Case Controller Installation Instructions and Test ... - icemeister.net

ALL RIGHTS RESERVED.The information contained in this manual has been carefully checked and is believedto be accurate. However, Computer Process Controls, Inc. assumes no responsibilityfor any inaccuracies that may be contained herein. In no event will Computer ProcessControls, Inc. be liable for any direct, indirect, special, incidental, or consequentialdamages resulting from any defect or omission in this manual, even if advised of thepossibility of such damages. In the interest of continued product development, ComputerProcess Controls, Inc. reserves the right to make improvements to this manual,and the products described herein, at any time without notice or obligation.THIS PRODUCT IS AN FCC CLASS A DIGITAL DEVICE.This equipment has been tested and found to comply with the limits for a Class A digitaldevice, pursuant to Part 15 of the FCC Rules. These limits are designed to providereasonable protection against harmful interference when the equipment is operated ina commercial environment. This equipment generates, uses, and can radiate radio frequencyenergy, and—if not installed and used in accordance with this instruction manual—maycause harmful interference to radio communications. Operation of thisequipment in a residential area is likely to cause harmful interference in which casecorrection of the interference will be at the user’s expense.

Description120 VAC 1 Phase/240 VAC 3 Phase Defrost, Full Configuration120 VAC 1 Phase/240 VAC 3 Phase Defrost, No Fuses,No Fuse Holder120 VAC 1 Phase/240 VAC 3 Phase Defrost, No Fuses,with Fuse HolderPartNumber Lights Fans816-3000 Yes Yes816-3005 Yes Yes YesAnti-Sweat816-3010 Yes Yes Yes Yes816-3100 Yes Yes816-3105 Yes Yes Yes816-3110 Yes Yes Yes Yes816-3200 Yes Yes816-3205 Yes Yes Yes816-3210 Yes Yes Yes Yes240 VAC 1 Phase, Full Configuration 816-3310 Yes Yes Yes YesTable 3 - Power Module Part NumbersPower Module Output RatingsOutput Volts Normally OpenNormallyClosedLights 120 V 20 A 10 A 20 A240 V 6 A 3 AFans 120 V ¾ hp ¼ hp 15 A240 V 1½ hp ½ hpAnti-Sweat 120 V 12 A 15 A240 V 12 ADefrost 120 V 30 A (1 or 2 pole)30 A25 A (3 pole)240 V 30 A (1 or 2 pole)25 A (3 pole)Table 4 - Power Module Output RatingsDefrostMaximum FuseCase Controller Installation Instructions Introduction • 3and Test Procedures

Full Output Cable for Alco ESR ValveThe CCB is designed to use the 24 V version of theAlco ESR Valve. The 24 V version of the valve has-24VDC appended to the part number. The ESR valve harnessfrom Alco comes in two versions. With an in-linemolex connector, the CPC harness (P/N 335-3159) can beused. If the valve is purchased with the in-line molex, theCPC Output Cable Harness with Quick Connects (335-3158) must be used. The connector must be cut off of theharness and the valve wired according to specifications inTable 5.Table 5 shows the relationship between the CPC outputcable colors and the associated valve cable colors.CPCWireColor Pin #Power ModulesCase Controller Power ModuleSizeALCOESVLiquidStepper(S/EEV)Unipolar(24V)Alco ESR(24 VOnly)SporlanSEILiquidStepper(S/EEV),EEPRBipolar(12V)Blue 1 Blue Red RedGreen 2 Red Blue GreenBlack/ 13 Black Black BlackYellowPurple/ 14 White White WhiteRedYellow 16 Yellow Not Used Not UsedTable 5 - Valve Cable Wire ColorsThe case controller power module measures 16.25inches long by 3 inches wide by approximately 3¼ inchesdeep. The base plate has one 0.218 inch mounting hole locatedat each corner.PowerThe case controller power module should be connectedto a 120 VAC single phase power source. Complete wiringof the case controller power module is diagrammed inFigure 11. Follow all local, NEC, and UL wiring practices.DEFROST HOTDEFROST HOTDEFROST HOTANTI-SWEAT HOTFANS HOTLIGHTS HOTHOTLINENEUTRALEARTH GROUNDFigure 11 - Case Controller Power Module Wiring SchematicSensor LocationDischarge Air Sensor (Green Leads)In general, the discharge air sensor should be located inthe air stream leaving the evaporator coil, but just beforethe air stream enters the food compartment of the refrigerateddisplay case.Coil Inlet Sensor (Blue Leads)Proper location of the coil inlet sensor is critical sincevalve control is dependent upon accurate measurement ofchanges to evaporator liquid temperature. The coil inletsensor should be located on either the first or second passthrough the evaporator. Preferably, the sensor should beplaced six inches into the evaporator on the first pass.Place the coil inlet sensor with the curved surfaceagainst the pipe and secure with the included Panduit lowtemperature cable tie number PLT2S-M120 or equivalent.The tie should be positioned in the groove on the top surfaceof the sensor. A second tie should be used to secure thelead to the pipe for additional support.Sensors located on refrigerant tubing should be insulatedto eliminate the influence of the surrounding air. A selfadheringinsulation that will not absorb moisture is recommendedto prevent ice accumulating at the sensor location.For orientation of the sensor on the coil, see Figure 12.Coil Outlet Sensor (Red Leads)COMCOM26513067Proper location of the coil outlet sensor is critical sincevalve control is dependent upon accurate measurement ofchanges to evaporator discharge gas temperature. The coiloutlet sensor should be located on a horizontal section ofNONO12345678OUTPUT CABLEDEFROST OUTDEFROST OUTDEFROST OUTANTI-SWEAT OUTFANS OUT (NC or NO)LIGHTS OUT (NC or NO)6 • Power Modules 026-1110 Rev 3 01-08-98

the suction line, near the evaporator outlet. Follow themounting instructions listed for the coil inlet sensor. Fororientation of the sensor on the coil, see Figure 12.26509022Figure 12- Sensor OrientationWiringComplete wiring of the Case Controller and Case ControllerPower Module is shown in Figure 13 and Figure 14.Case Controller Installation Instructions Installation • 7and Test Procedures

Figure 13 - Wiring for Case Controller, Power Module, and Pulse EEV ValveCase Controller Installation Instructions Installation • 9and Test Procedures

Figure 14 - Wiring for Case Controller, Power Module, and Sporlan EEPR ValveWiring • 10 026-1110 Rev 3 01-08-98

Test ProceduresTo confirm proper operation of the case controller onceit has been installed in the case, the following test proceduresshould be performed using a hand-held terminal.1. Plug the hand-held terminal into the case controllerjack.2. Press the key to ensure that the main screen isdisplayed (Figure 15).load should be activated and the LED lit on the case controller.Press the key again to deactivate the load.Key Output CommentsLightsFansDefrostAnti-SweatUnusedUnusedValve 2 (24 VAC)Pulse CCB onlyFigure 15- Main Screen3. Press the key to switch to the configurationscreen (Figure 16).Figure 16- Configuration Screen4. Press the key.5. Enter ‘987.’6. Press the key.The hand-held terminal is now in test mode and the testscreen shown in Figure 17 is displayed.Valve 1 (24 VAC)All outputs ON and stepperEEV openAll outputs OFF andstepper EEV closedAuto-testPulse CCB OnlyThe stepper valve willstep from closed to openbased on the BypassValve% entered in handheldterminalThe stepper valve willstep from open to closedbased on the BypassValve% entered in handheldterminalSequential toggle as follows:all outputs OFFodd outputs ONeven outputs ONall outputs OFFTable 6- Hand-Held Terminal Output Test Procedure KeypadDefinitionsWhen output testing is complete, press the key to returnthe case controller to normal operation and disconnectthe hand-held terminal from the case controller.To test each case controller input:1. Press the key to return to the main screen.Figure 17- Test ScreenThe test screen only displays valid readings for casecontroller outputs. To test CCB inputs, check the appropriateinput status screens for valid input readings (seeTable 7).2. Press the key to display the first input statusscreen.3. Press the key to scroll through the status screensto display the appropriate screens shown in Table 7.To test each case controller output, press the hand-held terminalkeys as shown in Table 6. The corresponding caseCase Controller Installation Instructions Test Procedures • 11and Test Procedures

A valid input sensor reading should be displayed foreach sensor input.Status Screen #s(Number of times to press the DOWN key from the main screen)Pulse CCB Liquid Stepper CCB Suction StepperInputCCBCoil 1 In 3 3 3Coil 1 Out 3 3 3Coil 2 In 5 not used 5Coil 2 Out 5 not used 5Discharge Air 12 10 12Return Air 12 10 12Door/Cleaning Switch not displayed in a status 12 not displayed in a statusscreen.screen.When input testing is complete, press the key to returnto the main screen and disconnect the hand-held terminalfrom the case controller.CommentsLook for CLSD status ifconnected.The status of the Door/Cleaning Switch is alsodisplayed in the TestScreen in all three CCBversions (see Figure17).Frost 14 12 13 Look for OPEN status ifconnected.Refrigeration Leak 14 12 13Table 7 - Input Test Procedure Status ScreensDefining Case TypeAfter testing is complete, the case type may be set asfollows:1. Plug hand-held terminal into the case controllerjack.2. Press the key to ensure that the main screen isdisplayed (Figure 15).3. Press the key to switch to the configurationscreen (Figure 16).4. Press the key.5. Enter Case Type number from Table 8.6. Press the key.12 • Defining Case Type 026-1110 Rev 3 01-08-98

Type Abbr. Description Type Abbr. Description0 Spare Spare for future use 33 PRBX Produce cooler box1 SDIC Single deck ice cream 34 MILK Milk case2 MDIC Multi-deck ice cream 35 PKDL Packaged deli3 SDFJ Single deck frz. juice 36 DLDS Deli display case4 MDFJ Multi-deck frz. juice 37 CHEZ Cheese case5 RIIC Reach-in ice cream 38 POBX Produce box6 ICBX Ice cream freezer box 39 BEER Beer/Beverage7 SDFF Single deck frz. food 40 BVCS Beverage case8 RIFJ Reach-in frz. juice 41 DLBX Deli cooler box9 FRBX Frozen food box 42 FHBX Fish cooler box10 FFBX Frozen fish box 43 SVDL Service deli11 FJBX Frozen juice box 44 PRCS Produce case12 MDFF Multi-deck frz. food 45 ISPR Produce case (Island)13 FZBK Multi-deck frz. bakery 46 SALD Salad table14 RIFF Reach-in frz. food 47 FLBX Flower cooler box15 SDMT Single deck meat 48 FLWR Flower cooler16 SDPF Single deck prepared 49 CTBX Controlled temp box17 PZZA Single deck pizza 50 SDPO Single deck poultry18 KOSH Single deck kosher 51 CAKE Bakery cake case19 SDFH Single deck fish 52 BART Bakery retarder20 MDMT Multi-deck meat 53 RTDR Bakery retarder21 MDPO Multi-deck poultry 54 MTPK Meat packaging room22 MDFH Multi-deck fish 55 MTCU Meat cutting room23 RIMC Reach-in meat 56 MTPR Meat prep room24 SVMT Service meat 57 MTWR Meat wrapping room25 SVFH Service fish 58 FHPR Fish prep room26 MTBX Meat cooler 59 SBCL Subcooler27 HDBX Meat holding box 60 PRPR Produce prep room28 DYCS Multi-deck dairy 61 SDFM Single deck frz. meat29 RFDY Rear load dairy 62 RIFM Reach-in frz. meat30 RIDY Reach-in dairy 63 MDFM Multi-deck frz meat31 DYBX Dairy cooler 64 BKFZ Bakery freezer box32 BKBX Bakery CoolerTable 8- Case Type SettingsCase Controller Installation Instructions Test Procedures • 13and Test Procedures