Pressing these keys simultaneouslybrings up the Secondary Menu startingat the alarm, tune, or cycle item(depending on programming).Pressing these keys for 5 seconds willbring up the Secure Menu.

Index and DownArrow

Pressing these keys simultaneously willallow backing up one menu item, or if atthe first menu item, they will cause thedisplay to return to the Primary Menu.

If an alarm condition has occurred, these keys may beused to reset the alarm.

Index and Enter Pressing these keys simultaneouslyand holding them for 5 seconds allowsrecovery from various error messages.

See table 6-5 for error message clarification.

CAUTION

Correct the problemsassociated with followingconditions first before usingreset keys. More than oneerror could be present.Caution is advised sinceseveral items are reset at onetime.

The following menu items will be reset:AliH: Secondary setpointbAD InP: RTD error messageOPEn: Thermocouple error messageCHEC CAL: Check calibration error message



6.6.2 Primary Menu Selections. Primary Menu selections are:

Sp (Set point Adjust, Control Point)

To make Primary Menu selections, proceed as follows:

a. Press Index to advance to the next menu item.

b. Press Up Arrow or Down Arrow to change the value in the display.

c. Press Enter to retain the value.



6.6.3 Secondary Menu Selections. The Secondary Menu selections and means of selection are defined in table 6-3.To select from the Secondary Menu, proceed as follows:

CAUTION

Incorrect settings may result in poor performance or equipment damage.

a. Hold Up Arrow and Enter.

b. Press Index to advance to the next menu item.

c. Press Up Arrow or Down Arrow to change the value in the display.

d. Press Enter to retain the value.

Table 6-3. Secondary Menu Selections

Menu Selection Definition/Function Action/Remarks

ALLo Secondary Setpoint Not required for SSRU application. Set to a value wellbelow anything seen by the SSRU (-199 °F).

ALHI Secondary Setpoint Both thermostats set at 52 °F, but control system usesonly the FRT for fan start-up after secondary defrosttermination.

CY Cycle Rate and Output Selection Select OnOF, 1, 2 to 80 seconds total cycle time.

OnOf Allows the control to operate as asimple on/off mode.

This setting forces the control to turn off at set point,and on at the set point plus the differential (SP_d).When selected the tunE, Pb, rES,OFS, rtE, and ArUPselections in the Secondary Menu and the SPOL andSPOH selections in the Secure Menu are suppressed.

1 A setting of 1 is recommended for solidstate outputs (SSR or 5VDC).

(Available, but not used for this application.)

2 to 80 Time Proportioning Control adjustablein 1 second steps.

(Available, but not used for this application.)Recommended for mechanical outputs (relays,solenoids, etc.). Select a time long enough to give goodcontact life, without causing the process to wander.

SP_d Set Point On-Off Differential Select 1 to 999°F. This value will be negative forreverse acting set points, and positive for direct actingoutputs. Setting the value for the amount of temperaturedifference between the turn off point (set point) and theturn on point. Only appears if CY is set to OnOf.

Out Fixed at ProP (Available, but not used for this application.) ForCurrent (Code 5) outputs only.

tunE Turning Choice (Available, but not used for this application.) SelectSELF or Pid.

SELF Automated Control (Available, but not used for this application.) Thethermostat will evaluate the Process Value and select thePID value to maintain good control. The ramp function(rt) cannot be selected while SELF tunE is active. Thetemperature description will flash while SELF tunE isactive. The control will switch to Pid tunE when thetuning function is complete.



Table 6-3. Secondary Menu Selections (Cont.)


Pid Manually adjust the PID value. (Available, but not used for this application.) PIDcontrol consists of three basic parameters: ProportionalBand Pb (Gain), Reset Time rES (Integral), and RateTime rtE (Derivative).

Pb Proportional Band (Bandwidth) (Available, but not used for this application.) Select 5to 5000°F (3 to 2778°C)

rES Automatic Reset Time (Available, but not used for this application.) SelectOFF, 0.1 to 99.9 minutes.Select OFF to switch to OFS.

OFS Manual Offset Correction (Available, but not used for this application.) SelectOFF, 0.1 to 9.99%Select OFF to switch to rES.

rtE Rate Time (Available, but not used for this application.) SelectOFF, 0.01 to 99.99 minutes (Derivative).

ArUP Anti-reset Windup Feature (Available, but not used for this application.) SelectON or OFF.

ON When ArUP is ON, the accumulatedReset Offset value will be cleared to0% when the process input is not withinthe Proportional Band.


OFF When ArUP is OFF, the accumulatedReset Offset value is retained inmemory when the process input is notwithin the Proportional Band.


rt Ramp Time Select OFF, 00.01 to 99.59 (HH.MM). When value isentered, control calculates a ramp slope from the currenttemperature to SP over the time entered. Changing rtor SP (or pressing Enter at either menu item) restartsthe ramp function, and recalculates the slope. Theright hand decimal point of the lower display will flashwhile the ramp function is active. Self tunE cannot beselected while the ramp function is active. SelectingOFF will stop a current ramp and drive the output asnecessary to reach set point.

InPC Input Correction Select+/- 500°F (+/- 278°C). This feature allows theinput value to be changed to agree with an externalreference or to compensate for sensor error. NOTE:InPC is reset to zero when the input type is changed, orwhen decimal position is changed.

FiLt Digital Filter Select OFF, 1 to 99. In some cases the time constantof the sensor or noise could cause the display to jumpenough to be unreadable. A setting of 2 is usuallysufficient to provide enough filtering for most cases (2represents approximately a one second time constant).When the 0.1 degree resolution is selected, the valueshould be increased to 4. If this value is set too high,control will suffer.

6.6.4 Secure Menu Selections. The Secure Menu selections and means of selection are defined in table 6-4. To selectfrom the Secure Menu, proceed as follows:



a. Hold Up Arrow and Enter keys for 5 seconds.

b. Press Index key to advance to the next menu item.

c. Press Up Arrow or Down Arrow to change the value in the display.

d. Press Enter to retain the value.

Table 6-4. Secure Menu Selections


SECr Security Code The display shows the current security level. To changesecurity levels change the password value using the UpArrow and Down Arrow keys and pressing the Enterkey. Four levels of security are provided. Refer to thefollowing password values for the correct value to enterfor the security level desired. The SECr menu itemsecurity level may be viewed or changed at any timeregardless of the present security level.

NOTEThe password values shown below cannot be altered.

Security Level

Menu Security Displayed Value Password Value to Enter

Primary Locked 1 1110

Secondary Locked 1 1110

Secure Locked 1 1110

Primary Unlocked 2 1101

Secondary Locked 2 1101



Secondary Unlocked 3 1011



Secondary Unlocked 4 111

Secure Unlocked 4 111

InP Input Type Select one of the following. The selection is limited tothe input type RTD provided in the SSRU (P392).

P385 100 ohm Platinum (DIN 0.00385Ω/Ω/°C).


P392 100 ohm Platinum (NIST 0.00392Ω/Ω/°C).

n120 120 ohm Nickel (US Industrial 0.00672Ω/Ω/°C).


F-C Temperature Descriptor Select temperature descriptor for Fahrenheit or Celsius.

F °F descriptor is on and temperatureinputs will be displayed in actual degreesFahrenheit.



Table 6-4. Secure Menu Selections (Cont.)


C °C descriptor is on and temperatureinputs will be displayed in actual degreesCelsius.


dPt Decimal Point Positioning Select 0 or 0.0. This only affects the Process Value, Sp,ALLo, ALHi, and InPC.

0 No decimal point is selected. (Available, but not used for this application.)

0.0 One decimal point is selected. If the Process Value moves outside of the decimal pointrange ends (-199.9 to +999.9), the Process Value displaywill autorange to whole degree resolution. When theProcess Value returns to the decimal point range, thedisplay will autorange back to tenth degree resolution.

InPt Input Fault Timer SelectOFF, 0.1 to 540minutes. Whenever an input is outof range (UFL or OFL displayed), shorted, or open, thetimer will start. When the time has elapsed, the controllerwill revert to a safe condition (Output Off, FlashingDisplay). If OFF is selected, the Input Fault Timer willnot be recognized (time = infinite).

SPL Set Point Low Select from the lowest input range value to SPH value.This will set the minimum SP value that can be entered.The value for SP will stop moving when this value isreached.

SPH Set Point High Select from the highest input range to SPL value. Thiswill set the maximum SP value that can be entered. Thevalue of SP will stop moving when this value is reached.

SPSt Set Point State Select dir or rE.

dir Direct Action As the input increases the output will increase. Used forcooling processes.

rE Reverse Action (Available, but not used for this application.) As theinput increases the output will increase. Used for coolingprocesses.

SPOL Set Point Output Low Limit (Available, but not used for this application.) Select 0to 100% but not greater than SPOH. This item limitsthe lowest output value. This is useful for adding a biasto the process when needed. Factory set to 0 for outputcodes 1, 2, and 3. Factory set to 20 for output code 5(20% output equals 4 mA output).

SPOH Set Point Output High Limit (Available, but not used for this application.) Select 0 to100% but not less than SPOL for output codes 1, 2, or3. Select 0 to 102% but not less than SPOL for outputcode 5. This item allows setting the maximum outputlimit. This is useful with processes that are over powered.Adjustment to 102% allows setting current output toforce a full on condition for output devices which do nothave bias adjustments. This is factory set to 100 for alloutput codes.

SPLP Set Point Lamp Select O on or OoFF.



Table 6-4. Secure Menu Selections (Cont.)


O on Lamp ON when Output is ON.

OoFF Lamp OFF when Output is ON. (Available, but not used for this application.)

6.6.5 Diagnostic Error Messages. The error messages shown in table 6-5 will assist the operator in programmingthe freeze room thermostat.If it is indicated that the thermostat has been programmed incorrectly proceed as follows:From any menu in the thermostat move to the Primary Menu as follows: Press the Up Arrow and Enter keys followed bypressing the Index and Down Arrow keys. This will bring the thermostat back to the Primary Menu. From the primary menu,only the setpoint can be adjusted.Most programming errors will occur in the Secondary Menu. Enter the Secondary Menu. The setting for CY (Cycle Rateand Output Selection) must be set to OnOf. The thermostat will display menu selections for tunE (setting SELF, Pid, Pb,rES, OFS, rtE), ArUP (setting ON, OFF), and rt (setting OFF, 00.01 to 99.59) if the thermostat Secondary Menu selectionCY is not set to OnOf. Additional Secondary Menu selections which apply to CY when set to OnOf are InPC and FILt.Note that InPC is reset to zero when the input type (thermocouple, or RTD) is changed or the decimal point is changed.Ideally the InPC will be zero anyway, but the sensor may drift over time resulting in an erroneous reading necessitating avalue other than zero in order for the thermostat to display the correct temperature. The InPC can be adjusted to compensatefor the error when a comparison is made to a referenced temperature standard. The temperature comparison should bemade at the desired temperature since the input correction value will not be the same over the entire temperature range ofthe sensor. FILt should be set to 4.Programming errors may occur in the Secure Menu. Enter the Secure Menu. InP should be set to P392 for a NIST RTD.dPt should be set for 0.0. Note that adjusting the dPt will reset the InPC to zero. InPt should be set to OFF. If SPOL orSPOH are displayed in the Secure Menu, this indicates that CY is not set to OnOf.Values for all other Secondary and Secure Menu settings should be as per table 6-6 of the tech manual.

Table 6-5. Thermostat Diagnostic Error Messages

Display Meaning SP Outputs Action Required

UFL or OFL Underflow or Overflow:Process value has exceededinput range ends.

Set Point output active.Alarms active.

Input signals may normally go above orbelow range ends, if not, check input andcorrect.

ULF, or OFL will sequence todisplay one of these messagesif the InPt is set for a timevalue.

Set Point outputinactive.Alarms active.

To reset use the Index and Enter keys.When InPt (input fault timer) has beenset for a time, the outputs will be turnedoff after the set time. Setting the timeto OFF causes the outputs to remainactive, however, UFL or OFL will still bedisplayed. Correct or replace sensor. Toreset use the Index and Enter keys.

bAdInP

For RTD inputs RTD is openor shorted.

OPEnInP

For THERMOCOUPLE inputsthermocouple is open.

CHECCAL

Check calibration appears asan alternating message if theinstrument calibration nearstolerance edges.

Set Point output active.Alarms active.

Remove the instrument for service and/orrecalibration. To reset use the Index andEnter keys.



Table 6-5. Thermostat Diagnostic Error Messages (Cont.)

Display Meaning SP Outputs Action Required

Check calibration appearsas a flashing message if theinstrument calibration exceedsspecifications.


Remove the instrument for service and/orrecalibration. To reset use the Index andEnter keys.

No display lighted Display is blank. Instrumentmay not be getting power, orthe supply voltage is too low.

Set Point outputinactive.Alarms inactive.

Check that the power supply is on or thatexternal fuses are good.

FAILtESt

Fail test appears upon powerup if the internal diagnosticsdetect a failure. This messagemay occur during operation ifa failure is detected. Displaysflash.


The display alternated between FAIL tEStand one of the following messages:FACt dFLt: Memory may be corrupted.Press the Enter key and the Down Arrowkey to start the factory default procedure.Recheck thermostat programming.rEt FACt: Cannot recover from error,return to manufacturer for service.

CHEC SPCHEC ALLOCHEC ALHi

This message will appear uponpower up if the set point is setoutside of the SPL or SPHvalues.


Correct the SP or adjust the SPL or SPHvalues by programming new values.

CHEC SPLorCHEC SPH

This message appears at powerup if SPL or SPH values areprogrammed outside the inputrange ends.


Correct the SPL or SPH values byprogramming new values.



6.6.6 Program Settings. The freeze room thermostat FRT program settings included in table 6-6 will ensure that themaintained temperature is -2 +4/-0°F. Paragraph 6.19.4 contains procedures for replacing the thermostat.

6.7 CHILL ROOM THERMOSTAT.

WARNING


Chill room thermostat CRT operational and functional characteristics are the same as freeze room thermostat FRT. The onlydifferences are in initial programming. Chill room thermostat program settings are listed in table 6-7 and will ensure that themaintained temperature is 33 +2/-0 °F. Paragraph 6.19.5 contains procedures for replacing the thermostat.

Table 6-6. Freeze Room Thermostat (FRT) Programmed Values

Menu Selection Function Menu Value

Sp Set Point: Primary -2°F

ALLo Secondary Set Point Secondary -199°F

ALHi Fan Start-Up Temperature Set Point forSecondary Defrost Termination

Secondary 52°F

CY Cycle Rate and Output Selection Secondary ON-OFF (OnOf)

SP_d Set Point Differential Secondary 4°F

InPC Input Correction Secondary 0°F

FiLt Digital Filter Secondary 2

InP Input Type Secure P392

F-C Temperature Descriptor Secure °F

dPt Decimal Point Positioning Secure 0.0

InPt Input Fault Timer Secure OFF

SPL Set Point Low Secure -5°F

SPH Set Point High Secure 52°F

SPSt Set Point State Secure DIRECT (dir)

SPLP Set Point Lamp Secure O ON

Table 6-7. Chill Room Thermostat (CRT) Programmed Values


Sp Set Point: Primary 33°F

ALLo Secondary Set Point Secondary -199°F

ALHi Secondary Set Point Secondary 52°F

CY Cycle Rate and Output Selection Secondary ON-OFF (OnOf)

SP_d Set Point Differential Secondary 2°F

InPC Input Correction Secondary 0 °F

FiLt Digital Filter Secondary 2



Table 6-7. Chill Room Thermostat (CRT) Programmed Values (Cont.)


InP Input Type Secure P392

F-C Temperature Descriptor Secure °F

dPt Decimal Point Positioning Secure 0.0

InPt Input Fault Timer Secure OFF

SPL Set Point Low Secure -5 °F

SPH Set Point High Secure 52 °F

SPSt Set Point State Secure DIRECT (dir)

SPSP Set Point Lamp Secure O ON

6.8 WATER FAILURE ON-DELAY RELAY.Water failure on-delay relay MM1 is a solid-state time delay relay. This control is not repairable and must be replaced ifmalfunctioning. Before replacing this relay per paragraph 6.19.3, inspect as follows:

WARNING


a. Open control panel door. Verify input voltage at 120 Vac, nominal.b. Inspect control circuit fuses, and verify that all wiring is connected properly and is not broken or loose. Refer to

figure FO-2.c. Verify potentiometer set at 45 seconds.d. If not, set potentiometer to 45 seconds.

6.9 CHILL ROOM AIR DAMPER ACTUATOR.The chill room air damper actuator DM (see figure FO-2, sheet 1) is mounted directly to the chill room damper operatingshaft with a universal clamp. The damper actuator provides true spring return operation for fail-safe operation and positiveclosure. The spring return system provides consistent torque to the damper with and without power applied to the actuator.The actuator provides 95 degrees of rotation and has a graduated position indicator showing 0 degrees to 90 degrees. Theair damper actuator is not repairable and must be replaced per paragraph 6.20.5 if it malfunctions. Before replacing the airdamper actuator inspect the following:

WARNING


a. Open control panel door. Verify input voltage at 120 Vac, nominal.b. Inspect control circuit fuses and verify that all wiring is connected properly and is not broken or loose. Refer to

figure FO-2.c. Inspect damper operating shaft universal clamp V-bolt holding nuts for tightness, and remove any obstruction that

may prevent damper blade from turning.d. Verify control signals from chill room thermostat CRT switch are present per figure FO-2.e. Tag the SSRU out of service (paragraph 6.1.1).f. Verify that when electric power is removed from actuator, it moves to closed position.g. Return the SSRU to service (paragraph 6.1.2).



6.10 DEFROST TERMINATION THERMOSTAT SWITCH.Defrost termination thermostat DTT switch is not repairable and must be replaced if it malfunctions. Before replacing defrosttermination thermostat switch per paragraph 6.20.1, perform the following tests and adjustments.

WARNING


a. Tag the SSRU out of service (paragraph 6.1.1).

b. Open Control Panel door and test switch operation by toggling bellows lever (figure 6-5, 5) with a wooden tonguedepressor or plastic stirrer (i.e. a nonmetallic object).

CAUTION

The snap-action of the switch is critical for proper control operation. If the switch does not haveproper snap-action it may operate erratically. To prevent damage to the switch, the nonmetallicobject used to toggle the switch must be kept out of the switch area. The only point that the switchshould be manually toggled is the bellows lever.

c. When toggling, a crisp snap should occur when control cuts in and out, and bellows lever should engage anddisengage pickup arm at correct position with correct clearance.

d. Return the SSRU to service (paragraph 6.1.2).



6.10.1 Temperature Setting. The default set point for the defrost termination thermostat switch is 40°F and defaultdifferential is 10°F (table 6-1). Set defrost termination thermostat switch (figure 6-6) as follows:

a. To set range scale to desired operating temperature, open Control Panel door and proceed as follows:

(1) Turn range adjustment screw (figure 6-6, 1) and read scale pointer on range scale (7).

(2) One full turn of range adjustment screw (1) equals approximately 7.5°F on range scale. To increase setting,turn range adjusting screw ccw.

(3) To decrease setting, turn range adjusting screw cw.

b. To set differential scale to desired operating temperature, proceed as follows:

(1) Turn differential adjustment screw (2) and read scale pointer on differential scale (8).

(2) One full turn of differential adjustment screw (2) equals approximately 9°F.

(3) To increase differential, turn range adjusting screw (1) cw. To decrease differential, turn range adjustingscrew (1) ccw.

(4) The cut-out setting may be obtained by subtracting the differential from the cut-in setting.



6.10.2 Capillary and Bulb. Before replacing defrost termination thermostat switch check capillary and bulb for sharpbends, kinks, strain and pinch marks. If either bulb or capillary have been ruptured the control will not operate and switchrequires replacement per paragraph 6.20.1. The bulb is located on the tubesheet at the top right of the evaporator coil asviewed from the upper equipment cabinet access panel.

6.11 HIGH DEFROST TEMPERATURE THERMOSTAT SWITCH.The high defrost temperature thermostat HTT switch is not repairable and must be replaced if it malfunctions. Beforereplacing high defrost temperature thermostat switch per paragraph 6.20.2, perform the following tests and adjustments.

WARNING


a. Tag the SSRU out of service (paragraph 6.1.1) and remove chill room upper access panel per paragraph 6.18.



b. Open Control Panel door and test switch operation by toggling bellows level (figure 6-4, 5) with a wooden tonguedepressor or plastic stirrer (i.e. a nonmetallic object).

CAUTION

The snap-action of the switch is critical for proper control operation. If the switch does not haveproper snap-action it may operate erratically. To prevent damage to the switch, the nonmetallicobject used to toggle the switch must be kept out of the switch area. The only point that the switchshould be manually toggled is the bellows lever.

c. When toggling, a crisp snap should occur when control cuts in and out and bellows lever should engage anddisengage pickup arm at correct position with correct clearance.

d. If necessary, the pickup adjustment can be checked visually and adjusted as follows:

(1) Turn differential adjustment screw (1) cw to apply spring pressure to differential arm (3).(2) With nonmetallic object, pry upward on end of bellows lever slowly until differential arm (3) stops against

clamping bracket stop (4).(3) Continue to apply force to bellows lever. The bellows lever should lift off differential arm window by 0.005 to

0.010 inch before switch toggles.(4) Relax pressure on nonmetallic object to allow bellows lever to touch bottom of differential arm. Continue

releasing pressure on tip of bellows lever. The differential arm should lift off clamping bracket stop by0.010 to 0.020 inch before switch toggles.

e. Return the SSRU to service (paragraph 6.1.2).

6.11.1 Temperature Setting. The default set point for the high defrost temperature thermostat switch is 95°F and defaultdifferential is 40°F (table 6-1). Set high defrost temperature thermostat switch settings (figure 6-6) as follows:

a. To set range scale to desired operating temperature, open Control Panel door and proceed as follows:

(1) Turn range adjustment screw (figure 6-6, 1) and read scale pointer on range scale (7).(2) One full turn of range adjustment screw (1) equals approximately 7.5°F on range scale. To increase setting,

turn range adjusting screw ccw.(3) To decrease setting, turn range adjusting screw cw.

b. To set differential scale to desired operating temperature, proceed as follows:

(1) Turn differential adjustment screw (2) and read scale pointer on differential scale (8).(2) One full turn of differential adjustment screw (2) equals approximately 9°F.(3) To increase differential, turn range adjusting screw (1) cw. To decrease differential, turn range adjusting

screw (1) ccw.(4) The cut-out setting may be obtained by subtracting the differential from the cut-in setting.

6.11.2 Capillary and Bulb. Before replacing high defrost temperature thermostat switch, check capillary and bulb forsharp bends, kinks, strain and pinch marks. If either bulb or capillary have been ruptured, control will not operate and switchrequires replacement per paragraph 6.20.2. The bulb is located on the tubesheet at the top right of the evaporator coil asviewed from the upper equipment cabinet access panel.

6.12 COMPRESSOR LOW PRESSURE SWITCH.The compressor low pressure switch LP1/LP2 (figure 6-7) is not repairable and must be replaced if it malfunctions.

WARNING




a. Open Control Panel door, remove chill room upper access panel (paragraph 6.18), and verify continuity betweenswitch terminals as follows:

(1) Trip main lever (9) with fingers only. Do not use screwdriver or other mechanical device.(2) Push up on main lever (9) to close circuit to terminals No. 1 (5) and No. 4 (4) and verify continuity.(3) Push down on main lever (9) to close circuit to terminals No. 1 (5) and No. 2 (6) and verify continuity.(4) If there is no continuity, replace the switch per paragraph 6.19.6. If there is continuity, but plant operation

indicates that switch adjustment is required, remove the switch for bench testing per paragraph 6.19.6, step a.through step j., to verify and adjust settings.

b. To verify pressure cut-in setting, proceed as follows:



(1) Attach electrical continuity tester to terminals No. 1 (5) and No. 4 (4).(2) Pump down (evacuate) the sensing line until continuity across terminals 1 and 4 is lost. Open port valve on

service gage and allow pressure to enter the sensing line gradually. Verify that continuity across terminals 1 and4 is regained on pressure rise to 0 psig.

(3) If continuity is regained on a pressure rise to 0 psig, remove the electrical continuity tester and proceedto step d. If not, adjust cut-in setting per step c.

c. To adjust cut-in setting, proceed as follows:

(1) Remove screw (11) and locking plate (10) before making any adjustment.(2) Pump down (evacuate) the sensing line until continuity across terminals 1 and 4 is lost. Open port valve on

service gage and allow pressure to enter the sensing line gradually to 0 psig.(3) Turn range adjustment screw (1) until continuity is regained.(4) If continuity is regained at pressure below 0 psig, turn range adjustment screw clockwise and repeat process. If

continuity is regained at pressure above 0 psig, turn the range adjustment screw counter-clockwise and repeatprocess. One full turn equates to a 7 psi change.

(5) Install locking plate (10) and screw (11) after adjustments are complete.(6) Verify cut-in setting per step b. above.

d. To verify cut-out setting, proceed as follows:

(1) Attach continuity tester to terminals 1 and 2.(2) Pump down (evacuate) the sensing line and verify that continuity is achieved at (not before) -6 psig (8.7

psia) vacuum.(3) If continuity is regained at -6 psig (8.7 psia) vacuum, remove the electrical continuity tester and proceed

to step f. If not, adjust cut-out setting per step e.

e. To adjust cut-out setting, proceed as follows:

(1) Remove screw (11) and locking plate (10) before making any adjustment.(2) Attach continuity tester to terminals 1 and 2.(3) Open port valve on service gage and allow pressure to enter the sensing line gradually to 0 psig.(4) Close port valve on service gage and pump down (evacuate) the sensing line until 14” Hg vacuum or continuity

across terminals 1 and 2 is achieved, whichever occurs first.(5) If continuity across terminals 1 and 2 is achieved before 14” Hg vacuum is reached, turn the differential

adjusting screw (2) counter-clockwise until continuity is lost and repeat step (3). One full turn equates to a1.5 psi change.

(6) If 14” Hg vacuum is reached before continuity across terminals 1 and 2 is achieved, turn the differentialadjusting screw (2) clockwise until continuity is achieved. One full turn equates to a 1.5 psi change.

(7) Install locking plate (10) and screw (11) after adjustments are complete.(8) Verify cut-out setting per step d. above.

f. Reinstall the switch per paragraph 6.19.6 steps k. through r. Disconnect manifold test gage set per paragraph 6.2.2.g. Release backseat on compressor suction valve.

6.13 COMPRESSOR HIGH PRESSURE SWITCH.This compressor high pressure switch HP1/HP2 (figure 6-8) is not repairable and must be replaced if malfunctioning.

WARNING




a. Open Control Panel door and verify continuity between switch terminals as follows:

(1) Trip main lever (8) with fingers only. Do not use screwdriver or other mechanical device.(2) Push up on main lever (8) to close circuit to terminals No. 1 (5) and No. 4 (4) and verify continuity.(3) Push down on main lever (8) to close circuit to terminals No. 1 (5) and No. 2 (6) and verify continuity.(4) If there is no continuity, replace the switch per paragraph 6.19.6. If there is continuity, but plant operation

indicates that switch adjustment is required, remove the switch for bench testing per paragraph 6.19.6, step a.through step j., to verify and adjust settings.

b. To verify pressure cut-out setting, proceed as follows:

(1) Attach electrical continuity tester to terminals No. 1 (5) and No. 2 (6).



(2) Apply pressure to sensing line and test gage until it reaches the high pressure cut-out setting 150 psig (table6-1). At this setting and at pressures above this setting, switch should be open with no continuity betweenterminals No. 1 (5) and No. 2 (6).

(3) If continuity is lost on a pressure rise to 150 psig, remove the electrical continuity tester and proceed to step d.If not, adjust cut-out setting per step c.

c. To adjust cut-out setting, proceed as follows:

(1) Remove screw (10) locking plate (9) before making any adjustment.

(2) Attach continuity tester to terminals No. 1 (5) and No. 2 (6).

(3) Bleed off pressure from the sensing line until continuity across terminals is regained. Pressurize the sensingline until continuity is lost.

(4) If the continuity is lost at a pressure below 150 psi, turn the adjustment screw clockwise and repeat process.One full turn equates to a 7 psi change.

(5) If the continuity is lost at a pressure above 150 psi, turn the adjustment screw counter-clockwise and repeatprocess. One full turn equates to a 7 psi change.

(6) Install locking plate (9) and screw (10) after adjustments are complete.

d. Reinstall the switch per paragraph 6.19.7 step k. through step r.

e. Release backseat on compressor discharge valve.

6.14 POWER SUPPLY VOLTAGE MONITOR.The compressor power supply monitor 1MM2/2MM2 (figure 6-9) is a fully adjustable, solid state monitor for the three-phase440 Vac compressor motor. When all voltages are acceptable an LED (4) will glow. The power supply voltage monitor isnot repairable and must be replaced if faulty. If ship’s power supply cannot be corrected, it may be necessary to reduce thesensitivity settings of this device. Before replacing either compressor power supply monitor per paragraph 6.19.8, inspectthe following.

WARNING


a. Open Control Panel door. Verify fast acting fuses installed external to the power supply monitor. Inspect three fuses,one for each power supply input terminal (2), ΦA, ΦB and ΦC.

b. Set LINE VOLTS adjustment (6) to 440 Vac.

c. Set VOLTAGE LINE BALANCE adjustment (7) at 2%.

d. Set TRIP DELAY adjustment (5) at 2 seconds.



LEGEND: 1. OUTPUT RELAY2. POWER SUPPLY INPUT TERMINALS3. OUTPUT RELAY TERMINALS4. LED5. TRIP DELAY ADJUSTMENT6. LINE VOLTAGE ADJUSTMENT7. VOLTAGE LINE BALANCE ADJUSTMENT

Figure 6-9. Power Supply Voltage Monitor

06468:0503

2

1

7 6

5

4

3

F A

F CF B

VOLTAGELINE BALANCE

LINEVOLTS

TRIPDELAY

C

NC

NO

RELAYENERGIZED

THREE PHASEVOLTAGE MONITOR

e. Verify phase sequence as follows:

(1) When power is applied and relay fails to energize, check the wiring of all three phases for 440 VAC andphase sequence ΦA, ΦB, ΦC.



(2) If phase sequence is incorrect, disconnect power supply and switch any two wires. LED indicator will glowwhen power is restored and all voltages are acceptable.

f. If LED is glowing and system does not start, verify control voltage. Control voltage should be 110 + 10/-0 Vac.When control voltage is low, output relay (1) will not energize.

6.15 ANTI-CYCLE LOCKOUT TIMER.

WARNING


The anti-cycle lockout timer 1MM1/2MM1 (figure 6-10) is a solid state relay that provides protection against short cycling ofthe compressor. Upon application of power there is an approximately one-second delay before the compressor starts. Theone-second delay-on feature eliminates contact chatter. Power should be applied for at least 15 seconds to achieve a totallockout delay. If power is applied for less than 15 seconds a proportionally shorter delay period will result. When theanti-cycle timer is deenergized, a 5-minute lockout is initiated to prevent the compressor from restarting. The anti-cyclelockout timer is not repairable and must be replaced if it malfunctions. If compressor cycles from off to on in less than 5minutes after power has been applied for at least 15 seconds, the timer has failed. If the compressor does not cycle on after a5-minute delay, the timer may be faulty and should be checked. Replace anti-cycle lockout timer per paragraph 6.19.9.



SOLID STATE TIMER

1

2

LEGEND:

1. MALE QUICK-CONNECT TERMINAL 1/4-INCH2. MOUNTING HOLE (1/4-INCH DIAMETER)

06469:0503

Figure 6-10. Anti-Cycle Lockout Timer

6.16 THERMAL EXPANSION VALVE.The thermal expansion valve (figure 6-11) controls the superheat of the suction gas leaving the evaporator coil. The valveis factory set to maintain the suction gas leaving the coil at 8 to 15°F (superheat) above the saturated suction temperature.The valve superheat is factory set and can be adjusted. Effective valve performance can be determined by measuring the



superheat. Superheat is reduced as the operating space temperature approaches - 5°F. Superheat adjustments should be madewith the space temperature in freeze room at 0°F. Observing frost on the suction line or considering only suction pressureor temperature will be misleading. Checking superheat is the first in a systematic analysis of thermal expansion valveperformance. Superheat should be checked when room temperatures are stabilized. If not enough refrigerant is beingfed to the evaporator, the superheat will be too high. If too much refrigerant is being fed to the evaporator, the superheatwill be too low. To evaluate superheat proceed as follows.

a. Shut SSRU down and tag OUT OF SERVICE per paragraph 6.1.1.

b. Open Control Panel door and remove service panel to access evaporator coil area of equipment cabinet.

NOTEWhen service panel is removed, two expansion valves are visible. The valve nearest the entering airside of the evaporator coil is the thermal expansion valve for Plant #1. The other valve serves Plant #2.

c. Inspect installation of thermal expansion valve sensing bulb (5) for appropriate system as follows:

(1) Ensure that bulb is strapped firmly to the suction line, but not crushed.

(2) Inspect suction line and sensing bulb for cleanliness. Both must be free of dirt or corrosion.

(3) Ensure that insulation surrounding sensing bulb and suction line is in good condition and tightly wrapped.

d. If necessary, correct discrepancies in installation and retest SSRU before continuing.

e. Install remote reading test thermometer or thermocouple as follows:



(1) Attach remote reading test thermometer or thermocouple to the suction line at same location as the thermalexpansion valve sensing bulb being tested.

(2) Ensure that thermometer bulb or thermocouple is well insulated.

(3) Ensure that remote thermometer bulb or thermocouple is readable from outside equipment cabinet.

(4) Replace service panel to access evaporator coil area of equipment cabinet.

f. Remove upper equipment cabinet access panel per paragraph 6.18.

g. Connect manifold test gage set to Schrader fitting on suction line per paragraph 6.2.1.

h. Install upper equipment cabinet access panel taking care not to crush test gage line.

WARNING


i. Return SSRU to service per paragraph 6.1.2.

j. Measure thermal expansion valve superheat as follows:

(1) Allow the SSRU to reach stable operating conditions before measuring superheat.

(2) Record the temperature of the test thermometer or thermocouple installed on the evaporator coil suction line.

(3) Record the pressure of the test gage installed on compressor suction service valve.

(4) Most service gages indicate temperature and saturated pressure on dual-scale. If not, use table 3-1 to convertthe pressure obtained in step j(3) to saturated evaporator temperature.

(5) Subtract the temperature obtained in step j(4) above from the temperature in step j(2). The difference issuperheat. If the superheat is not between 8°F and 15°F, the valve may need either adjustment or replacement.Superheat should be adjusted as close to 15°F as possible without going over.

NOTEIf superheat is too high, ensure that conditions are at design temperature. Superheat will not becorrect during pulldown. Excessive superheat may indicate a clogged TXV strainer.

k. Adjust thermal expansion valve superheat as follows:

(1) Shut SSRU down and tag OUT OF SERVICE per paragraph 6.1.1.

(2) Open Control Panel and remove service panel to access evaporator coil area of equipment cabinet.

(3) Remove seal cap (3) from thermal expansion valve (2).

(4) Mark starting position of adjusting stem (4).

(5) To reduce superheat, turn adjusting stem (4) ccw.

(6) To increase superheat, turn adjusting stem (4) cw.

(7) When adjusting valve, make no more than 1/4 turn of stem at a time.

(8) Replace service panel to access evaporator coil area of equipment cabinet.

(9) Repeat step i and step j above.

l. Observe the change in superheat closely, to prevent overshooting desired setting. As much as 30 minutes may berequired for the system to balance after an adjustment is made. Ensure that superheat measurements are made withthe freeze room at 0°F.

m. Repeat adjustment as necessary. If the space temperatures cannot be maintained with the superheat between 8°F to15°F, the valve must be replaced per paragraph 6.20.16.



6.17 WATER REGULATING VALVE.The water regulating valves (figure 6-12) are used to maintain the condensing temperature at 70°F saturated condition (71psig). The valves open and close in response to refrigerant pressure in the condenser. The condensing pressure is sensedthrough a pressure connection at the bellows assembly. Adjust the water regulating valve as follows:

WARNING


a. Install manifold test gage per paragraph 6.2.1. Remove lower equipment cabinet access panel (under the Controlpanel) per paragraph 6.18.

CAUTION

To avoid damage to equipment, do not force adjustment screw beyond stops.

b. Tag in electrical power to Control Panel (paragraph 6.1.2) and start unit per paragraph 2.3.1.1. Allow unit to stabilize.

c. If the manifold test gage indicates a temperature below 70°F, slowly turn adjustment screw (1) cw to increase thepower spring (2) pressure and increase condensing temperature, observing the manifold test gage. Allow unitto stabilize to determine if adjustment is sufficient.

d. If the manifold test gage indicates a temperature above 70°F, slowly turn adjustment screw (1) ccw to lower ordecrease the condensing temperature, observing the manifold test gage. Allow unit to stabilize to determine ifadjustment is sufficient.

e. Tag out Control Panel electrical power out of service per paragraph 6.1.1.

f. If water regulating valve cannot be adjusted or is damaged, replace per paragraph 6.20.14.

g. Remove manifold test gage set per paragraph 6.2.2.



SECTION 2. REPAIR.

WARNING

When making any repair that could result in refrigerant HFC-134a being present in the atmosphere, thespace shall be ventilated with fresh air. Be sure ventilation in the space is adequate to keep the concentrationof refrigerant below 1000 parts per million. Ventilation air should be exhausted outside the ship. Failure toproperly ventilate the space could result in injury or death to personnel.

Check for refrigerant vapor presence prior to entering equipment cabinet. A concentration of refrigerantvapor can cause suffocation or result in heart failure.

Rotating parts can cause death or injury. Do not wipe down or place hands in the vicinity of rotating parts.Ensure that rotating parts are deenergized and tagged out of service before performing maintenance on them.

Some components within the operating system may be at temperatures greater than 125°F. Chemical safetygoggles or a full face shield, chemical resistant gloves and chemical resistant long sleeve shirts must beworn when performing any service or maintenance. Contact with unprotected skin can result in seriousburns or injury to personnel.

CAUTION

Dispose of all non-metallic waste parts and products (such as rags contaminated with oil, grease, solvents,or other compounds, or compounds themselves) in accordance with OPNAVINST P-45-110-96, disposalmethod 1, or approved maintenance activity requirements and procedures, as applicable.




6.18 ACCESS PANEL REMOVAL AND INSTALLATION.Remove and install access panels in the freeze and chill rooms and equipment cabinet per the following steps. Internalaccess panels (figure 1-2, 12) have attached battens which are removed along with the access panels, or which in somecases must be removed in order to remove the access panels. For batten information, refer to paragraph 6.22.1, figure6-27, and parts table 7-2.

WARNING

Prior to removing any access cover to the refrigeration unit, check for the presence of HFC-134arefrigerant using the SHIPS Central Air Monitoring System (CAMS) or portable electronic leakdetector. A concentration of refrigerant vapor can cause suffocation or result in heart failures.

a. To remove either of two access panels in chill room bulkheads (figure 1-2, 12), turn four knobs ccw, grasp handles,and remove access panel.

b. To remove either of four access panels in external freeze room bulkhead (figure 1-2, 12), turn four knobs ccw,grasp handles, and remove access panel.

c. To remove lower equipment cabinet access panel (figure 1-2, 13), in either freeze room or chill room, rotate fourknobs ccw, grasp handle, and remove access panel.

d. To remove upper access panel from equipment cabinet in chill room (figure 1-2, 13), remove 22 bolts and accesspanel.

e. To remove lower equipment cabinet access panel located under Control Panel (figure 1-2, 13), remove 38 boltsand access panel.

f. To remove upper equipment cabinet access panel located inside Control Panel (evaporator coil access not shown),open Control Panel door and remove 20 bolts and access panel.

g. Install all access panels in reverse order of removal.

6.19 CONTROL PANEL REPAIR.Control Panel (figure 7-1, 12) repair consists of replacement of relays and controls that are faulty as defined by thetroubleshooting procedures in Chapter 5. The wire list data in figure FO-2 shows point-to-point connections of ControlPanel wiring as well as electrical control wiring in the SSRU. Additional repair procedures in this paragraph describe thereplacement of specific controls and SSRU major components.Perform the following general procedures for Control Panel repairs:

WARNING


a. Before performing any repairs to Control Panel, shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.

b. Open the Control Panel door by turning the door handle (shown on figure 7-3, sheet 1).

c. Tag all electric wires before disconnecting and note routing.

d. Cord grip/stuffing box bulkhead feed through installation is shown in figure 6-13. Observe routing of cables throughthese interfaces and loosen and tighten as necessary for removal and installation of cables.

e. Cables are secured with tie wraps that should be removed and replaced as necessary. Typical nylon cable clampinstallation is shown in figure 6-13.

f. To replace indicator lamps, tag and disconnect all wires, remove indicator lens and jam nut, and remove indicatorbody from Control Plant.

g. To replace switches, tag and disconnect all wires, remove jam nuts and attaching hardware, and remove switchfrom Control Panel.



ELECTRICBOX BACK

INSULATION

EXTRUDEDALUMINUM PANEL

5

8

7

6

5

1 234

INSULATIONEXTRUDEDALUMINUM PANEL

LEGEND:

1. CLAMP2. SCREW3. LOCKWASHER4. WASHER5. PVC PIPE NIPPLE6. CORD GRIP7. PVC PIPE COUPLING8. PVC BULKHEAD FITTING

06472:0503

Figure 6-13. Cord Grip/Stuffing Box Installation and Cable Clamp Installation

NOTE: PART NUMBER INFORMATION IS PROVIDED ON TABLE 7-7.



6.19.1 Defrost Initiation Timer Replacement. To replace defrost initiation timer TD1 (figure 7-3, 13; see also figure6-3), proceed as follows:

a. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.b. Open Control Panel, remove attaching hardware from timer, and pull timer from enclosure to access wire leads.c. Tag and remove wire leads from terminals.d. Set timer controls on replacement timer as follows:

(1) Set decimal point location with white plastic lever mounted behind the front face of timer. This lever movesto three positions. Position decimal point in the desired location, and observe front of timer for mechanicalposition. This procedure sets the decimal point electronically as well as mechanically.

(2) Set time units (sec/min/hr) by moving arm located on the side closest to the units (sec/min/hr) window in aslotted arc. Press arm slightly with a pencil or pen point and move to desired position. Defrost initiation timeunits should be set at 4 hours.

(3) Four display modes are pin programmable on side of timer. The fifth pin is for test mode only. All pins areclearly marked by function. Set defrost initiation timer pin in up and stop position.

(4) Set two-pin programming on side of timer to 60 Hz line power pin.

e. When settings are completed, remove tags and attach wire leads to terminals.f. Insert timer into enclosure, and secure in place with mounting hardware.g. Verify timer operation per paragraph 6.4.h. Close Control Panel.i. Return SSRU to service per paragraph 6.1.2.

6.19.2 Defrost Cycle Timer Replacement. To replace defrost cycle timer TD2 (figure 7-3, 13; see also figure 6-3),proceed as follows:

a. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.b. Open Control Panel, remove attaching hardware from timer, and pull timer from enclosure to access wire leads.c. Tag and remove wire leads from terminals.d. Set timer controls on replacement timer as follows:

(1) Set decimal point location with white plastic lever mounted behind the front face of timer. This lever movesto three positions. Position decimal point in the desired location, and observe front of timer for mechanicalposition. This procedure sets the decimal point electronically as well as mechanically.

(2) Set time units (sec/min/hr) by moving arm located on the side closest to the units (sec/min/hr) window in aslotted arc. Press arm slightly with a pencil or pen point and move to desired position. Defrost terminationtime units should be set at 15 minutes.

(3) Four display modes are pin programmable on side of timer. The fifth pin is for test mode only. All pins areclearly marked by function. Set defrost termination timer pin in up and stop position.

(4) Set two-pin programming on side of timer to 60 Hz line power pin.

e. When settings are completed, remove tags and attach wire leads to terminals.f. Insert timer into enclosure, and secure in place with mounting hardware.g. Verify timer operation per paragraph 6.5.h. Close Control Panel.i. Return SSRU to service per paragraph 6.1.2.

6.19.3 Water Failure On-Delay Relay Replacement. To replace water failure on-delay MM1 (figure 7-3, sheet 2, 45),proceed as follows:

a. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.



b. Open Control Panel and remove screws holding relay to mounting board.c. Before installing new relay, set proper timing functions per paragraph 6.8.d. Install relay to mounting board with screws.e. Close Control Panel.f. Return SSRU to service per paragraph 6.1.2.

6.19.4 Freeze Room Thermostat Replacement. To replace freeze room thermostat FRT (figure 7-3, sheet 1, 15; seealso figure 6-4), proceed as follows:

a. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.b. Open Control Panel door such that back side of thermostat is visible.c. Tag and disconnect wire leads from back of thermostat.d. Hold thermostat housing with one hand and with other hand, pull spring-loaded mounting collar with ratchets

evenly to remove from housing.e. Remove thermostat through front of Control Panel door.f. Remove gasket from housing flange.g. Install new housing gasket against housing flange before installing thermostat.h. Install new thermostat from front of Control Panel door.i. Install mounting collar over housing from rear of Control Panel door.j. Hold housing with one hand and with other hand, push collar evenly against panel door until springs are compressed.

Ratchets will hold mounting collar and housing in place.k. Install electric wires for resistive temperature detector (RTD) probe to terminals No. 1, No. 3 and No. 4 per

figure 6-4.l. Verify proper programming as follows:

(1) Attach temporary 120 Vac power to terminals No. 19 and No. 20.(2) Default values are listed in table 6-6. Make all necessary changes in Secure Menu (table 6-4) before making

changes to Secondary Menu (table 6-3) per paragraph 6.6. If error messages occur, check Diagnostic ErrorMessages in table 6-5.

(3) At the conclusion of programming, remove temporary power from terminals No. 19 and No. 20.(4) Reconnect control wires for power terminals No. 19 and No. 20 and set point output wires on terminals No. 13,

No. 14 and No. 15. At this point all wires removed in step c should be in place.

m. Close Control Panel door.n. Return SSRU to service per paragraph 6.1.2.

6.19.5 Chill Room Thermostat Replacement. To replace chill room thermostat CRT (figure 7-3, sheet 1, 15; seealso figure 6-4), proceed as follows:

a. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.b. Open Control Panel door such that back side of thermostat is visible.c. Tag and disconnect wire leads from back of thermostat.d. Hold thermostat housing with one hand and with other hand, pull spring-loaded mounting collar with ratchets

evenly to remove it from housing.e. Remove controller through front of Control Panel door.f. Remove gasket from housing flange.g. Install new housing gasket against housing flange before installing thermostat.h. Install new thermostat from front of Control Panel door.i. Install mounting collar over housing from rear of Control Panel door.



j. Hold housing with one hand and with other hand, push collar evenly against Control Panel door until springs arecompressed. Ratchets will hold mounting collar and housing in place.

k. Install electric wires for resistive temperature detector (RTD) probe to terminals No. 1, No. 3 and No. 4 perfigure 6-4.

l. Verify proper programming as follows:

(1) Attach temporary 120 Vac power to terminals No. 19 and No. 20.(2) Default values are listed in table 6-7. Make all necessary changes in Secure Menu (table 6-4) before making

changes to Secondary Menu (table 6-3) per paragraph 6.7. If error messages occur, check Diagnostic ErrorMessages in table 6-5.

(3) At conclusion of programming, remove temporary power from terminals No. 19 and No. 20.(4) Reconnect control wires for power terminals No. 19 and No. 20 and set point output wires on terminals No. 13,

No. 14 and No. 15. At this point all wires removed in step c should be in place.

m. Close SSRU Control Panel door.n. Return SSRU to service per paragraph 6.1.2.

6.19.6 Compressor Low Pressure Switch Replacement. To replace compressor low pressure switch LP1 or LP2(figure 7-3, sheet 2, 31; figure 6-7), proceed as follows:

WARNING


a. Pump down SSRU per paragraph 2.3.1.2.b. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.c. Remove lower chill room (for compressor #2) or freeze room (for compressor #1) equipment cabinet access

panels per paragraph 6.18.d. Backseat suction service valve on compressor associated with switch to be replaced.e. Open Control Panel door.f. Remove protective cover from front of compressor low pressure switch.g. Tag and disconnect wires.h. Remove access panel below Control Panel per paragraph 6.18.i. Remove clamps securing compressor low pressure switch capillary tube.j. Remove and retain attaching hardware securing compressor low pressure switch in Control Panel and remove

switch, capillary tube and 1/4-inch flare nut.k. Obtain a new switch and adjust per paragraph 6.12 prior to installation. Then install new switch with attaching

hardware.l. Reinstall clamps that secure capillary tube. Coil excess capillary tube and secure where it will not vibrate. Vibration

can break capillary tube.m. Connect wire leads to switch.n. Install protective cover on switch, and close Control Panel door.o. Verify switch settings per paragraph 6.12.p. Release backseat on suction service valve.q. Install all access panels removed per paragraph 6.18.r. Return SSRU to service per paragraph 6.1.2.

6.19.7 Compressor High Pressure Switch Replacement. To replace compressor high pressure switch HP1 or HP2(figure 7-3, sheet 2, 30; figure 6-8), proceed as follows:



WARNING


a. Pump down SSRU per paragraph 2.3.1.2.b. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.c. Remove lower chill room and freeze room equipment cabinet access panels per paragraph 6.18.d. Backseat discharge service valve on compressor associated with switch to be replaced.e. Open Control Panel door.f. Remove protective cover from front of compressor high pressure switch.g. Tag and disconnect wires.h. Remove access panel below Control Panel per paragraph 6.18.i. Remove clamps securing compressor high pressure switch capillary tube.j. Remove and retain attaching hardware securing compressor low pressure switch in Control Panel and remove

switch, capillary tube and 1/4-inch flare nut.k. Obtain a new switch and adjust per paragraph 6.12 prior to installation. Then install new switch with attaching

hardware.l. Reinstall clamps that secure capillary tube. Coil excess capillary tube and secure where it will not vibrate. Vibration

can break capillary tube.m. Connect wire leads to switch.n. Install protective cover on switch, and close Control Panel door.o. Verify switch settings per paragraph 6.13.p. Release backseat on discharge service valve.q. Install all access panels removed per paragraph 6.18.r. Return SSRU to service per paragraph 6.1.2.

6.19.8 Power Supply Voltage Monitor Replacement. To replace power supply voltage monitor 1MM2 or 2MM2 (figure7-3, sheet 2, 20; see also figure 6-9), proceed as follows:

a. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.b. Open Control Panel door.c. Tag and disconnect wire leads from three power supply input terminals (2) and output relay terminals (3) (NC

terminal not used).d. Remove and retain attaching hardware securing voltage monitor to Control Panel and remove voltage monitor.e. Set line voltage, voltage line balance and trip delay per paragraph 6.14.f. Install monitor with attaching hardware.g. Attach three wire leads to power supply input terminals (2) and two wires to output relay terminals (3) (NC

terminal not used).h. Return SSRU to service per paragraph 6.1.2.

6.19.9 Anti-Cycle Lockout Timer Replacement. To replace anti-cycle lockout timer 1MM1 or 2MM1 (figure 7-3, sheet2, 33; see also figure 6-10 and paragraph 6.15), proceed as follows:

a. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.b. Open Control Panel door.c. Tag and disconnect wire leads from quick-connect terminals (1).d. Remove screw that secures lockout timer to Control Panel and remove timer.



e. Install replacement timer with screw.f. Attach wire leads to quick-connect terminals (1).g. Return SSRU to service per paragraph 6.1.2.

6.19.10 Indicator Lamp Replacement. To replace Control Panel indicator lamps (figure 7-3, sheet 1, 2), proceed asfollows:

a. Remove colored lens.b. Press and turn bulb to remove.c. Install bulb (figure 7-3, 2).d. Install colored lens.

6.20 EQUIPMENT CABINET.

WARNING


6.20.1 Defrost Termination Thermostat Switch Replacement. To replace defrost termination thermostat switch(figure 6-6), proceed as follows:

a. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.b. In chill room, remove upper equipment cabinet access panel per paragraph 6.18.c. On inboard bulkhead of equipment cabinet, remove protective cover from front of thermostat switch.d. Tag and disconnect wire leads to switch.e. Remove upper equipment cabinet access panel inside Control Panel per paragraph 6.18.f. Remove and retain clamps that secure bulb and capillary to evaporator coil tubesheet.g. Remove attaching hardware that holds thermostat inside equipment cabinet and remove switch, capillary and bulb.h. Install new switch with attaching hardware removed in step g.i. Carefully install bulb and capillary using extreme care to avoid sharp bends, kinks, strain or pinch marks.j. Install clamps to secure capillary and bulb. Coil and secure any excess capillary where it will not vibrate. Vibration

can be a source of capillary tube breakage.k. Install upper equipment cabinet access panel inside Control Panel per paragraph 6.18.l. Set operating temperature of switch per paragraph 6.10.m. Connect wire leads to switch.n. Install protective cover to front of thermostat switch.o. In chill room, install upper equipment cabinet access panel per paragraph 6.18.p. Return SSRU to service per paragraph 6.1.2.

6.20.2 High Defrost Temperature Thermostat Switch Replacement. To replace high defrost temperature thermostatswitch (figure 7-3, sheet 3, 53; figure 6-6), proceed as follows:

a. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.b. In chill room, remove upper equipment cabinet access panel per paragraph 6.18.c. On inboard bulkhead of equipment cabinet, remove protective cover from front of thermostat switch.d. Tag and disconnect wire leads to switch.e. Remove upper equipment cabinet access panel inside Control Panel per paragraph 6.18.f. Remove and retain clamps that secure bulb and capillary.



g. Remove attaching hardware that holds thermostat inside equipment cabinet and remove switch, capillary and bulb.

h. Install new switch with attaching hardware removed in step g.

i. Carefully install bulb and capillary using extreme care to avoid sharp bends, kinks, strain or pinch marks.

j. Install clamps to secure capillary and bulb. Coil and secure any excess capillary where it will not vibrate. Vibrationcan break capillary tube.

k. Install upper equipment cabinet access panel inside Control Panel per paragraph 6.18.

l. Set operating temperature of switch per paragraph 6.1.1.

m. Connect wire leads to switch.

n. Install protective cover to front of thermostat switch.

o. In chill room, install upper equipment cabinet access panel per paragraph 6.18.

p. Return SSRU to service per paragraph 6.1.2.

6.20.3 Solenoid Coil Replacement. To replace solenoid valve coil (figure 7-2, sheet 1, 7A; figure 6-14), proceed asfollows:

a. Pump down SSRU per paragraph 2.3.1.2.

b. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.

c. Remove upper equipment cabinet access panel in chill room per paragraph 6.18.

d. Remove two screws (figure 6-14, 1) to access electrical connection on solenoid (2) and tag and remove electricalconnections.

e. Remove screw (3) and cover (4) from solenoid (2) and replace solenoid coil.

f. Connect electrical wires to replacement coil and install cover (4) and screw (3).

g. Connect electrical wires to solenoid and install electric box cover with two screws (1).

h. Install upper equipment cabinet access panel in chill room per paragraph 6.18.




1

2

LEGEND: 1. SCREW2. SOLENOID3. SCREW4. COVER

06473:0503

Figure 6-14. Solenoid Coil Replacement

34

6.20.4 Fan Motor Replacement. To replace fan motor (figure 6-15), proceed as follows (see table 7-5 for part numberinformation):



WARNING

Rotating parts can cause death or injury. Do not wipe down or place hands in the vicinity of rotatingparts. Ensure that rotating parts are deenergized and tagged out of service before performingmaintenance on them.

NOTEReplacement of fan motor 1 and fan motor 2 is identical.


b. Remove upper equipment cabinet access panel in chill room per paragraph 6.18.

c. Remove four screws (5) and electrical cover (6) from fan motor (7).

d. Tag and disconnect electrical wires to fan motor (7).

WARNING

Fan motor mounting assembly weighs approximately 100 lb. Use proper lifting equipment toavoid personnel injury.

e. Remove four bolts (1), eight spacers (2), four locknuts (3) and fan motor mounting assembly (4).

f. Remove cotter pin (8) and nut (9) from fan motor shaft (10).

g. Remove three screws (11), tapered bushing (12), and fan (13) blades from motor shaft (10).

h. Remove four bolts (14) and locknuts (15) securing fan motor (7) to mounting assembly (4).





i. Install nut (9) and new cotter pin (8) onto the motor shaft (10).

j. Reconnect fan motor wiring and install cover (6) with four screws (5).

k. Install fan motor mounting assembly (4) with four bolts (1), eight spacers (2), four locknuts (3).

l. Install upper equipment cabinet access panel in chill room per paragraph 6.18.

m. Return SSRU to service per paragraph 6.1.2.

6.20.5 Chill Room Air Damper Actuator Replacement. To replace chill room air damper actuator (see figure 6-16 andparts listing on table 7-5), proceed as follows:


b. Remove ten screws (1) and cover plate assembly (2) containing right chill room air inlet.

c. Disconnect electric cable from actuator (3) by rotating electric cable fitting (12) counterclockwise. Locate wiresplice and disconnect.

d. Remove three bolts (4) and locknuts (5) from damper actuator (3) and separate actuator from bracket (6).

e. Loosen universal clamp V-bolt nuts (7), and remove universal clamp and retaining clip.

f. Disconnect damper shaft (9) from actuator (3) and remove actuator.

g. Manually move chill room damper (8) to fail-safe, closed, position. If shaft rotates ccw, installation is ccw. If shaftrotates cw installation is cw. In a left hand installation, damper actuator side marked CW faces out, while ina cw installation, the side marked CCW faces out.

h. Install replacement actuator in reverse order of removal. Replacement actuators are furnished with universalclamp (10) mounted on CW side of actuator. If clamp is not on correct side, remount clamp. If clamp is oncorrect side proceed to step j.

i. If mounting actuator with CCW side out, position clamp such that pointer section of tab is pointing to 0 degrees andspline pattern of clamp mates with spline of actuator. Slip clamp over spline. Lock clamp to actuator using retainingclip (11). Follow this same procedure if CW side is out.

j. Verify that damper is still in fail-safe, closed position.





k. Mount return actuator onto chill room damper shaft (9).

l. Tighten universal clamp V-bolt nuts (7) finger tight only.

m. Loosen universal clamp nuts (7).

n. Without rotating damper shaft (9), rotate actuator approximately 5 degrees in direction that would open damper.

o. With actuator in this position, tighten universal clamp V-bolt nuts (7) to secure actuator to damper shaft.

p. Rotate actuator approximately 5 degrees in the direction that would close damper and re-engage anti-rotation strapto apply pressure to damper seals and provide tight closure.

q. Tighten all attaching hardware.

r. Splice the actuator and power wires together. Connect electric cable to actuator (3) by rotating electric cablefitting (12) clockwise.

s. Verify actuator operation per paragraph 6.9.

t. Install cover plate assembly (2) to right of chill room inlet with ten screws (1).

u. Return SSRU to service per paragraph 6.1.2.

6.20.6 Compressor Crankcase Heater Replacement. To replace compressor crankcase heater for Plant #1 or Plant #2(figure 7-4, sheet 2, 14; figure 6-17), proceed as follows:

NOTEReplacement of compressor 1 crankcase heater and compressor 2 crankcase heater is identical.Compressor 1 crankcase heater replacement is shown as typical.


b. Remove lower equipment cabinet access panel and chill room lower equipment cabinet access panel (for compressor#2) or freeze room lower equipment cabinet access panel (for compressor #1) per paragraph 6.18.

WARNING


c. Allow compressor and compressor heater to cool for 4 to 6 hours and verify that compressor and crankcase heaterare cool.

d. Tag and disconnect two electrical leads between compressor crankcase heater (1) and auxiliary terminal box(figure 1-2, sheet 6, 35).

e. Tag and disconnect heater ground (figure 6-17, 2) to isolator base (3) and remove screw (4) and heater groundfrom isolator ground strap (5).

f. Loosen crankcase heater clamp band (6) and remove heater from compressor (7).

g. Install replacement heater in reverse order of removal.





6.20.7 Compressor Replacement. To replace compressor for Plant #1 or Plant #2 (figure 7-4, sheet 1, 2; figure 6-18), theisolator base assembly must first be removed. Proceed as follows:

WARNING


NOTEReplacement of compressor 1 and compressor 2 is identical. Compressor 1 replacement is shown astypical.

a. Remove to isolator base assembly in accordance with paragraph 6.20.18.

WARNING


b. Allow compressor and compressor heater to cool for 4 to 6 hours and verify that compressor and crankcase heaterare cool.





c. Tag and disconnect heater ground (figure 6-17, 2) to isolator base (3) and remove screw (4) and heater fromisolator ground strap (5).

d. Loosen crank case heater clamp band (6) and remove heater from compressor (7).

e. Disconnect Rotalock suction service valve (figure 6-18, 1) and Rotalock discharge service valve (2) fromcompressor (3).

f. Remove four bolts (6), washers (7), isolators (8) and locknuts (9) securing compressor (3) to isolator base (10).

g. Remove compressor (3) from equipment cabinet.

h. Install replacement compressor in reverse order of removal.

i. Connect Rotalock suction service valve (1) to compressor (3) and torque union connector to 20 to 50 ft-lbs.

j. Connect Rotalock discharge service valve (2) to compressor (3) and torque union connector to 15 to 40 ft-lbs.

k. Install crank case heater (figure 6-17, 1) on compressor (7) and tighten clamp (6).

l. Attach heater ground strap (2) to isolator base (3) with screw (4).

m. Reinstall isolator base assembly in accordance with paragraph 6.20.18.

n. Return SSRU to service per paragraph 6.1.2.

6.20.8 Isolator Mount Assembly Replacement. To replace isolator mount assembly (figure 7-5, 2; figure 6-19),proceed as follows:

NOTEReplacement of four isolator mount assemblies is identical. There is enough flexibility in the pipingsystem to lift the isolator base assembly and replace the isolator.


b. Remove lower equipment cabinet access panel and chill and freeze room lower equipment cabinet access panelsper paragraph 6.18.

c. Remove bolt (3), washer (4), two spacers (5), isolator (6), and locknut (7) securing isolator base (1) to isolatorchannel (8).



d. Remove chilled water inlet and outlet piping hanger located in back of the isolator base compartment.

WARNING

Isolator with piping and component weigh approximately 660 lbs. Use proper hoisting equipmentto avoid personnel injury.

e. Raise isolator base (1) from deck using a jack or lever arm and block to remove weight off the isolator mountassembly (2). Isolator with piping and components weighs approximately 660 lbs.

f. Lift isolator base (1) only as much as needed to remove weight off of isolator mount assembly (2).

g. Remove two bolts (9), locknuts (10) and isolator mount assembly (2).

h. Install replacement isolator mount assembly in reverse of removal. Torque to 150 ft-lb +25/-10.

i. Attach the chilled water inlet and outlet piping hanger in back of the isolator base compartment.

j. Install lower equipment cabinet across panel and chill and freeze room lower equipment cabinet access panelsper paragraph 6.18.

k. Return SSRU to service per paragraph 6.1.2.



6.20.9 Evaporator Coil Heater Replacement. The heater elements (figure 6-20) are not repairable and must be replacedif they malfunction. Before replacing the elements, verify continuity and function of the elements, and then replace elements ifnecessary, as directed in the following:

WARNING

Evaporator coil heater elements can be very hot and could cause severe burns if not sufficientlycooled. To prevent injury to personnel, exercise care in working near evaporator coil heatersand allow to cool thoroughly before replacing.

NOTEThere are 12 evaporator coil heater elements (figure 7-2, 3). Replacement of coil heater elements isidentical.


b. Remove upper equipment cabinet access panel located inside Control Panel per paragraph 6.18.

c. Tag and remove electrical connection to evaporator coil heater element (1).

d. Verify continuity and function of heater element as follows:

CAUTION

The heater element may be difficult to remove. Ensure the element is defective prior to removal,because excessive force may damage the element.

(1) Using a digital multimeter (DMM), verify continuity across the heater element leads.

(2) Verify insulation resistance by performing a 500 VDC insulation resistance test between the heater elementleads and housing (ground) to be greater than 10MΩ.

(3) If readings in step (1) or (2) are less than stipulated, proceed to step e. to replace the heater element. If theabove readings are acceptable, proceed to step h. below.

e. Remove three screws (2) and jumper wires on outboard side of evaporator coil, and gently pull heater element (1)from evaporator coil (3).

f. Install replacement heater element (1) with three screws (2).

g. Reconnect electrical connections to evaporator coil heater element (1).

h. Install upper equipment cabinet access panel located inside Control Panel per paragraph 6.18.






6.20.10 Drip Pan Heater Replacement. The heater elements (figure 6-20) are not repairable and must be replaced ifthey malfunction. Before replacing the elements, verify continuity and function of the elements, and then replace elements ifnecessary, as directed in the following:

WARNING

Drip pan heater elements can be very hot and could cause severe burns if not sufficiently cooled.To prevent injury to personnel, exercise care in working near drip pan heaters and allow to coolthoroughly before replacing.

NOTEThere are three drip pan heater elements (figure 7-2, 5). Replacement of drip pan heater elements isidentical.


b. Remove upper equipment cabinet access panel located inside Control Panel per paragraph 6.18.

c. Remove two nuts (4) and tag and remove electrical connections to drip pan heater element (5).

d. Verify continuity and function of heater element as follows:

(1) Using a digital multimeter (DMM), verify continuity across the heater element leads.

(2) Verify insulation resistance by performing a 500 VDC insulation resistance test between the heater elementleads and housing (ground) to be greater than 10MΩ.

(3) If readings in step (1) or (2) are less than stipulated, proceed to step e. to replace the heater element. If theabove readings are acceptable, proceed to step h. below.

e. Remove screw (6) and gently pull heater element from drip pan (7). Element is seated in bracket at far end of drippan.

f. Install replacement drip pan heater element with screw (6).

g. Reconnect electrical connections to drip pan heater element (5) and secure with two nuts (4).

h. Install upper equipment cabinet access panel located inside Control Panel per paragraph 6.18.


6.20.11 Drain Line and Trap Heater Replacement. To replace drip pan drain line and trap heater (figure 7-2, sheet 2,21; figure 6-21), proceed as follows:


b. Remove lower equipment cabinet access panel and chill and freeze room lower equipment cabinet access panelsper paragraph 6.18.

c. Open Control Panel and locate electrical wires from drain line heat tape (1) to control transformer No. 3 (TR3)per figure FO-2, sheet 2, and figure 2-1.



d. Tag and disconnect wires from heat tape (figure 6-21, 1).e. Remove heat tape (1) from drain line and trap (2).f. Install replacement heat tape to drain line and trap and connect electrical wires to control transformer No. 3

(TR3) per figure FO-2, sheet 2.g. Install lower equipment cabinet access panel and chill and freeze room lower equipment cabinet access panels

per paragraph 6.18.h. Return SSRU to service per paragraph 6.1.2.

6.20.12 Water Bypass/Diverter Valve Replacement. To replace water bypass/diverter valve (figure 7-4, sheet 2, 16;figure 6-22), proceed as follows:

NOTEReplacement of three water bypass/diverter valves is identical.

a. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.b. Remove lower equipment cabinet access panel (for bypass/diverter valve #2) and chill room lower equipment

access panel (for bypass/diverter valve #1) or freeze room lower equipment access panel (for bypass/divertervalve #3) per paragraph 6.18.



c. Secure ship water supply to SSRU and tag all control valves for chill water entering and leaving SSRU.

d. Place suitable container under valve to be replaced to catch water.

e. Remove nut (1), lever (2), two followers (3), two spring washers (4), and stop disk (5). Label and observe positionof stop disk plates and handle.

f. Remove four bolts (6) securing valve body (7) to bracket (8).

g. Remove twelve bolts (9) and lockwashers (10) securing the three chilled water pipe flanges (11) to valve body (7).Remove valve body (7) and gaskets (16, 17).

h. Connect the three chilled water pipe flanges (11) to valve body (7) with twelve lockwashers (10) and bolts (9).

i. Install replacement valve body (7) and gaskets (16, 17) to bracket (8) with four bolts (6).

j. Install handle and mounting hardware in reverse order of removal.

k. Restore ship water supply to SSRU and inspect valve for leaks.

l. Install lower equipment cabinet access panel and chill and freeze room lower equipment cabinet access panelsper paragraph 6.18.






6.20.13 Flow Switch Replacement. To replace flow switch (figure 7-4, sheet 2, 16A; figure 6-22), proceed as follows:


b. Remove chill and freeze room lower equipment cabinet access panels per paragraph 6.18.

c. Secure ship water supply to SSRU and tag all control valves for chill water entering and leaving SSRU.

d. Place suitable container under flow switch to be replaced to catch water.

e. Tag and remove electrical connections between Control Panel and flow switch (12).

f. Loosen two bolts (13) securing chill water outlet pipe (14).

g. Disconnect two union fittings (15) and remove flow switch (12) and O-rings (18) from chill water piping.

h. Install replacement flow switch (12) and O-rings (18) into chill water piping with two union fittings (15). Torqueunions to 25 to 60 ft-lbs.

i. Tighten two bolts (13), securing chill water outlet pipe (14).

j. Connect electrical connections to flow switch (12).

k. Restore ship water supply to SSRU and inspect switch for leaks.

l. Install lower equipment cabinet access panel and chill and freeze room lower equipment cabinet access panelsper paragraph 6.18.


6.20.14 Water Regulating Valve Replacement. To replace water regulating valve (figure 7-4, sheet 1, 5; figure 6-23),proceed as follows:

NOTEReplacement of two water regulating valves is identical.

a. Pump down SSRU per paragraph 2.3.1.2.

b. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.

c. Remove lower equipment cabinet access panel and chill room lower (for WRV #1) or freeze room for (WRV #2)lower equipment cabinet access panels per paragraph 6.18.

d. Secure ship water supply to SSRU and tag all control valves for chill water entering and leaving SSRU.

e. Place suitable container under valve to be replaced to catch water.

f. Close refrigerant shutoff valve (1) to the water regulating valve (2) actuator shutoff valve.

g. Disconnect refrigerant line flare fitting (3) from water regulating valve (2) actuator shutoff valve.

h. Remove nine bolts (4), washers (5), and locknuts (6) connecting chill water piping (7) to valve (2) and removevalve body and gaskets (9).





i. Install replacement valve and gaskets (9) in reverse order of removal.

j. Connect refrigerant line flare fitting (3) to water regulating valve (2) actuator shutoff valve.

k. Open refrigerant shutoff valve (1) to refrigerant line to water regulating valve (2).

l. Restore ship water supply to SSRU and inspect valve for leaks.

m. Verify valve adjustment per paragraph 6.17.

n. Install lower equipment cabinet access panel and chill and freeze room lower equipment cabinet access panelsper paragraph 6.18.

o. Return SSRU to service per paragraph 6.1.2.

6.20.15 Moisture Indicator/Sight Flow Indicator Replacement. If excessive water is present in the refrigerant thenthe indicator salts will dissolve causing permanent damage to the indicator. The indicator may remain yellow or white andwill require replacement. The indicator may also be damaged by the acid formed by a hermetic motor burnout and indicatorreplacement will be required.When a system is circulating an excessive amount of oil, the indicator may become saturated and appear brown or translucentand lose its ability to change color, but it is not permanently damaged. The circulating refrigerant will remove the excess oiland the indicator element will return to its proper color. Indicator replacement will not be required.To replace the element in the moisture indicator/sight flow indicator (figure 7-4, sheet 2, 8; figure 6-24, 1), proceed as follows:


NOTEReplacement of element in two moisture/sight flow indicators is identical.

b. Recover and evacuate SSRU refrigerant per paragraph 6.3.

c. Remove lower equipment cabinet access panel per paragraph 6.18.

d. Remove the plug (2) and replace the cylinder and indicator paper assembly (3).

e. Recharge HFC-134a refrigerant per paragraph 6.3.

f. Return SSRU to service per paragraph 6.1.2.





6.20.16 Refrigerant Component Replacement. The following procedures are general instructions for the replacement ofrefrigerant components. Repairs are to be made per NAVSEA 0900-LP-001-7000 and standard shop practices. Refrigerantmust be recovered from both systems before performing any hot work such as brazing. Refer to figure 6-25 for locationof components and service Schrader valves.

WARNING


a. The SSRU must be secured. If either plant is operating, it must be shut down and tagged OUT OF SERVICE perparagraph 6.1.1.

NOTERemove applicable access panels as follows depending on location of component.

b. Remove lower equipment cabinet access panels from chill room and freeze room per paragraph 6.18.

c. Remove upper equipment cabinet access panel from chill room per paragraph 6.18.

d. Remove upper equipment cabinet access panel from inside Control Panel per paragraph 6.18.

e. Remove lower equipment cabinet access panel from under Control Panel per paragraph 6.18.

f. Recover refrigerant per paragraph 6.3.1 and evacuate per paragraph 6.3.2.

g. Secure ship’s chill water supply to SSRU chill water and purge water piping completely before replacing condenser.

h. Remove all insulating materials before repair. Insulation of refrigerant lines shall be in accordance with MilitaryStandard MIL-STD-769.

i. All brazing shall be done in accordance with NAVSEA 0900-LP-001-7000.

j. Refrigerant liquid, suction and discharge lines are copper tubing ASTM-B88 type L.

k. When brazing valves, valve need not be disassembled unless otherwise instructed. Wrap valve with wet fabric toabsorb excess heat and ensure hand valves are disassembled or partially open. Also, ensure valve is positioned witharrow on valve body pointing in direction of flow.

l. Remove components by cutting and/or debrazing joints and adapters as appropriate to location or existing piping.

m. Refer to figure 6-25 for location of condensers, filter/dehydrators, and TXV.

n. Leak test per paragraph 6.3.5, evacuate per paragraph 6.3.2, and recharge HFC-134a refrigerant per paragraph 6.3.

o. Return SSRU to service per paragraph 6.1.2.











6.20.17 Control Circuit Fuse Checkout and Replacement. Refer to figure 2-1, sheet 2, 44 (TR1) and 42 (TR2). Seealso figure 7-3, sheet 2 and table 7-7. To verify fuse continuity proceed as follows:

a. Tag the SSRU out of service (paragraph 6.1.1).b. Open the control panel door.c. Locate the applicable fuse and remove the fuse from its holder.d. Using a digital multimeter (DMM), test the fuse for continuity.e. If the meter reads a value of 0.0 or 0.1 the fuse is good and is to be reinstalled in its holder. If the meter reads O.L.

(overload) or similar, the fuse is bad and should be replaced.f. Close the control panel door.g. Return the SSRU to service (paragraph 6.1.2).

6.20.18 Isolator Base Assembly Removal and Reinstallation. To remove and reinstall isolator base assembly (figure7-5), proceed as follows.

a. Secure SSRU unit and tag out of service per paragraph 6.1.1.b. Remove lower equipment cabinet access panel and chill and freeze room lower equipment cabinet access panels

per paragraph 6.18.c. Recover and evacuate HFC-134a refrigerant from both circuits per paragraph 6.3.d. Identify, tag and disconnect the electrical wires at the water flow switch (figure 6-25, sheet 2, 17).e. Secure the chill water to the RSS unit and disconnect inlet (figure 8-1, 2) and outlet unions (3).f. Identify, tag and disconnect the electrical wires at the compressor #1 junction box (figure 6-25, sheet 3, 27A).

Repeat for compressor #2 (sheet 4, 33).g. Identify, tag and disconnect the power wires between the crank case heater (figure 6-17, 1) for both compressors and

the auxiliary terminal box (figure 1-2, sheet 6, 35).h. Identify, tag and disconnect the isolator base grounding strap (figure 6-17, 5).i. Identify, tag and disconnect the power wires in the drain line heater junction box (8).j. Identify, tag and disconnect the high and low pressure capillary tube 1/4 inch flare connections from the rotalock

suction valve (figure 6-25, sheet 3, 24) and discharge valve (23) of compressor #1. Be very careful not to kinkthe capillary tubes. Loosely coil the tubing and tape them out of the way.

k. Identify, tag and disconnect the high and low pressure capillary tube 1/4 inch flare connections from the rotalocksuction valve (figure 6-25, sheet 4, 30) and discharge valve (29) of compressor #2. Be very careful not to kinkthe capillary tubes. Loosely coil the tubing and tape them out of the way.

l. Remove insulation and caulking from around the four refrigerant lines as they go through the pipe chase between theisolator base compartment and the evaporator coil compartment.

m. For unit #1, identify and tag the 7/8 inch suction line (figure 6-25, sheet 1, 6), and 3/8 inch discharge line (12).Identify and tag in two places for each tube, above the pipe chase and below the pipe chase.

n. For unit #2, identify and tag the 7/8 inch suction line (5), and 3/8 inch discharge line (13). Identify and tag in twoplaces for each tube, above the pipe chase and below the pipe chase.

o. Remove the tube clamps securing the refrigerant lines to the deck of the evaporator coil compartment.p. Working in the isolator base compartment, un-braze the four refrigerant tubes (5), (6), (12) and (13) at any convenient

joint near the overhead of the compartment. Apply heat to the joint while applying upward pressure from inside theevaporator coil compartment. Be careful not to damage any surrounding capillary tubes, wires or insulation.

q. Lift and support the refrigerant tubes in the evaporator coil section so they do not project down into the isolatorbase compartment.

r. Remove the four 5/8-11 bolts (figure 6-19, 3) and lock nut (7) holding the isolator base (1) to the isolator (2). Notethe orientation of the isolator spacer (5) between the top of the isolator (2) and the bottom of the isolator base (1).

s. Lift slightly and slide the isolator base out of its compartment. The isolator base with components and piping weighsapproximately 660 lbs and will require mechanical assistance. Be careful not to snag any of the capillaries orwiring disconnected previously.



t. Replace compressor(s), if necessary, in accordance with paragraph 6.20.7.

u. Replace isolators, if necessary, in accordance with paragraph 6.20.8. Install chilled water inlet (figure 8-1, 2) andoutlet (3) unions. Torque to 25 to 60 ft-lbs.

v. Re-assemble in reverse order. All brazing shall be done in accordance with NAVSEA 0900-LP-001-7000.Refrigerant suction and discharge lines are copper tubing ASTM-B88 Type L.

w. Be careful to connect the refrigerant lines, capillaries, and wiring to the correct location.

x. Leak check re-assembled pipe joints in accordance with paragraph 6.3.5.

y. Evacuate both refrigerant circuits in accordance with paragraph 6.3.2.

z. Add refrigerant to both circuits in accordance with paragraph 6.3.3.

aa. Restore SSRU to service in accordance with paragraph 6.1.2.

6.21 DOOR REPAIR.Repairs to the chill room and freeze room door hardware and associated electrical circuits are described in the followingparagraphs. Refer to figure 6-26 and parts listing in table 7-3.

6.21.1 Door Heater Replacement. To replace door heater (figure 6-26), proceed as follows:


b. Remove two screws (1) from cover (2) of heater controller (3).

c. Tag and disconnect electrical wires to heater controller.

d. Remove two screws (4) and heater controller (3).

e. If necessary to replace sill heater element (16), remove 44 screws (5) and sill plate assembly(6).

f. Remove sill heater element (16) and replace.

g. Install sill plate assembly (6) with Dow Corning 732 adhesive (aluminum colored) per MIL-A-46106.

h. Install 44 screws (5) and sill plate assembly (6).

i. Install replacement heater controller (3) with two screws (4).

j. Connect electrical wires to heater controller (3) and install cover (2) with two screws (1).

k. Return SSRU to service per paragraph 6.1.2.

6.21.2 Door Hinge Replacement. To replace door hinges (figure 6-26), proceed as follows:

a. Remove four screws (7) from hinge (8) and door (9).

b. Remove six screws (7) securing hinge (8) to door frame (10).

c. Install replacement hinge (8) to door (9) with ten screws (7).



6.21.3 Door Latch and Strike Plate Replacement. To replace door handle striker and latch plate (figure 6-26),proceed as follows:

a. Remove six screws (11) securing door handle and striker (12) to door (9).

b. Remove three screws (11) securing inner handle (13) to door (9) and remove door handle and striker (12) andinner handle with through-rod from door.

c. Remove four screws (11) to remove latch (14) from door frame (10).

d. Install replacement door handle, striker and latch plate in reverse order of removal.

6.21.4 Door Gasket Replacement. To replace door gaskets (figure 6-26, 15), inspect gaskets for tears or deterioration,remove defective gaskets, cut replacement gaskets to fit and install with BOSTIK 1142M per MMM-A-121 or equivalent.

6.21.5 Door Adjustment. Perform door adjustment in accordance with the following (refer to figure 6-26).

NOTEA properly adjusted door makes contact with the door gasket all around the perimeter. When the dooris closed, proper compression should not allow for a piece of paper to be slid between the door gasketand doorjamb. When a piece of paper is closed in the door between the door gasket and doorjamb,proper compression should allow for the piece of paper to be removed with slight resistance.Do not compress the gasket more than necessary. Excessive compression may make the door difficultto close and may cause excessive gasket wear.

a. To adjust the gasket compression along the latch side of door (figure 6-26) proceed as follows:

(1) To increase compression, turn latch adjusting screw (18) clockwise to move pawl (20) in towards the doorframethus increasing gasket compression.

(2) To decrease compression, turn latch adjusting screw (18) counterclockwise to move pawl (20) out fromthe doorframe thus decreasing gasket compression.

b. To adjust the gasket compression along the hinge side of the door (figure 6-26) proceed as follows:

(1) To increase compression, it will be necessary to remove shim(s) (19) from behind the hinge butt plate (8) on thedoorjamb. Do this one hinge and one shim at a time. Remove the three screws (7) holding the hinge butt plate(8). One of the three screws is underneath the hinge. It will be necessary to open the door to gain access.One person should hold and support the door when the door is open to prevent damage to the door or hinge.Slide the shim package (19) from behind the butt plate (8). Peel off one of the stacked shims (19), replace theremaining stack of shims back behind the hinge butt plate (8). Replace the three screws (7) into the hinge buttplate (8) and tighten. Repeat this process for the other hinge if necessary.

(2) To increase compression along the hinge for the other door repeat step (1).

(3) To decrease compression, it will be necessary to remove shim(s) (19) from behind the hinge butt plate (8) onthe doorjamb. Do this one hinge and one shim at a time. Remove the three screws (7) holding the hinge buttplate (8). One of the three screws is underneath the hinge. It will be necessary to open the door to gain access.One person should hold and support the door when the door is open to prevent damage to the door or hinge.Slide the shim package (19) from behind the butt plate (8). Add one shim (19), replace the remaining stack ofshims back behind the hinge butt plate (8). Replace the three screws (7) into the hinge butt plate (8) and tighten.Repeat this process for the other hinge if necessary.

(4) To decrease compression along the hinge for the other door repeat step (3).

6.22 CHILL AND FREEZE ROOM REPAIR.

6.22.1 Bulkhead Batten Replacement. Aluminum battens are located on 10-inch centers on freeze and chill roombulkheads. To remove bulkhead batten from chill room or freeze room bulkhead, remove attaching screws, washers, and nylonwashers from aluminum spacers. Typical attaching hardware is located every 8 to 10 inches along length of batten. Battens arealso attached to access panels. See figure 6-27 and associated parts listing in table 7-2.



6.22.2 Floor Grating and Ceiling Grating Replacement. To replace floor and ceiling grating (figure 6-28), proceed asfollows:

a. Remove and replace floor grating per position diagram in figure 6-28.

b. Remove and install 6-inch ceiling grating sections (3) by removing two screws (1) from each end of each gratingsection and removing from aluminum angle (2) welded to bulkheads.

6.22.3 Freeze Room Inlet Screen and Evaporator Coil Inlet Damper Replacement. To replace evaporator coil inletdamper, remove bolts (figure 7-2, sheet 2, 17A) securing screen (17) to equipment cabinet and remove bolts (17A) securingdamper (18) to equipment cabinet opening. Installation is the reverse of removal.

6.22.4 Evaporator Fan Outlet Damper Replacement. To replace evaporator fan outlet dampers, proceed as follows:


b. In chill room, remove upper equipment cabinet access panel per paragraph 6.18.

c. Remove fan motors and mount assemblies per paragraph 6.20.4.

d. Remove bolts securing damper to equipment cabinet opening.

e. Install replacement adapter.



f. Install fan motor and mount assembly per paragraph 6.20.4.

g. In chill room, install upper equipment cabinet access panel per paragraph 6.18.

h. Return SSRU to service per paragraph 6.1.2.



6.22.5 Floor Drain Plate Replacement. To replace floor drain plate (figure 7-1, sheet 1, 7; figure 6-29) in either freezeroom or chill room, proceed as follows:

a. Remove floor grate as necessary per paragraph 6.22.2.b. Remove six screws (1) and floor drain plate (2).c. Install replacement floor drain plate with six screws.d. Install floor grate per paragraph 6.22.2.

6.22.6 Light Switch Replacement. To replace chill room or freeze room light switch (figure 7-1, sheet 1, 14), proceed asfollows:

a. Shut down SSRU and tag OUT OF SERVICE per paragraph 6.1.1.b. Remove two screws and light switch cover.c. Tag and disconnect wires from light switch.d. Remove jam nut and switch body from switch box.e. Connect wires to replacement switch body.f. Install switch into switch box with jam nut.g. Install two screws and light switch cover to switch box.h. Return SSRU to service per paragraph 6.1.2.

6.22.7 Light Replacement. To replace chill room or freeze room lights (figure 7-1, sheet 1, 13), proceed as follows:NOTE

It is necessary that replacement room lights not exceed the recommended wattage in order that thecontrol transformer is not overloaded. An overload could result in a blown fuse, and disablingof the control transformer.

a. Remove ceiling grating adjacent to light to be removed per paragraph 6.22.2.b. Remove lamp guard (figure 7-1, sheet 2, 13A).



c. Remove lamp globe (13B).

d. Remove light bulb (13C).

e. Install replacement light bulb (13C).

f. Install lamp globe (13B) and guard (13A).

g. Replace ceiling grating per paragraph 6.22.2.

6.22.8 Chill Room and Freeze Room Caulk Repair. To repair caulk on bulkhead seams in chill room or freeze room,proceed as follows:

CAUTION

Ceiling joints shall not be caulked so that moisture can escape if necessary. Repeated freezing andthawing of accumulated moisture could result in frostheaving which could damage panels.

NOTEThe chill rooms and freeze rooms on some ships may have welded bulkhead seams and will notrequire caulking.


b. Remove produce from SSRU as necessary.

c. Allow chill room or freeze room wall to warm to 50°F.

d. Remove broken or damaged caulk from area to be repaired and clean thoroughly.

e. Recaulk seam using Dow Corning 732 multi-purpose sealant, clear, (MIL-A-46106, group 1, type 1) or equivalentper manufacturer’s instructions. Ensure that adequate ventilation is present and allow to cure thoroughly.


6.22.9 Chill Room and Freeze Room Pressure Equalization Valve (PEV) Replacement. To replace the chill room orfreeze room pressure equalization valve (PEV) (figure 7-1, sheet 1, 2) proceed as follows:


b. Remove the three screws (figure 7-1, sheet 2, 2A) securing the PEV cover plate (2B).

c. Pull out the valve body and cut the electrical leads to the heating element.

d. Replace the valve and rewire the electrical leads to the valve heating element.

e. Secure the cover plate (2B) using the screws (2A) removed previously.




CHAPTER 7

PARTS LIST

7.1 INTRODUCTION.This chapter consists of tabular listings that locate and identify all repair parts required for the level of maintenance covered bythis technical manual. The listings are cross referenced to provide access to the part locator drawing. The parts list eitherreferences or includes illustrations that show the location of repair parts.

7.2 LIST OF MAJOR COMPONENTS.Table 7-1 is a list of major components for the Ship Stores Refrigeration Unit (SSRU). It references the Parts List tableswhere the component parts are listed.

Table 7-1. Major Components

Part Number Qty. Nomenclature Reference

1298-00-D 1 REFRIGERATION UNIT, SHIP STORES Table 7-2

48-000-001 (LEFT HAND)48-000-002 (RIGHT HAND)

2 DOORS AND ASSOCIATED PARTS Table 7-3

1298-10-D 1 CABINET ASSEMBLY, REFRIGERATION UNIT Table 7-4

(VARIOUS) 2 FANS/MOTORS AND ASSOCIATED PARTS Table 7-5

(VARIOUS) 1 CHILL ROOM DAMPER/ACTUATOR ANDASSOCIATED PARTS

Table 7-6

1298-20-D 1 ELECTRICAL ASSEMBLY, REFRIGERATIONUNIT

Table 7-7

1298-30-D 1 PIPING ASSEMBLY, REFRIGERATION UNIT Table 7-8

1298-40-D 1 ISOLATOR BASE ASSEMBLY, REFRIGERATIONUNIT

Table 7-9

Marlo Coil 700-000-305 1 REFRIGERATION CHARGING AND TEST KIT,INCLUDING CYLINDER ADAPTER, YELLOWJACKET 19105

Table 1-2

7.3 PARTS LISTS.Table 7-2, table 7-3, table 7-4, table 7-5, table 7-6, table 7-7, table 7-8, and table 7-9 identify and describe repair parts forthe various assemblies and subassemblies in the SSRU. Illustrations for the repair parts are cross referenced to the parts listby means of a Figure and Index Number. The Figure number, Sheet Number and Index Number indicate the first sheet onwhich the part is located.Order package or piece parts as indicated. Items supplied by manufacturers other than Marlo are listed by the manufacturer’spart number. Manufacturers are identified by a Commercial and Government Entity (CAGE) code in accordance withHandbook H4/H8. The entry NO NUMBER indicates that the assembly/part has no identified applicable part number. Shouldsuch a part have to be ordered, the order/request should include all the data in the description column. The manufacturers namesand addresses are provided in paragraph 7.4. Requests for parts should include, as applicable, the information listed below.

a. Serial number and model number of component. Obtain from component nameplate and quote accurately.

b. Part number as shown in the table.



c. Name and description information as shown in the table.

Table 7-2. Ship Stores Refrigeration Unit

Figure (Sheet)/Index No. Description Qty. CAGE

ManufacturersPart No.

7-1(1)/1 STOREROOM ASSEMBLY, REFRIGERA-TION UNIT

1 38450 1298-00

7-1(1)/2 VALVE, HEATED, PRESSUREEQUALIZATION

2 NONE4 1830

7-1(2)/2A SCREWS, PRESSURE EQUALIZATIONVALVE COVER (PROVIDED WITH ITEM7-1(1)/2)

3 (PERVALVE)

NONE4 (PART OF 1830)

7-1(2)/2B COVER, PRESSURE EQUALIZATIONVALVE (PART OF ITEM 7-1(1)/2)

1 (PERVALVE)

NONE4 (PART OF 1830)

7-1(1)/3 DOOR ASSEMBLY-LEFT HAND SWING(SEE TABLE 7-3)

1 31670 48-000-001

7-1(1)/4 HEATER, DOOR DEFROST 2 31670 BY-18

7-1(1)/5 PANEL, ACCESS, LOWER EQUIPMENTCABINET

1 38450 1298-07-A

7-1(1)/6 DOOR ASSEMBLY-RIGHT HAND SWING(SEE TABLE 7-3)

1 31670 48-000-002

7-1(1)/7 DRAIN ASSEMBLY, DECK 2 96169 NO NUMBER

7-1(1)/8 PANEL, ACCESS, SHIP SYSTEMS 6 38450 1298-07-B

7-1(1)/9 CABINET ASSEMBLY (SEE TABLE 7-4) 1 38450 1298-10-D

7-1(1)/10 REFRIGERATION PLANT (SEE TABLE 7-8) 1 38450 1298-30-D

7-1(1)/11 ISOLATOR BASE ASSEMBLY (SEE TABLE7-9)

1 38450 1298-40-D

7-1(1)/12 CONTROL PANEL (SEE TABLE 7-7) 1 38450 1298-20-D

7-1(1)/13 FIXTURE, LIGHT WITH GUARD 4 75282 NVX15GG

7-1(2)/13A GUARD, LIGHT (PROVIDED WITH ITEM13)

4 75282 (PART OFNVX15GG)

7-1(2)/13B GLOBE, GLASS 4 75282 VCGP-100

7-1(2)/13C LAMP, INCANDESCENT A19, 40A/S-130V 4 25795 1E329

7-1(1)/14 BOX, CONTROL STATION 2 75282 PWB-4

(NOTSHOWN)/14A

COVER, BOX, CONTROL STATION 2 75282 PWC-11

(NOTSHOWN)/14B

SWITCH, SELECTOR, 2 POSITION 2 75282 WCD5-2A3F

(NOTSHOWN)/14C

CONTACT BLOCK, 1 NO, 1 NC 2 56365 KA1-Y238

(NOTSHOWN)/14D

NAMEPLATE, ON OFF 2 75282 16156AAAB

7-1(1)/15 DOOR HOOK, BRACKET, AND STOPASSEMBLIES (SEE TABLE 7-3)

2 31670 (TABLE 7-3)



Table 7-2. Ship Stores Refrigeration Unit (Cont.)



7-1(1)/16 BATTENS AND ASSOCIATED FASTENERS -- -- --

NOTEREFER TO FIGURE6-27 AND THEFOLLOWING FORTYPICAL BATTENCONFIGURATIONS.

6-27/1 BATTEN, 1/4” THICK X 1-1/2” ALUMINUMBAR, 65.250 LG

35 38450 1298-08-51


4 38450 1298-08-55


6 38450 1298-08-57


18 38450 1298-08-61


12 38450 1298-08-52


18 38450 1298-08-59


5 38450 1298-08-60

6-27/8 BOLT, HEX HEAD (AR = AS REQUIRED) AR (510TOTAL)

38450 13-005-060

6-27/9 WASHER, FLAT, 3/8” SST AR (510TOTAL)

38450 13-175-017

6-27/10 WASHER, NYLON, 3/8” (MCMASTER-CARR #90205A170)

AR (550TOTAL)

39248 13-175-097

6-27/11 SPACER, 1” DIA ROUND X 0.750” LG.,ALUMINUM, MACHINED

AR (510TOTAL)

38450 1298-08-50

6-27/12 NUT, SPLINED, BLIND RIVET, OPEN END AR (510TOTAL)

38450 13-121-015



Table 7-3. Doors and Associated Parts (See Figure 6-26)



DOOR ASSEMBLY, PLYFORMSHIPSTORES FREEZER DOOR, REFDOC L173001, OPENING 1’ 6-1/2” WX 3’-2”H

1 31670 48-000-001 (LEFTHAND)48-000-002 (RIGHTHAND)

7-1(1)/3 (LEFTHAND) AND7-1(1)/6(RIGHTHAND)

NOTEAS INDI-CATEDBELOW,SOME ITEMSHAVE NOSEPARATEPART NUM-BER ANDARE PRO-VIDED ASPART OF ANASSEMBLYRATHERTHAN INDI-VIDUALLY.QUANTITIESLISTEDBELOW AREPER DOOR.

6-26/1 SCREW (PROVIDED WITH HEATERCONTROLLER, ITEM 3)

2 31670 (PART OF BY-18)

6-26/2 COVER (PROVIDED WITH HEATERCONTROLLER, ITEM 3)

1 31670 (PART OF BY-18)

6-26/3 HEATER CONTROLLER 1 31670 BY-18

6-26/4 SCREW (PROVIDED WITH HEATERCONTROLLER, ITEM 3)

2 31670 (PART OF BY-18)

6-26/5 SCREW (PROVIDED WITH DOORASSEMBLY ITEM 7-1(1)/3, LH, OR7-1(1)/6, RH)

20 31670 (PART OF 48-000-001/002)

6-26/6 SILL PLATE (PROVIDED WITHDOOR ASSEMBLY ITEM 7-1(1)/3 ORITEM 7-1(1)/6, RH)

1 31670 (PART OF 48-000-001/002)


20 31670 (PART OF 48-000-001/002)

6-26/8 HINGE 2 31670 431-150 (LEFT HAND)431-151 (RIGHT HAND)

6-26/9 DOOR (PROVIDED WITH DOORASSEMBLY ITEM 7-1(1)/3, LH, ORITEM 7-1(1)/6, RH)

1 31670 (PART OF 48-000-001/002)



Table 7-3. Doors and Associated Parts (See Figure 6-26) (Cont.)



6-26/10 FRAME (PROVIDED WITH DOORASSEMBLY ITEM 7-1(1)/3, LH, OR7-1(1)/6, RH)

1 31670 (PART OF 48-000-001/002)


6 31670 (PART OF 48-000-001/002)

6-26/12 HANDLE AND STRIKER ASSEMBLY 1 31670 4191-001-04

6-26/13 INNER HANDLE 1 31670 441-259

6-26/14 LATCH (ONLY AVAILABLE AS PARTOF ITEM 6-26/12)

1 31670 PART OF 4191-001-04

6-26/15 GASKET, HI-LO TEMP 1 31670 512-006

6-26/16 DOOR STOP ASSEMBLY (A = WALLPORTION, B = DOOR

1 38450 1298-09-A/1298-09-A/B

6-26/17 DOOR HOOK AND BRACKET 1 38450(31670)

48-000-083 (4127)

6-26/18 ADJUSTMENT SCREW 1 31670 441-227

6-26/19 SHIMS (FOR HINGE BUTT), 1/32INCH

AS REQUIRED 31670 431-156

6-26/20 PAWL (LATCH TONGUEASSEMBLY)

1 31670 441-253

6-26/21 HEATER ELEMENT (HEATERCABLE), 145 WATT, 1.2AMP, BY-18

18 FTLENGTH

31670 122-115

6-26/22 DOOR BRACKET 1 31670 48-000-004

Table 7-4. Cabinet Assembly



7-2(1)/1 DAMPER, CHILL ROOM, ALUMINUM (SEETABLE 7-6)

1 34081 24-070-020 (CD50 10 WX 5 H)

7-2(1)/2 DAMPER, OUTLET 2 NONE3 3200 17IN X 17IN

7-2(1)/3 HEATER, DEFROST-EVAPORATOR COIL 12 74924 519X-180429

7-2(1)/4 PAN, DRAIN 1 38450 1298-13

7-2(1)/5 HEATER, DRAINPAN, 500 W, U-BEND 3 74924 511X-180428

7-2(1)/6 PANEL, ACCESS, ISOLATOR BASE 2 38450 1298-14

7-2(1)/7 VALVE, SOLENOID 2 78462 ESS 130

7-2(1)/7A COIL, REPLACEMENT 2 78462 MKC-1-120/60

7-2(1)/8 COIL EVAPORATOR ASSEMBLY 1 38450 1298-31

7-2(1)/9 MOTOR, ALTERNATING CURRENT 2 57368 MR1035

7-2(1)/10 PANEL, ACCESS, FAN 1 38450 1298-12



Table 7-4. Cabinet Assembly (Cont.)



7-2(1)/11 PLATE ASSEMBLY, COVER, DAMPERACTUATOR

1 38450 1298-16

7-2(2)/12 ACTUATOR, DAMPER (SEE TABLE 7-6) 1 0WFS5 24-070-21(LS-240 US)

7-2(2)/13 MOUNT RESILIENT 8 81860 11M15

7-2(2)/14 FAN, 16 IN DIA, 8 BLADE (SEE TABLE 7-5) 2 63988 16-8-3R-PAG-35-A

7-2(2)/15 TAPERED BUSHING, MARTIN JA-5/8 2 38450 JA-5/8

7-2(2)/16 MOUNTING ASSEMBLY (FRAME, FANVENTURI, 16 IN.)

2 38450 1298-17

7-2(2)/17 SCREEN, AIR 1 38450 1298-15

7-2(2)/17A BOLTS, HEX, SERRATED HEAD, 1/4-20 X 1,SST 34

12 38450 13-010-085

7-2(2)/17B TAPE, INSULATION, PLASTIC 30 FT 38450 11-400-057

7-2(2)/18 DAMPER, INLET 2 NONE3 3200 19IN X 27.23IN

7-2(2)/19 CABINET 1 38450 1298-10

7-2(2)/20 VALVE, THERMAL EXPANSION 2 78462 EMCE-23-JC

7-2(2)/21 HEATER, DRAIN LINE, 10 FT. 1 65586 SRL3-1-CT

7-2(2)/21A POWER CONNECTION, DRAIN LINE 1 65586 RTPC

7-2(2)/21B END SEAL, HEATER 1 65586 RTES

7-2(1)/22 VALVE, 1/4” (SCHRADER VALVE) 2 08885 CD8404/VAX-4

Table 7-5. Fans/Motors and Associated Parts (See Figure 6-15)



6-15/1 BOLT, HEX HEAD, 1/4-20 X 2-1/4, SST 8 38450 13-005-022

NOTEAS INDICATEDIN THIS TABLE,SOME ITEMSHAVE NOSEPARATE PARTNUMBER ANDARE PROVIDEDAS PART OFAN ASSEMBLYRATHER THANINDIVIDUALLY.

6-15/2 SPACER (ISOLATOR), #11M51,MIL-M-19379

8 18444 30-040-12



Table 7-5. Fans/Motors and Associated Parts (See Figure 6-15) (Cont.)



6-15/3 LOCKNUT, NYLON INSERT, 1/4-20, SST,ASTM A563

8 38450 13-127-014

6-15/4,7-2(2)/16

MOUNTING ASSEMBLY (FRAME, FANVENTURI 16 IN.)

2 38450 1298-17

6-15/5 SCREW (PART OF MOTOR, ITEM 7) 4 (PERMOTOR) 57368 (PART OF28-035-015)

6-15/6 COVER (PART OF MOTOR, ITEM 7) 1 (PERMOTOR) 57368 (PART OF28-035-015)

6-15/7 FAN MOTOR, 1 HP, 1750 RPM,MIL-M-17059

2 57368 28-035-015

6-15/8 COTTER PIN, 1/8 X 1-1/4 LONG,STAINLESS STEEL

2 38450 13-205-025

6-15/9 NUT, CASTLE, 5/8-11 UNC STAINLESSSTEEL

2 38450 13-106-060

6-15/10 SHAFT (PART OF MOTOR, ITEM 7) 1 (PERMOTOR) 57368 (PART OF28-035-015)

6-15/11 SCREW (PART OF BUSHING, ITEM 12) 2 38450 (PART OF JA-5/8,16-038-015)

6-15/12,7-2(2)/15

TAPERED BUSHING, MARTIN JA-5/8 2 38450 JA-5/8 (16-038-015)

6-15/13,7-2(2)/14

FAN, 16 IN. DIA, 8 BLADE 2 63988 16-8-3R-PAG-35-A

6-15/14 BOLT, MACHINE, HEX HEAD, 5/16–18X 1 LONG, SST

4 38450 13-005-040

6-15/15 LOCKNUT, NYLON INSERT, 5/16-18,SST, ASTM A563

4 38450 13-127-021



Table 7-6. Chill Room Damper/Actuator and Associated Parts (See Figure 6-16)



6-16/1 SCREW, MACHINE, #10-24 X 1/2” LG,RH, PHILLIPS, SST

10 38450 13-015-026

NOTEAS INDICATEDIN THIS TABLE,SOME ITEMSHAVE NOSEPARATE PARTNUMBER ANDARE PROVIDEDAS PART OFAN ASSEMBLYRATHER THANINDIVIDUALLY.

6-16/2, 7-2(1)/11 PLATE ASSEMBLY, COVER, DAMPERACTUATOR

1 38450 1298-16

6-16/3, 7-2(1)/12 ACTUATOR, DAMPER 1 34081(0WFS5)

24-070-21(LS-240 US)

6-16/4 BOLT, HEX HEAD, 1/4-20 X 2-1/4, SST 3 38450 13-005-022

6-16/5 LOCKNUT, NYLON INSERT, 1/4-20, SST,ASTM A563

3 38450 13-127-014

6-16/6 BRACKET, MAKE FROM SHEET 14 GA,(0.75) 304 SST, ASTM A240, 4.000 W X17.440 L

1 38450 1298-16-02

6-16/7 NUT, V-BOLT (PROVIDED WITHACTUATOR, ITEM 3)

2 34081(0WFS5)

(PART OF24-070-21/LS-240US)

6-16/8, 7-2(1)/1 DAMPER, CHILL ROOM, ALUMINUM 1 34081 24-070-020(CD5010 W X 5 H)

6-16/9 SHAFT, ACTUATOR ROD, 13.500 LG(PART OF DAMPER, ITEM 8)

1 34081 (PART OF24-070-20)

6-16/10 UNIVERSAL CLAMP (PROVIDED WITHACTUATOR, ITEM 3)

1 34081(0WFS5)

(PART OF24-070-21/LS-240US)

6-16/11 RETAINING CLIP (PROVIDED WITHACTUATOR, ITEM 3)

1 34081(0WFS5)

(PART OF24-070-21/LS-240US)

6-16/12 CABLE FITTING (PROVIDED WITHACTUATOR, ITEM 3)

2 34081(0WFS5)

(PART OF24-070-21/LS-240US)



Table 7-7. Control Panel



7-3(1)/1 LIGHT, INDICATOR 12 56365 9001-SKT1

7-3(1)/2 LAMP, INCANDESCENT 14 08806 755

7-3(1)/3 NUT, RING 19 56365 9001K49

7-3(1)/4 LENS, LIGHT-GREEN 6 56365 9001G-9

7-3(1)/5 LENS, LIGHT-WHITE 1 56365 9001W-9

7-3(1)/6 LENS, LIGHT-BLUE 1 56365 9001L-9

7-3(1)/7 LENS, LIGHT-RED 3 56365 9001R-9

7-3(1)/8 LENS, LIGHT-AMBER 4 56365 9001A-9

7-3(1)/9 METER, TIME TOTALIZING 3 14907 635K

7-3(1)/10 LIGHT, INDICATOR-FLASHING 1 56365 9001-SKTF1

7-3(1)/11 LAMP, INCANDESCENT 1 0EE74 267

7-3(1)/12 LIGHT, INDICATOR 2 56365 9001-SKT5

7-3(1)/13 TIMER, STOP 2 08887 365A300Q30PX

7-3(1)/14 STRAP, THERMOSTAT 2 38450 1298-21-04

7-3(1)/15 THERMOSTAT 2 0T4J0 D85123-0

7-3(1)/16 SWITCH ASSEMBLY 1 56365 9001-SKR2BH6

7-3(1)/17 SWITCH ASSEMBLY 1 56365 9001-SKR3YH5

7-3(1)/18 SWITCH ASSEMBLY 1 56365 9001-SKR24GH5

7-3(1)/19 SWITCH, ROTARY 1 01121 800H-JR2KD7BBMM

7-3(2)/20 RELAY, ELECTROMAGNETIC 2 53010 RLM911

7-3(2)/21 TERMINAL BOARD 1 26405 1423122

7-3(2)/22 FUSE HOLDER 1 75915 LJ60030-3S

7-3(2)/23 FUSE, CARTRIDGE-TIME DELAY 3 75915 JTD 30 ID

7-3(2)/24 FUSE, CARTRIDGE 2 75915 312-375

7-3(2)/25 FUSEHOLDER, BLOCK 1 75915 354 802-GY

7-3(2)/26 FUSE, CARTRIDGE 6 75915 KLK2

7-3(2)/27 FUSEHOLDER, BLOCK 2 75915 L60030M-3SQ

7-3(2)/28 TERMINAL BOARD 7 58536 AA59125/2117TB10F

7-3(2)/29 TERMINAL BOARD 2 58536 AA59125/104TB08F

7-3(2)/30 SWITCH, HIGH PRESSURE 2 NONE1 60-2065

7-3(2)/31 SWITCH, LOW PRESSURE 2 NONE1 60-2063



Table 7-7. Control Panel (Cont.)



7-3(2)/32 TIMER, SHORT CYCLE 2 53010 TL120A5T

7-3(2)/33 CONTACTOR, MAGNETIC 1 56365 8502-SBO2V02S

7-3(2)/34 INTERLOCK, INTERNAL 5 56365 9999SX11

7-3(2)/35 INTERLOCK, INTERNAL 3 56365 9999SX12

7-3(2)/36 PLATE, MOUNTING, ELECTRICAL(PART OF ENCLOSURE, ITEM 38)

1 38450 1298-21-02

7-3(2)/37 PANEL, COIL/HEATER ACCESS 1 38450 1298-22

7-3(2)/38 ENCLOSURE, CONTROL PANEL 1 38450 1298-21

7-3(2)/39 TRANSFORMER, POWER 3 56365 9070-TF350D1

7-3(2)/40 FUSE, CARTRIDGE 3 75915 KLDR 5

7-3(2)/41 FUSE, CARTRIDGE 6 75915 KLDR-2.0

7-3(2)/42 UNIT, THERMAL OVERLOAD 6 56365 B17-5

7-3(2)/43 STARTER, MOTOR 2 56365 8536-SBO2V02S

7-3(2)/44 CONTACTOR, MAGNETIC 2 56365 8502-SAO12V02S

7-3(2)/45 RELAY-TIME DELAY 1 25795 2A562

7-3(2)/46 RELAY, ELECTROMAGNETIC, 4 POLE 5 56365 8501XOOO-V02

7-3(2)/47 STANDARD CONTACT CARTRIDGE 15 56365 XC1

7-3(2)/48 OVERLAPPING CONTACT CARTRIDGE 1 56365 XC2

7-3(3)/49 SENSOR, TEMPERATURE 2 58989 56422-1231

7-3(3)/50 ENCLOSURE, NEMA 4X, 8” X 6” X 4” 1 57403 BN4080604CHSS

7-3(3)/51 PANEL, INTERIOR, 6-3/4” X 4-7/8” 1 57403 P0806

7-3(3)/52 THERMOSTAT, DEFROST TERMINA-TION

1 50992 060-100

7-3(3)/53 THERMOSTAT, HIGH DEFROSTTEMPERATURE

1 50992 060-100

6-13 CORD GRIP/STUFFING BOX ANDCABLE CLAMP PARTS (REF FIGURE6-13)

- - -

6-13/1 CLAMP, NYLON, NATURAL(CLOSED DIA., 0.547), #W6NY-562-9(CATAMOUNT)

36 65664 45-125-022

6-13/2 SCREW, MACHINE, #10-32 X 3/4” LG,RH, PHILLIPS, SST

24 38450 13-015-041

6-13/3 LOCKWASHER, STAR, #10, SST 24 38450 13-170-027

6-13/4 WASHER, FLAT, #10, SST 24 38450 13-175-015

6-13/5 NIPPLE, PVC PIPE, 1” MPS X 6.000 LG,1” NPT EACH END

5 38450 16-176-200



Table 7-7. Control Panel (Cont.)



6-13/5 NIPPLE, PVC PIPE, 3/4” MPS X 6.000 LG,3/4” NPT EACH END

10 38450 16-176-201

6-13/5 NIPPLE, PVC PIPE, 1/2” MPS X 6.000 LG,1/2” NPT EACH END

10 38450 16-176-202

6-13/6 GRIP, CORD, WET LOCATION, 1” MALE(0.625 - 0.750 DIA. CORD)

2 38450 45-028-041

6-13/6 GRIP, CORD, WET LOCATION, 3/4”MALE (0.375 - 0.500 DIA. CORD)

15 38450 45-028-025

6-13/6 GRIP, CORD, WET LOCATION, 1/2”MALE (0.375 - 0.500 DIA. CORD)

30 38450 45-028-045

6-13/7 PIPE COUPLING, PVC, 1” FPT, #4596K54 5 38450 16-050-001

6-13/7 PIPE COUPLING, PVC, 3/4” FPT,#4596K53

10 38450 16-050-002

6-13/7 PIPE COUPLING, PVC, 1/2” FPT,#4596K52

10 38450 16-050-003

6-13/8 FITTING, BULKHEAD, 1”, PVC SOCKETX NPT FEMALE, #36895K113

5 38450 45-082-002

6-13/8 FITTING, BULKHEAD, 3/4”, PVCSOCKET X NPT FEMALE, #36895K112

10 38450 45-082-001

6-13/8 FITTING, BULKHEAD, 1/2”, PVCSOCKET X NPT FEMALE, #36895K111

13 38450 45-082-000

Table 7-8. Refrigeration Plant



7-4(1)/1 VALVE, 3-WAY, WATER REGULATING, 1/2”(LR)

1 21013 M700P-50FL-3W

7-4(1)/1A GASKET (FOR ITEM 1), RED RUBBER, AMSZZR765

3 21013 11-250-040

7-4(1)/2 COMPRESSOR, SCROLL 2 14569 ZS38K4E

7-4(1)/3 CONDENSER, FLAT 2 NONE2 C2A

7-4(1)/4 RECEIVER, REFRIGERANT, VERTICAL 2 94112 ARL2077

7-4(1)/5 VALVE, SHUTOFF 2 28193 6231N

7-4(1)/5A,7-4(2)/5A

VALVE, SCHRADER, WITH TEE, 1/4” FLARE,AS SHOWN IN DETAIL IN FIGURE 6-23.

2 38450 16-230-036

7-4(1)/6 VALVE, 3-WAY, WATER REGULATING, 1/2”(UL/UR)

1 21013 M700P-50FL-3W

7-4(1)/6A GASKET (FOR ITEM 6), RED RUBBER AMSZZR765

3 21013 11-250-040



Table 7-8. Refrigeration Plant (Cont.)



7-4(1)/7 VALVE, BALL, BYPASS, CHILL WATER, 180DEG TURN, 3 POSITION, FLOW PATTERN 5,OPTIONS B7-H8-1H-2S-A0-1P

1 92021 1 IN IPS-MN-34-SB(1)-2-P0-C0

7-4(1)/8 INDICATOR, SIGHT, LIQUID 2 78462 SA-13S

(NOTSHOWN)/8A

CYLINDER AND INDICATOR PAPERASSEMBLY

2 78462 K-SA-4

7-4(2)/9 VALVE, BALL, OUTLET, CHILL WATER, 90DEG TURN, 2 POSITION, FLOW PATTERN 1,OPTIONS B7-H8-1H-2S-A0-1P

1 92021 1 IN IPS-MN-34-SB(1)-2-P0-C0

7-4(2)/9A GASKET, END BODY (FOR ITEM 9) 1 92021 MPRTE013

7-4(2)/9B GASKET, SIDE BODY (FOR ITEM 9) 3 92021 MPRTE014

(NOTSHOWN)/9C

STEM PACKING (FOR VALVE, ITEM 9) 2 92021 SPRTH109

7-4(2)/10 VALVE, ROTALOCK-DISCHARGE, 5/8” ODF,SWEAT COUPLING SIZE 1”-14

2 17812 24641-P

7-4(2)/11 VALVE, ROTALOCK-SUCTION, 7/8” ODF,SWEAT COUPLING SIZE 1-1/4”-12

1 17812 24614-P

7-4(2)/12 VALVE, ROTALOCK-SUCTION, 7/8” ODF,SWEAT COUPLING SIZE 1-1/4”-12

1 17812 24218-P

7-4(2)/13 FILTER-DRIER, REFRIGERANT 2 78462 C-083-S

7-4(2)/14 HEATER, CRANKCASE OIL 2 14569 918-0043-01

7-4(2)/15 VALVE, BALL, INLET, CHILL WATER, 90DEG TURN, 2 POSITION, FLOW PATTERN 2,OPTIONS B7-H8-1H-2S-A0-1P

1 92021 1 IN IPS-MN-34-SB(1)-2-P0-C0

7-4(2)/16 SWITCH, FLOW, BRONZE, WITH SS BONNETHOUSING

1 04034 FS-200-UE-LW-0.50-V-3.0GPM-A

7-4(2)/16A O-RING, 1” IPS, PER AS568-129 IAWMIL-R-83248/1 CLASS 1 RUBBER (INCLUDEDWITH GEMS FLOW SWITCH REPAIR KIT182560)

2 04034 (PART OF 182560)



Table 7-9. Isolator Base Assembly



7-5(1)/1, 6-19/1 ISOLATOR BASE 1 38450 1298-40

7-5(1)/2, 6-19/2 MOUNT, RESILIENT (ISOLATOR) ASSY 4 81349 6E150

7-5(1)/3, 6-19/8 CHANNEL, ISOLATOR SUPPORT 4 38450 1298-40-01

6-19/3 BOLT, HEX HEAD, 5/8-11 X 4, GR. 5, ZINCPLD, ASTM A449

4 38450 13-002-003

6-19/4 WASHER, FLAT, 5/8”, ZINC PLD, F844-90 4 38450 13-175-091

6-19/5 SPACER (PART OF RESILIENTMOUNT/ISOLATOR ASSY)

4 38450 (PART OF 6E150)

6-19/6 ISOLATOR (PART OF RESILIENTMOUNT/ISOLATOR ASSY)

4 38450 (PART OF 6E150)

6-19/7, 6-19/10 LOCKNUT, NYLON INSERT, 5/8-11, ZINCPLD., ASTM A563

12 38450 13-127-016

6-19/9 BOLT, HEX HEAD, 5/8-11 X 1, GR. 5, ZINCPLD., ASTM A449

8 38450 13-005-267





4"5"

5"

2B

2A ELECTRICAL LEADS TOHEATING ELEMENTITEM 2 (REF)

ITEM 13 (REF)

13A

13B

13C

06576:0503

Figure 7-1. Ship Stores Refrigeration Unit (Sheet 2)

















7.4 LIST OF MANUFACTURERS.Table 7-10 lists manufacturers of repair parts. The list is in CAGE code sequence. Appropriate CAGE codes for parts arefound in the tables of paragraph 7.3



Table 7-10. List of Manufacturers

CAGE Manufacturer Name and Address

01121 Rockwell Automation Inc.1201 S 2nd St.Milwaukee, WI 53204-2496414-382-2000

04034 Gems Sensors Inc.1 Cowles Rd.Plainville, CT 06062860-747-3000

04845 Automatic Switch Co. (ASCO)50 Hanover RoadFlorham Park, NJ 07932973-966-2000 (Phone)973-966-2628 (Fax)

08806 General ElectricLighting Business GroupNela Pk.Cleveland, OH 44112216-266-2536

08885 J. Schrader Co.4603 Fenwick Ave.Cleveland, OH 44102-4534

08887 Automatic Timing and Control Co.Division of Standard Instrument Corp.959 Cheney Ave.Marion, OH 43302614-387-8827

0EE74 General Electric Co.4400 Cox RdGlen Allen, VA 23026800-624-0624

0T4J0 Dwyer Instruments, Inc.P.O. Box 373102 Highway 212Michigan City, IN 46361-0373219-879-8000 (Phone)219-872-9057 (Fax)

0WFS5 Belimo Aircontrols/USA/Inc.P.O. Box 292843 Old Ridgebury Rd.Danbury, CT 06813800-543-9038 (Phone)203-791-9919 (Fax)

14569 Copeland Corp.1675 West Campbell Rd.Sidney, OH 45365-0669937-498-3011



Table 7-10. List of Manufacturers (Cont.)


14907 Cramer Co. Inc.105 Nutmeg Road SouthSouth Windsor, CT 06074860-291-8402

17812 Primore Sales Inc.2300 W. BeecherP.O. Box 605Adrian, MI 49221-9769517-265-6168

18444 Oil States Industries Inc.Special Products DivisionDivision of LTV Energy Products Co.1031 Commercial Blvd N.Arlington, TX 76001-7124

21013 Metrex Valve Corp.505 S. Vermont Ave.Glendora, CA 91741626-335-4027

25795 Grainger W. W. Inc.100 Grainger ParkwayLake Forest, IL 60045708-913-8333

26405 Marathon Special ProductsSubsidiary-Marathon Electric Mfg Corp.P.O. Box 46813300 Van Camp Rd.Bowling Green, OH 43402-9328419-352-8441 (Phone)800-515-7151 (Fax)

28193 Henry Technologies Inc.701 South Main StreetChatham, IL 62629217-483-2406

31670 Jamison Door Co.P.O. Box 7055 J. V. Jamison DriveHagerstown, MD 21740301-733-3100

34081 Ruskin Manufacturing Co.Division of Phillips Industries Inc.3900 Dr. Greaves Rd.Grandview, MO 64030816-761-7476

38450 Marlo CoilP.O. Box 1716060 Highway PPHigh Ridge, MO 63049636-677-6600





39248 GSM Industries Inc.151 Dixon DriveChestertown, MD 21620

41947 Mueller BrassP.O. Box 50212199 Laper Ave.Port Huron, MI800-533-3336

50992 Ranco Inc.Ranco Controls Division8115 US RT 42 NPlain City, OH 43064-9671614-873-9671

53010 SSAC Inc.P.O. Box 10008242 Loop RdBaldwinsville, NY 13027315-638-1300

56365 Square D Co. Corporate Offices1415 S. Roselle Rd.Palatine, IL 60067847-397-2600

57368 Mil-Spec Inc.931 Biltmore Dr.Fenton, MO 63026636-349-2205

57403 E.M. Wiegmann and Co. Inc.501 Douglas Rd.Freeburg, IL 62243618-539-3193 (Phone)618-539-5794 (Fax)

58536 Federal Commercial Item DescriptionPromulgated by General Services AdministrationWashington, DC

58989 Love ControlsA Division of Dwyer Instruments, Inc.P.O. Box 338102 Highway 212Michigan City, IN 46361-0338219-879-8000

5R056 Dolsey Ltd.863 W. 44th. St.Norfolk, VA 23508757-423-3037

63988 Crowley Co. Inc.15030 Berkshire Industrial ParkwayP.O. Box 425Burton, OH 44021





65586 Emerson Electric Co. dba Chromalox103 Gamma Dr. ExtensionPittsburg, PA 15238412-967-3914 (Phone)412-967-148 (Fax)

65664 Catamount Mfg Inc.158 Governor DriveP.O. Box 720Orange, MA 01364-0720

74924 Industrial Engineering and Equipment Co.425 Hanley Industrial Court W.St. Louis, MO 63144314-644-430

75282 Killark Electric Manufacturing Co.3940 Dr. Martin Luther King Dr.P.O. Box 5325St. Louis, MO 63115

75915 Littelfuse Inc.800 E. Northwest HwyDes Plaines, IL 60016847-824-1188

78462 Sporlan Valve Co.206 Lange Dr.Washington, MO 63090636-239-1111

81349 Military Specifications Promulgated by Military Departments/AgenciesUnder Authority of Defense Standardization Manual 4120 3-M

81860 Barry Wright Corp.P.O. Box 910540 Guest St.Brighton, MA 02135617-787-1555 (Phone)617-254-7381 (Fax)

dba Barry Controls82 S StreetHopkinton, MA 01748

84256 Avibank Mfg. Inc.11500 Sherman WayNorth Hollywood, CA 91605818-255-2094

92021 PBM, Inc.1020 Sandy Hill Rd.Irwin, PA 15642800-967-4726 (Phone)724-863-0550 (Phone)724-864-9255 (Fax)





94112 A C and R Components, Inc.701 S. Main St.Chatham, IL 62629217-483-2406

96169 Electric Boat Corp.A Company of General Dynamics Corp.75 Eastern Point Rd.Groton, CT 06340860-433-4644 (Phone)840-433-1345 (Fax)

NONE1 Danfoss Automatic Controls1775-G MacLeod DriveLawrenceville, GA 30243

NONE2 Flatplate, Inc.Cytec Bldg.2161 Pennsylvania Ave.York, PA 17404800-774-0474 (Phone)717-767-9160 (Fax)

NONE3 PHL Inc.P.O. Box 11243859 Old Easton Rd.Doylestown, PA 18901215-345-8405

NONE4 Kason Mid-America1239 Atlantic St.North Kansas City, MO 64116816-472-7456



CHAPTER 8

INSTALLATION

8.1 INTRODUCTION.The nominal 1.0 ton Ship Stores Refrigeration Unit (SSRU) is a self-contained unit comprising freeze storeroom, chillstoreroom, and a refrigeration plant. The refrigeration plant contains two separate refrigeration systems designed for minimalmaintenance. The SSRU is delivered as a single unit mounted on a removable base structure assembly. Installation ofthe SSRU requires connecting the unit to the shipboard electrical system, connecting the unit to input and return waterlines supplying chilled water for cooling, connecting the unit to three drain lines, and connecting the unit to the Total ShipMonitoring System (TSMS).

8.2 INSTALLATION DRAWINGS.Information applicable to installation of SSRU is provided in the Level III drawing package. The SSRU is dimensionallycompatible with ship plans and structure. Figure FO-3 is provided as a welding map. Weld points on the removable basestructure assembly are indicated. SSRU drain positions are dimensionally compatible with ship plans and structure.

8.3 SITE INFORMATION.Provide minimum clear space on all sides of SSRU for inspection and installation.

8.4 REFERENCE PUBLICATIONS.Refer to ships cooling water distribution and electric plant data for interface. Brazing requirements are found in NSTM0900-LP-001-7000.

8.5 SPECIAL TOOLS.Installation of SSRU requires a set of tools such as those normally found in a standard Navy tool box. A shipyard crane andgrinding and welding facilities are required for installation of the assembled unit.

8.6 UNPACKING.SSRU will arrive on site mounted on the base structure assembly per figure FO-3. The base structure assembly provides fourlifting lugs.

a. Inspect SSRU on base structure assembly for shipping damage upon receipt. Report any damage immediately.

b. Remove shrink wrap from SSRU and base structure assembly.

c. Remove plywood protective casing from Control Panel.

d. Remove clear plastic wrap from SSRU.

e. Locate and set aside two 5-inch sections of 1-1/2-inch threaded PVC pipe for use during SSRU interface connection(paragraph 8.9.2).

8.7 PREPARATION OF FOUNDATION.Refer to figure FO-3 and ship builder drawings for information concerning foundation and structure. The foundation andsupport equipment must be prepared to accept the equipment before it is brought to the site. Figure FO-4 details SSRUinterfaces.

8.8 INPUT REQUIREMENTS.Input requirements are as follows:Power: 440 Vac, 3 Phase, 60 HzCooling Water: Chilled water, 5 gpm, 44°F to 60°F



8.9 INSTALLATION PROCEDURE.The following paragraphs provide instructions for installation of SSRU.

8.9.1 Removal of Base Structure Assembly. Refer to figure FO-3 for location of welds attaching base structureassembly to SSRU.

WARNING

SSRU weighs approximately 10,000 lbs. Exercise suitable precautions to prevent injury to personnelor damage to equipment when moving and positioning SSRU.

a. Using suitable lifting equipment and exercising extreme caution, hoist SSRU in place for installation.

b. While supporting SSRU on base structure assembly, break welds shown in figure FO-3 by grinding or suitablemethod.

c. Raise SSRU from base and slide unit from base structure assembly onto ship’s structure. (SSRU base plateincorporates a 5-degree skid.)

d. Remove 6-inch angled edge from base plate after SSRU has been positioned onto ship’s structure leaving 1/2-inchbedplate lip.

8.9.2 SSRU Interface Connections. Install SSRU to ship’s system as follows:

a. Adjust SSRU position to ship’s plans and structure and weld SSRU frame to ship structure according to weldplan in figure FO-3.

b. Attach freeze room and chill room foamed-in drains (figure FO-4, 4 and 5) to ship’s drain system with two 5-inchlong 1-1/2-inch PVC tailpiece extensions. Cut extensions to fit as necessary.

c. Open Control Panel door and connect ΦA, ΦB, and ΦC 440 Vac, 60 Hz input power supply to power block(figure 8-1, 1).

d. In Control Panel, connect Total Ship Monitoring System (TSMS) connections to TB7 per figure FO-2, sheet 2.

e. At opening in back of SSRU equipment cabinet, connect input chill water source to input 1-inch chill waterunion connection (figure 8-1, 2). Connect return chill water to outlet 1-inch chill water connection (3). Torqueboth unions to 25 to 60 ft-lb.

f. At back of equipment cabinet, braze 3/4-inch evaporator coil condensate line (4) to ship’s drain system.

8.10 INSTALLATION CHECKOUT.Proceed as outlined in the following steps to inspect, start, and check out SSRU installation.

a. Inspect installation of items and systems described in paragraph 8.9.2.

b. Verify positions of manual chill water bypass/diverter valves per Chapter 2.

c. Verify presence of requisite source chill water and electrical power.

d. Power up SSRU and operate refrigeration plant per Chapter 2.





GLOSSARY

GLOSSARY

A Amperes

AR As Required

BTUH British Thermal Units per Hour

C Centigrade

CAGE Commercial and Government Agency

CCH Crankcase Heater

CCW Counterclockwise

CFM Cubic Feet per Minute

CR Control Relay

CRLI Chill Room Light Indicator

CRT Chill Room Thermostat

CRVH Chill Room Vent Heater

CW Clockwise

D-Level Depot Level (Maintenance)

DM Damper Motor

DPDT Double Pole Double Throw

DTT Defrost Termination Thermostat

ET Elapsed Timer

F Fahrenheit

FRLI Freeze Room Light Indicator

FRT Freeze Room Thermostat

FRVH Freeze Room Vent Heater

Ft Foot, feet

FU Fuse

Gpm Gallons Per Minute

H High

HFC Hydrofluorocarbon

HP High Pressure

Hr Hour

HTT High (Defrost) Temperature Thermostat

Hz Hertz

I-Level Intermediate Level (Maintenance)

IMA Intermediate Maintenance Activity

-4FOR OFFICIAL USE ONLY


GLOSSARY

In. Inch, inches

IPB Illustrated Parts Breakdown

L Long

Lb Pound, pounds

LED Light Emitting Diode

LP Low Pressure

Min Minute

NC Normally Closed

NO Normally Open

No. Number

O-Level Organizational Level (Maintenance)

Ph Phase

POE Polyol Ester

PLD Plated

PMS Planned Maintenance System

PSI Pounds per Square Inch

Qty Quantity

REF Reference

RTD Resistive Temperature Detector

Sec Second

SPST Single Pole Single Throw

SSRU Ship Stores Refrigeration Unit

TB Terminal Block

TOS Tagged Out of Service

TR Transformer

TSMS Total Ships Monitoring System

TXV Thermal Expansion Valve

Vac Volts Alternating Current

Vdc Volts Direct Current

W Watts, Wide


EVAPORATOR COILEVAPORATOR COIL

COMPRESSORCOMPRESSOR

SIGHT GLASSSIGHT GLASS

FILTER / DRYERFILTER / DRYER

ROTALOCK VALVEROTALOCK VALVE

CONDENSERCONDENSER

RECEIVERRECEIVER

THERMALTHERMALEXPANSIONEXPANSION

VALVEVALVE

WATERWATERREGULATINGREGULATING

VALVEVALVE

WATER INWATER INWATER OUTWATER OUT

COMPRESSORCOMPRESSOR

ROTALOCK VALVEROTALOCK VALVE

EVAPORATOR COILEVAPORATOR COIL


VALVEVALVE

SIGHT GLASSSIGHT GLASS

FILTER / DRYERFILTER / DRYER

RECEIVERRECEIVER

CONDENSERCONDENSER

WATERWATERREGULATINGREGULATING

VALVEVALVE

SOLENOID VALVESOLENOID VALVE

SOLENOID VALVESOLENOID VALVE

THERMALTHERMALEXPANSIONEXPANSIONVALVE BULBVALVE BULB


VALVE BULBVALVE BULB

LOW FLOWLOW FLOWSWITCHSWITCH

HPHP HPHPHIGH DISCHARGEHIGH DISCHARGE

PRESSUREPRESSURESWITCHSWITCH

HIGH DISCHARGEHIGH DISCHARGEPRESSUREPRESSURE

SWITCHSWITCH

SHUT-OFFSHUT-OFFVALVEVALVE

WATER BYPASS/WATER BYPASS/DIVERTER VALVEDIVERTER VALVE

#3#3


#1#1


#2#2

PLANT #2PLANT #2 PLANT #1PLANT #1

LPLP

LOW SUCTIONLOW SUCTIONPRESSUREPRESSURE

SWITCHSWITCH

LPLP

LOW SUCTIONLOW SUCTIONPRESSUREPRESSURE

SWITCHSWITCH

ROTALOCKROTALOCKVALVEVALVE

ROTALOCKROTALOCKVALVEVALVE

SUCTION PRESSURESUCTION PRESSURETEST PORTTEST PORT

(SCHRADER)(SCHRADER)

HIGH PRESSUREHIGH PRESSURETEST PORTTEST PORT


FLEX HOSEFLEX HOSEFLEX HOSEFLEX HOSE

FLEX HOSEFLEX HOSE FLEX HOSEFLEX HOSE

FLEX HOSEFLEX HOSEFLEX HOSEFLEX HOSE

FLEX HOSEFLEX HOSE FLEX HOSEFLEX HOSE

SHUT-OFFSHUT-OFFVALVEVALVE

HIGH PRESSUREHIGH PRESSURETEST PORTTEST PORT


SUCTION PRESSURESUCTION PRESSURETEST PORTTEST PORT


06577:050306577:0503Figure FO-1. Ship Stores Refrigeration Unit Hydraulic SchematicFigure FO-1. Ship Stores Refrigeration Unit Hydraulic Schematic

WATERWATER

INSTRUMENTSINSTRUMENTS

REFRIGERANTREFRIGERANT




Ref: NAVSEAINST 4160.3A NAVSEA S0005-AA-GYD-030/TMMP

NAVSEA/SPAWAR TECHNICAL MANUAL DEFICIENCY/EVALUATION REPORT (TMDER) INSTRUCTIONS: Continue on 8 ½” x 11” page if additional space is needed. 1. Use this report to indicate deficiencies, problems and recommendations relating to publications. 2. For CLASSIFIED TMDERs see OPNAVINST 5510H for mailing requirements. 3. For TMDERs that affect more than one publication, submit a separate TMDER for each. 4. Submit TMDERs at web site https://nsdsa2.phdnswc.navy.mil or mail to: COMMANDER, CODE 310 TMDER BLDG 1389, NAVSURFWARCENDIV NSDSA, 4363 MISSILE WAY, PORT HUENEME CA 93043-4307

1. PUBLICATION NUMBER 2. VOL/PART 3. REV/DATE OR CHG/DATE 4. SYSTEM/EQUIPMENT ID

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7a. Page # 7b. Para # 7c. RECOMMENDED CHANGES AND REASONS

8. ORIGINATOR’S NAME AND WORK CENTER 9. DATE 10. ORIGINATOR’S E-MAIL ADDRESS 11. TMMA of Manual (NSDSA will complete)

12. SHIP OR ACTIVITY Name and Address (Include UIC/CAGE/HULL) 13. Phone Numbers: Commercial ( ) -

DSN - FAX ( ) -

NAVSEA 4160/1 (Rev. 7-2003) S/N 0116-lf-985-4100

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