Tyler Refrigeration Alpine A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB display merchandiser Installation & Service Manual

Low and Medium Temperature
Narrow Depth Glass Door Display Merchandisers
INSTALLATION & SERVICE MANUAL (ISM)
For Model Numbers:
A5FGN(T), A5FG(T)BB • A5NGN(T), A5NG(T)BB
Manual Part no. 10000004
ISM Document Information
Issue Date
February 2009
~
Revision Mark
First Edition
~
Replaces
n/a
Details of each revision can be
found on page 32 of this manual.
Individual product ISM’s are designed as supplements to Tyler’s General Installation & Service Manual.
Copies of current ISM’s are available on the Tyler Refrigeration website in the Quick Reference section.
Tyler Refrigeration • 1329 Lake Street, Niles Michigan 49120 USA
ph: 800.992.3744 • fax: 269-684-9802 • email: [email protected] • www.carrier-tyler.com
A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
TABLE OF CONTENTS
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Evaporator
Expansion Valve
Defrost Heater Element . . . . . . . . . . . . . . . . . . . .30
Heater Element Removal
Evaporator Fans
Air-Curtain Velocity
Fan Removal
Ballasts
Fluorescent Lighting
Optional Lighting . . . . . . . . . . . . . . . . . . . . . . . . .31
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Delivery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .3
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
INSTALLATION
Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Case Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Drain Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Lineup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Front Edge Trim Replacement . . . . . . . . . . . . . . .31
Kickplate and Bumper . . . . . . . . . . . . . . . . . . . . . . .12
REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Under-Case Return Airflow . . . . . . . . . . . . . . . . . . .13
EQUIPMENT WARRANTY . . . . . . . . . . . . . . . . . . . .33
REFRIGERATION
Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . . . .14
Temperature Control Adjustment . . . . . . . . . . . . . . .14
Leak Check > Evacuation > Charging . . . . . . . . . . .15
Line Sizing Tables . . . . . . . . . . . . . . . . . . . . . . . . . .16
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Optional Electrical Wiring . . . . . . . . . . . . . . . . . . . . .19
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . .20
DEFROSTING
Defrost Setting and Controls . . . . . . . . . . . . . . . . . .25
Electric Defrost Operation . . . . . . . . . . . . . . . . . . . .26
Gas Defrost Operation . . . . . . . . . . . . . . . . . . . . . . .26
Limit Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Coil Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . .27
USER INFORMATION AND SERVICE
User Information . . . . . . . . . . . . . . . . . . . . . . . . . .28
Cleaning
Shelf Location
Shelves
Loading the Case
Light Switch
Case Thermometer
Case Lineup Combinations and Length Chart . . .29
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Manual Part #: 10000004
INTRODUCTION
Information contained in this manual pertains to both
low-temperature and medium-temperature display
merchandisers, including models:
A5FGN
A5FGNT
A5FGBB
A5FGTBB
A5FGNE
A5FGNTE
A5NGNE
A5NGNTE
A5NGN
A5NGNT
A5NGBB
A5NGTBB
Consult the factory if your store exceeds these test
conditions.
Delivery Inspection
These display cases were carefully tested in the factory,
inspected and properly packed to ensure delivery in the
best possible condition. The equipment should be
uncrated and checked for damage immediately upon
delivery. DAMAGE MUST BE NOTED AT TIME OF
DELIVERY AND ALL CLAIMS FOR DAMAGES MUST
BE FILED WITH THE TRANSPORTATION COMPANY NOT WITH TYLER. The carrier will supply necessary
report and claim forms.
The use of the name “merchandiser” and “case” are
used interchangeably and have the same meaning. Also,
the term “freezer” refers to the A5F series of frozen glass
door merchandisers, while the term “cooler” represents
the A5N medium temperature versions.
Packaging
Tyler has made every effort to provide refrigeration
equipment of the highest quality using state-of-the-art
components. Merchandisers are built with the thickest
insulation in the industry with a high-efficiency evaporator coil.
Each case within a lineup is labeled to identify the lineup
and joint. Labels use a number and letter designation
(Figure 1). The number indicates the lineup. The letter
indicates the case joint. Case joints begin with the letter
A at the left most joint in the lineup, when looking at the
front of the lineup. The joint for two cases has the same
number-letter designation. Back-to-back cases have a
unique designation. The leftmost joint in the lineup when
looking at the front of the case is labeled 1-A. The joint
on the back of the case is 1-A1.
Potential case features include:
•
Brushless D.C. electronic motors or PSC or
shaded pole fan motors
•
T8 fluorescent lamps
•
LED lighting
•
Standard-energy, low-energy or no-energy doors
Insulated dividers are factory installed to separate low
and medium temperature cases. They are also used to
join different case models. Factory installed “Plexi” glass
dividers separate refrigeration circuits.
These display cases were designed and tested using the
following industry standards:
•
ASHRAE Standard 72-2005 – Method of Testing
Commercial Refrigerators and Freezers (ANSI
Approved)
•
ARI 1200- Performance Rating of Commercial
Refrigerated Display Merchandisers and Storage
Cabinets (ANSI Approved)
•
UL 471- Commercial Refrigerators and Freezers
(ANSI Approved) (equipment certified by ETL)
•
NSF 7- Commercial Refrigerators and Freezers
(ANSI Approved) (equipment certified by NSF)
The first case in the lineup (with it’s right side labeled A)
has a packet attached to the door handle that contains
the manual, special instructions for installing ordered
options, and touch up paint if the cases are custom
painted. Every other case in the lineup has a packet
attached to the door that contains the specific information for that case. The packing slip is taped to each
case’s right hand door.
Bumpers and kickplates are shipped on top of the case.
Shelves for the case are tie wrapped and blocked into
the individual cases. Other accessories like, drain traps,
drain pans, condensate evaporating pans, and hat
channels are shipped in the case that require the parts.
ASHRAE 72-2005 specifies the test conditions for the
equipment. It includes the ambient conditions of 75° F
dry bulb and 55% RH. It also specifies the door opening
requirements for the performance test. Doors are
opened six times in one hour for 6 seconds. The door
opening test period is for 8 hours during one 24-hour
performance test. As an example a 5-door case will
have 240 door openings during one 24-hour test.
February 2009
Materials for joining cases include caulk, joining bolts,
splices and T or J strips. These parts are supplied in
cases that have a left-side insulated divider or no left
end. The parts are bagged and taped to the coil covers.
The T and J strips are tied to the shelves.
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Introduction
A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
and merchandisers set back-to-back should be
positioned to allow a minimum of 2" - 4" of space behind
the back of the unit(s). This will allow necessary air to
circulate behind the display case(s). Higher humidity
stores with minimal air circulation require a 4" gap.
Location
These cases must not be installed in the direct rays of
the sun or near a source of radiant heat.
Be certain that the floor under the installation is of sufficient strength to prevent sagging. Out of level conditions
will result in reduced performance.
Wall merchandisers (those set with their backs to a wall)
Figure 1: Case label information
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Manual Part #: 10000004
INSTALLATION
A
Leveling
Merchandisers must be installed perfectly level to allow
efficient operation of the refrigeration coils and complete
drainage of defrost water. Since a level area is seldom
available, the following steps are recommended to
insure a level installation.
1. Measure off and mark on floor the exact dimensions
of the case lineup. (Check blueprints).
2. Snap a chalk line at the locations for the front and
back positions of the base rails (Figure 2-A).
B
3. Mark locations of all joints (front and back).
4. Using a laser or transit, find the highest point along
both base rail position lines. Using the high point as
a reference, mark the difference directly on the floor
to each joint (front and back)(Figure 2-B).
5. If you plan on using optional hat channels to raise
the case height, place them under each pair of
bases (Figure 3). Three and four door hat channels
will be angled slightly to support the front and rear
bases.
C
6. Place the required number of shims under each
base or optional hat channel at each joint (front and
back) to equal the highest point.
Ca
s
The A5FGN(T) and A5NGN(T) 2 through 5 door
merchandisers have segmented bases mounted at
the ends and under the center section of the case.
Back-to-Back versions have full bases that run from
front to back and are located at the ends and under
the center sections of the case. The A5FGN(T)E
and A5NGN(T)E crown-ends have segmented
bases that run front-to-back.
eF
ron
t
Shim Placement
Ca
se
Fro
n
t
Figure 2: Leveling cases prior to joining
7. Tape all shims in place (Figure 2-C).
8. Correctly orient the shims under the base or channel.
Both corners of the base must be supported by shims
to prevent the base from buckling (Figure 4).
9. Place additional support shims under all other bases
or hat channels (Figures 5A, 5B & 5C).
Base
10.If you’ve purchased seismic restraints, specific
instructions for attaching those restraints are included
in your document package. These instructions
should be read and followed before the line up is
assembled.
Shim
Base
Shim
Hat section
Figure 3: Typical hat channel locations
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Installation
Figure 4: Shims under bases and case
Figure 5A: Base Locations
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Manual Part #: 10000004
Figure 5B: Base Locations for 2-5 door back-to-backs
Figure 5C: Base Locations for end case
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Installation
A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
The following fork-lift dimensions must be maintained to
avoid damaging the case when it is lifted:
Case Movement
The back-to-back (BB) cases are shipped with wood
planks that allow the use of pipe rollers. These wood
planks should be removed after the case is moved to its
final location (Figure 6).
2-Door Merchandisers
Forks must extend from 26" to no more than 30"
under the case.
All cases have steel protective support plates under the
ends (not under insulated dividers). They are designed
to protect the end from Johnson bar damage.
3-Door Merchandisers
Use 48" long forks. Forks must extend from 39" to no
more than 43" under the case.
Use the following methods to move the cases.
4 and 5 Door Merchandisers
Model
Use 48" long forks. Forks must extend from 44" to
47" under the case.
Fork lift Johnson Furniture Pipe Safe (case)
from ends
bar
Dolly
Rollers
jacks
A5F(N)GN(T)
A5F(N)G(T)BB
A5F(N)GN(T)E
*
Fork blades wider than 4" will not fit into the bases.
For low shipping height applications such as the use of
the optional Remote Condenser Unit (RCU), Tyler has
optional expandable bases. As shipped, the base is
1-3/4" tall. It is attached with spacers that allow the base
to slide away from the bottom of the case creating a gap
that allows the use of a 1-1/2" thick fork-truck blade.
* Fork-lift from the rear
Care should be taken when moving the cases. The
doors should be secured so they cannot open while the
case is moved.
Only experienced certified fork truck drivers should use
fork trucks to move the cases. The case should only be
lifted off the floor as high as necessary for transport. The
fork truck should be driven slowly avoiding any abrupt
motions or bumps.
Figure 6: Removing wood planks
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Drain Line
The drain is located at the center of the case in the floor
pan. The drain can be reached by removing the center
coil covers and then removing a fan motor. The 1" PVC
drain outlet is located at the center-front of the case
behind the kickplate.
Install the tee to the outlet pipe and a drain trap to the
tee. Plug the open end of the tee using the clean-out
plug supplied with the drain trap kit. The drain line must
be pitched away from the case. The tee, drain trap and
plug are supplied with the case, and the factory installs a
drain support at the front of the case. A trap support is
supplied and is field mounted to the case (Figure 7).
The drain trap must be level and should be primed with
water after installation.
Figure 7: Trap Support
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Installation
A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
Lineup Assembly
1. Set the first case into the desired position and
level it. Run a 1/4" to 3/8" diameter bead of Butyl
caulk 1/2" in from both the inner and outer
surfaces of the case end. (Figure 8).
2. Push the second case against the end of the first.
Level the second case. Remove the left and right
end-coil covers and the rectangular pocket hole
covers, accessing the holes in the end frames of
each case as shown. The bolt kit supplied with
the cases includes diagrams of these locations.
Install tee-strips between the door frames at case
joints (See Figure 9). Use the special screws
and nuts provided.
3. Start the joining bolts, but do not tighten them.
Begin tightening the bolts at the top rear, working
down the back of the case and up the front
making sure that the front seams are flush.
4. For NSF case installation, the interior case
seams need to be sealed using NSF approved
caulk (not supplied) (Figure 10).
5. The end-panel protector support plates should
be removed after the cases are set in their final
position.
Figure 9: T-Strips
DO NOT APPLY EXCESS AMOUNTS OF BUTYL SEALANT THAT WOULD CAUSE IT TO SQUEEZE ONTO END
FRAME METAL AREAS. Caulk-sealant used to join cases and complete the sealing requirements for NSF compliance
should not come in contact with butyl sealant. Apply to clean, dry surfaces free of contaminants that adversely affect
adhesion and could change color of sealant joint areas over time.
B
Procedure for Joining Cases
A
1/4" - 3/8" TYPICAL
BUTYL SEALANT
BEADS
1. Apply two 1/4" to 3/8" wide beads of Butyl sealant, 1/2" in
from the inside and outside edges of the foamed insulated
ceiling, rear wall, base, and door frame to be joined. Apply to
only one case joint to avoid excessive amounts of Butyl
sealant that would squeeze out of the joint. Sealant is not
applied to the structural steel end frames. After cases are
joined, caulk the top and back exterior seams (if possible) at
this time.
DETAIL A
SCALE 1 : 5
DETAIL B
SCALE 1 : 5
These procedures are critical! Failure to follow these
guidelines will result in a poorly functioning case. This
is especially true of freezers.
1/4" - 3/8" TYPICAL
BUTYL SEALANT
BEADS
2. When joining ends of cases, caulk sealant should be
applied in the same like manner for joints.
If 4 shipping blocks are installed to inside of base
ends, remove them to comply with NSF.
Figure 8: Caulking cases to be joined
Tyler Refrigeration • Niles Michigan USA
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Manual Part #: 10000004
Figure 10: Required sealing for NSF approved installations
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Installation
A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
Installing the Front Kickplate &Bumper
(Figures 11A & B)
Kickplate and Bumper
A custom Tyler cart bumper is standard on all case
models and is installed at the bottom front of the case.
The assembly is adjustable to compensate for uneven
floors.
The front kickplate and bumper attaches using 1½"
screws attached to support brackets located on the front
of the case. The kickplate can be adjusted up and down
to fit the height of the floor below it.
Installing the End Kickplate (Figure 11A)
1. Starting from the left end of the lineup, attach a
Tinnerman clip to each kickplate support. Locate
them over the slot in the kickplate support.
The end kickplate attaches to small brackets that are
affixed to each side of the case. The kickplate can be
adjusted vertically to match the height of the floor below
it.
2. Attach a kickplate splice to the right side of the front
kickplate using the ¾" screw in the lower hole.
1. Attach a Tinnerman clip to the side kickplate support.
3. Lean the kickplate against the kickplate support.
2. Place the end kickplate against the Tinnerman clip on
the end kickplate support.
4. Place the bumper assembly on the case by hanging
the bumper support onto the bumper hanger. The
kickplate should be located behind the bumper
support.
3. Install a black 3/4" screw through the end kickplate
into the Tinnerman clip. A scratch-awl or similar tool
can be used to line up the holes.
5. Install the black 1½" screw through the bumper, front
kickplate, kickplate splice, and into the Tinnerman
clip. A scratch-awl or similar tool can be used to line
up the holes.
4. The front lip of the end kickplate lies behind the front
kickplate and is attached with screws to the front
kickplate and front-end kickplate supports.
6. Follow these steps to install the next bumper in the
Figure 11A: Installing the bumper and kickplate
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Manual Part #: 10000004
lineup. A bumper support splice (provided) should be
installed between the two cases. Center the splice
over the gap using self-tapping screws (provided).
Attach the upper portion of the splice using the
predrilled holes in the splice. Then with two more
screws, attach the lower half.
Figure 11B: Bumper and Kickplate Configuration
Under-Case Return Airflow
To assemble the bumper for under case return airflow, a
spacer (provided) must be inserted between the bumper
support and kickplate (Figure 12). The spacer is held in
place with the standard black assembly screw used to
attach the bumper. One 3/8" spacer is required at each
screw location (2 spacers on a 2-door, 3 spacers on a 3door, etc.).
1. To ease installation, hook the bumper to the case and
position the kickplate. Then pull the bottom edge of
the bumper forward, hold the spacer in place, and
then insert the assembly screw through the bumper,
spacer, kickplate, bumper bracket and into the
Tinnerman clip.
2. With the spacers in place, air will be allowed to flow
between the bumper and kickplate and then underneath the case. The target airflow rate under the case
should be 50 cfm/door.
Figure 12: Bumper / Under-case air flow
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A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
REFRIGERATION
General
Unless otherwise specified, the liquid and suction
connections are made inside the case under the evaporator fan/coil cover. Refrigerant piping may enter the
case through the front left bottom, the left rear bottom of
case or the left rear top of case. The copper pipe should
not touch or rub on the edges of the sheet metal. After
connections have been made, the refrigeration access
hole in the case must be sealed completely with
aerosol¬ dispensed Urethane insulation or equivalent
(i.e.: Great Stuff). Penetrations made in sheet metal
baffles should also be sealed (Figure 13).
Refrigerant Piping
Correct refrigeration line sizing and installation is essential for proper system operation (see wiring diagrams on
pages 16-18). A P-trap must be installed at the bottom
of all vertical suction risers (Figure 14). Various risers
are available as a factory installed option.
Figure 13: Penetration sealing
When two or more case sections are connected to one
compressor, the main liquid and suction line for the
group should be run through the cases and be brought
out through the refrigeration outlet of one case only. The
factory recommends one riser per circuit/system for hot
gas defrost when using top back refrigeration exit. Circuit
risers are available as a factory installed option. Insulate
the tubing for at least 20 feet from the case outlet. On
30" wide door cases with suction lines over 1-3/8"
diameter, a P-trap made with 45° elbows is required
(Figure 14). A piping chase in front of the fan shroud
allows the refrigerant lines to be run through the right or
left end frame.
selected with adequate contact capacity for the switching
load. In rack systems, an evaporator pressure-regulating
valve may be used to control the evaporating temperature.
Piping should not be placed near the electric defrost
heaters. The defrost heaters on the 30" door cases will
grow one inch to the left of the coil when they reach
operating temperature.
When factory installed, the temperature control is
located toward the right end of the case behind the black
kick plate. The sensing bulb is located under the coil
cover on the back side of the fan shroud. It can be wired
in series with the low pressure (L.P.) control. It can also
be used in a pump-down system by wiring it in series
with the liquid solenoid valve. A thermostat is shown in
Figure 15.
The settings (See Figure 16) are approximate due to
variations in gauge accuracy, differences in compressor
efficiency, line pressure drop, and super heat settings.
Before making adjustments for store or stocking conditions, make sure the super heat is set between 6°F and
10°F. Close coupled systems typically run at the higher
end of this range to avoid flood back.
Temperature Control Adjustment
The compressor should be installed as close as possible
to the cases to reduce pressure drop. Install a shallow
trap at the bottom of the riser.
The suction and liquid lines may be taped together to
form an external heat exchanger.
Discharge-air temperature probes for electronic case
controllers may be installed in many different customer
specified locations including, but not limited to, honeycomb, ceiling pocket cover, rear wall, and return air.
The best location for the liquid line drier is inside the
freezing compartment. However, it may be installed near
the compressor for easy maintenance. Install moisture
indicating sight glass at the outlet end of the drier.
A low pressure or temperature control can be used to
control case temperature. The control should be
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Leak Check > Evacuation > Charging
After all of the refrigeration piping and system components have been assembled, the entire system must be pressurized and checked for leaks.
When the system is leak free, evacuate with a deep vacuum pump. Triple evacuation to a minimum of 500 microns
and nitrogen sweep is recommended. After the system has been thoroughly evacuated of all moisture and noncondensable gas, charge the system with the proper refrigerant, using “hi-side/low-side” charging techniques.
Figure 14: 45 degree elbow suction line
Figure 15: Temperature control
Figure 16: Temperature Settings for R404a Refrigerant
Condensing Unit
Cut-in
Cut-out
(psig)
(psig)
Discharge Air Temperature
Cut-in
Cut-out
(°F)
(°F)
Return Air Temperature
Cut-in
Cut-out
(°F)
(°F)
Application
Evaporator
Temp (°F)
Frozen Food
-7
35
24
+3
-3
+6
0
Ice Cream
-16
27
16
-3
-12
-3
-9
Medium Temp.
+28
Note: These set points may require optimization for your applications to prevent short-cycling or delayed cycling.
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Refrigeration
A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
R-404a Line Sizing Tables for Tyler A5 Frozen Foods Merchandisers (-7° Evap. Temp.)
Tyler Refrigeration • Niles Michigan USA
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R-404a Line Sizing Tables for Tyler A5 Ice Cream Merchandisers (-16° Evap. Temp.)
February 2009
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Refrigeration
A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
R-404a Line Sizing Tables for Tyler A5 Medium Temp. Merchandisers (+28° Evap. Temp.)
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Manual Part #: 10000004
ELECTRICAL
is not installed in the liquid line.
CAUTION !
The power to operate each display case is connected at
each cases’ disconnect switch. The power to operate
the condensing unit is connected at the condensing unit.
There are no interconnecting wires between the
condensing unit and display case. There are interconnecting wires that need to be connected between the
cases. The liquid line solenoid valve needs to be
installed in the common liquid line before the liquid is
distributed to the cases.
DISCONNECT POWER TO THE CASE
BEFORE SERVICING ELECTRICAL COMPONENTS
TO AVOID PERSONAL INJURY AND DAMAGE TO
THE UNIT.
Figure 17 shows the typical wiring diagram for a freezer
equipped with electric defrost, Figure 18 shows the
typical wiring diagram for a freezer equipped with hot
gas defrost, and Figure 19 shows a medium-temperature
cooler with time-off defrosting. Each case ships with a
wiring diagram located in the electric box that shows the
exact wiring of the case.
The controls operate the system as a pump down
defrost. When the display case begins defrost, the liquid
line solenoid valve, fans and anti-sweat heaters are deenergized. The defrost heaters are energized. The
compressor continues to run and pumps down the coil.
There are many control options available for multiple
case defrost systems. Wiring diagrams and instructions
can be obtained by contacting the Tyler Refrigeration
Service Department.
The master case contains the time clock. Interconnecting case wiring allows the master case to control the
satellite cases. When defrost is initiated in the master
case, it sends an electrical signal to each satellite case
to energize the defrost relay and initiate a defrost in all of
the cases. A second set of interconnecting wires are
connected in series between each of the cases. Each
case defrost heater is de-energized when the coil
reaches the defrost termination temperature. An
additional signal is relayed to the next case indicating
that the termination temperature has been reached.
When all of the cases have reached termination temperature, the defrost termination circuit is complete and the
defrost is terminated.
External wiring should be sized according to the
amperage rating stamped on the serial plate. The serial
plate is located on the ceiling inside the left-hand door.
Typical electrical values are shown on specification
sheets for each of these cases in the bag attached to the
case or are available at the Tyler Refrigeration website
(www.carrier-tyler.com). All internal wiring has been
completed at the factory. Cases with standard wiring
have their control wires terminated in the electrical
compartment located behind the kickplate at the right
end of the case. A terminal block has been used to
simplify field connections. An electrical box is mounted
on the top of the unit for cases equipped with the
optional top mount electrical connections.
The liquid line solenoid is energized at the end of the
defrost cycle and the defrost heaters are de-energized.
The suction line pressure rises and the compressor
starts. When the evaporator reaches operating temperature, the delay thermostat (klixons) will close, energizing
the fans and anti-sweat door heaters.
All wiring must comply with the National Electrical Code
and all local codes. After installation of the equipment,
correct operation of the electrical circuits and controls
and defrost operation and termination should be verified.
All operating voltages and amperages should be
measured and recorded.
Optional Electrical Wiring
Master-Satellite Connection
The “master-satellite” connection system allows one
condensing unit to be connected to multiple cases.
Figures 20 and 21 shows typical diagrams for this
system.
All of the display case controls including the disconnect
switch, time clock, temperature control, and defrost
temperature control are installed behind the kick plate
and pre-wired. The liquid line solenoid is pre-wired but
February 2009
19
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Wiring Diagram
Figure 17: Electric Defrost A5FGN(T), A5FG(T)BB
Tyler Refrigeration • Niles Michigan USA
20
February 2009
Wiring Diagram
Figure 18: Hot Gas Defrost A5FGN(T), A5FG(T)BB
February 2009
21
Manual Part #: 10000004
www.carrier-tyler.com
Wiring Diagram
Figure 19: Time-off Defrost A5NGN(T), A5NG(T)BB
This wiring diagram for A5NGN(T)
cooler merchandisers is applicable to
both master and satellite cases. The
diagram shows a Defrost Time Clock,
Temperature Control, and Solenoid
Valve. These are required only on the
master case. The satellite case would
only require terminal blocks for lights,
fans, and anti-sweats. Field-install
from the master to the satellite wires
to the respective terminal blocks.
Tyler Refrigeration • Niles Michigan USA
22
February 2009
A5FGN(T), A5FG(T)BB
Master / Satellite Wiring Diagrams (low-temp)
Figure 20: Master (Controller)
February 2009
23
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Master / Satellite Wiring Diagrams (low-temp)
Figure 21: Satellite (Controlled)
Tyler Refrigeration • Niles Michigan USA
24
February 2009
Manual Part #: 10000004
DEFROSTING
Preferred Termination: For optimal performance,
Tyler recommends a temperature-terminated defrost,
using a defrost termination thermostat or probe
sensing the coil temperature.
General
Periodic defrosting to keep the coil free of frost is accomplished automatically by a time clock only in mediumtemperature coolers, or used in conjunction with an
electric or hot gas defrost in low-temperature freezers.
A5FGN and A5FGNT door case has the probe located at
the right hand side of the coil in the center of the bottom
row of tubes.
Defrost Settings and Controls
Off-Cycle Defrost
The A5FGNE and A5FGNTE case has the probe located
at the right hand side of the coil in the top row of tubes.
Medium temperature coolers are typically defrosted by
using an “off-cycle defrost”. During an off-cycle defrost,
refrigeration to the cases is halted, but the evaporator
fans continue to run. Frost is melted by the warmth of
the display case’s internal air. Typically, anti-sweat
heaters and display lights operate during defrost. Defrost
may be terminated by time (30 minutes) or upon
reaching a coil temperature of 43°F.
Tyler provides a defrost termination thermostat as
standard unless a control system defrost probe is
requested. The defrost termination temperature is 50°F.
Temperature termination based on coil temperature
allows the length of defrost to vary depending on how
much frost is on the coil and the defrost heater voltage.
Coil frost is a function of shopping patterns, stocking
habits, general door maintenance and ambient temperature and humidity. More frost requires a longer defrost. A
lower defrost heater voltage extends the defrost period.
Electric Defrost
Frequency: One electric defrost per day is recommended.
Alternate Termination: If it is not possible to terminate the
defrost cycle based on a defrost termination thermostat
or probe sensing the temperature at the coil, and the
only available temperature probe is sensing the
discharge air temperature, then the termination temperature should be set to 65°F, zero minutes drip time.
Time of day: Nighttime defrosting is preferred to avoid
periods of shopping or stocking.
Duration: Electric defrost does not require any drip time
because Tyler provides a built-in fan delay thermostat.
Electric defrost for low-temp and off-cycle for mediumtemp Fail-safe Times:
Ice Cream
Frozen Food Med. Temp
A5FGN(BB)
1/day at 45 mins 1/day at 45 mins
A5FGNT(BB)
1/day at 55 mins 1/day at 55 mins
A5NGNT(BB)
Tyler electric defrost freezers are delivered with the
defrost thermostat open-on-rise contacts wired-in series
with the defrost heaters. Unless the installer rewires the
defrost thermostat, the defrost heater is de-energized
when defrosting is complete.
Tyler electric defrost freezers are also equipped with a
high-limit, snap-disc thermostat that de-energizes the
defrost heater if the coil temperature exceeds 80°F to
provide a secondary safety termination.
3/day at 30 mins
Hot Gas Defrost
Frequency: One hot gas defrost per day is recommended.
At ASHRAE test conditions and 208 volt defrost heater
operation, the typical observed A5FGN 30" door defrost
durations are 28 minutes for ice cream and 19 minutes
for frozen food. At the same conditions, the typical
observed A5FGNT 30" door defrost durations are 39
minutes for ice cream and 26 minutes for frozen food.
A5FGN(T)E Crown End defrost durations are 43
minutes.
February 2009
Time of day: Nighttime defrosting is preferred to avoid
periods of shopping or stocking.
Duration: Hot gas defrost requires a 5 minute drip time.
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Defrosting
A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
The timer starts the gas defrost cycle by energizing a
solenoid, reversing valve, or directional valve. The gas is
injected from the source into the suction line of the
evaporator to be defrosted. The gas flows into the
serpentine coil attached to the floor of the case and then
into the evaporator. Condensed liquid leaves the evaporator through the side port distributor, through a check
valve into the liquid line. (Figure 23).
Hot Gas Defrost Fail-safe Times:
Ice Cream
Frozen Food
Hot Gas
1/day at 30 mins 1/day at 30 mins
5 min. drip
5 min. drip
Reduced
Temperature
Gas
1/day at 40 mins 1/day at 40 mins
5 min. drip
5 min. drip
General Notes
Preferred Termination: For optimal performance,
Tyler recommends a temperature-terminated defrost,
using a defrost termination thermostat or probe
attached to the dump line.
•
The refrigeration technician should recheck coil
condition after one week of retail operations to be
certain that the frequency and duration of defrost
is adequate for the particular store and locality.
For example, if defrost voltage is below 200 volts,
additional fail-safe time may be required.
Defrost termination thermostats are optional on hot gas
or reduced-temperature gas applications. If the cases
are so equipped, the defrost termination is 65°F.
•
When using time terminated defrost, defrost termination thermostat should be wired in series with
the defrost heater.
Electric Defrost Operation
•
Defrost termination thermostats may be wired in
series for multiple evaporator installations.
•
Defrost termination thermostats may be used as a
digital input for electronic controllers.
At ASHRAE test conditions, termination ranges from 1222 minutes.
The compressor stops when the defrost is initiated in a
non-pump-down system. On pump-down systems, the
liquid line solenoid will be de-energized when the defrost
is initiated. The clock will energize the 208/230 volt
defrost heater, and energize the normally closed
208/230 volt contactor or relay. This de-energizes the
115-volt fans, lights and anti-sweat heaters. If you don’t
have a light circuit limit thermostat, the lights will not deenergize.
Limit Thermostat
Each freezer has factory set limit thermostats (Klixons)
attached to the return bends of the coil on the right end
of the freezer to regulate the operation of the evaporator
fans and anti-sweat door heaters. A limit thermostat is
optional for the light circuit. When a limit thermostat is
provided in the lighting circuit, the lights will be off during
defrost.
After the defrost period, the compressor will operate.
When the coil temperature reaches +5°F, the fan, light
and anti-sweat heater limit thermostats (Klixons) will
close, starting the fans, lights and anti-sweat heaters
(Figure 22).
IMPORTANT! OPERATION OF THE LIMIT THERMOSTATS CAUSES THE EVAPORATOR FANS, FREEZER
LIGHTS, AND ANTI-SWEAT DOOR HEATERS TO
REMAIN OFF UNTIL THE COMPRESSOR IS
OPERATING AND THE COIL TEMPERATURE IS
BROUGHT BELOW THE THERMOSTAT CUT-IN
SETTING (+5°F ). SUPERHEAT MUST BE SET
CORRECTLY BY THE INSTALLING CONTRACTOR
FOR PROPER THERMOSTAT OPERATION.
Gas Defrost Operation
Several types of gas defrost methods in conjunction with
time actuated, time or temperature terminated defrost
timers can be used to defrost the evaporator.
The refrigeration system designer and installer are
responsible for correct line sizing for effective gas
defrost and liquid return from the freezers. Sizing and
component selection depend on the type of defrost, size,
and location of high side refrigeration system.
When the freezer first operates, the fans and lights may
cycle off and on a few times until coil temperature is
below +5°F. The superheat must be set for proper
operation.
Tyler freezers equipped for gas defrost consist of a side
port distributor and a TXV check valve for coil defrost,
and a suction line check valve to bypass hot gas to the
serpentine coil. The serpentine coil is attached to the
bottom of the pan to ensure pan and drain defrost.
Tyler Refrigeration • Niles Michigan USA
The 30" door models have a high limit thermostat
installed on the coil return bend, wired in series with the
defrost heaters. This thermostat opens when the temperature reaches 80°F.
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February 2009
Manual Part #: 10000004
ITEM NO.
PART NAME
1
COIL COVER
2
FAN
3
4
LIQUID LINE
5
FAN HOUSING
6
HEAT EXCHANGER
7
EXPANSION VALVE
8
FRONT HEATING ELEMENT
9
REAR HEATING ELEMENT
10
HEATER CLIP
11
DEFROST TERMINATION
PROBE LOCATION
SUCTION LINE
Figure 22: Coil Parts Breakdown, Electric Defrost
ITEM NO.
PART NAME
1
COIL COVER
2
FAN
3
FAN HOUSING
4
COIL
5
CHECK VALVE
6
SERPENTINE
7
SLHX HEAT EXCHANGER
8
TXV VALVE
9
HAND VALVE (OPTIONAL)
10
DRIER (OPTIONAL)
11
CHECK VALVE
12
SIGHT GLASS (OPTIONAL)
13
DEFROST TERMINATION
PROBE LOCATION
Figure 23: Coil Parts Breakdown, Hot Gas Defrost
February 2009
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A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
USER INFORMATION & SERVICE
down to prevent the case lights from cycling off and on.
Always turn the light switch off when replacing lamps.
User Information
Cleaning
Case Thermometer
Cases should be thoroughly cleaned before start-up and
routinely thereafter to maintain a clean appearance. Use
mild detergent and warm water (never an abrasive
cleaner) to wipe out the inside of the case. Wash down
all glass doors with glass cleaner. Do not use any
products containing silicon on anti-fog glass coatings.
Clean interior glass reduces fogging and increases
visibility. The case will remain bright and sparkling with
just a few minutes of cleaning each week. Internal
components can be cleaned after removal of access
panels. The case drain should be regularly cleared of
debris and price tags.
Cases are typically shipped with 2 thermometers. One
thermometer is factory mounted in the discharge air
stream. The second thermometer is shipped loose and
should be installed in the warmest product location.
Specific instructions are packaged with the shipped
loose thermometer.
Service
Cart bumpers must be removed to gain access to drain
clean-outs and electrical connections. Disassemble the
bumper and kickplate by removing the 2 or 3 metal
screws located in the kickplate. The bumper assembly
can be lifted up and removed from the case. The
kickplate can be removed, exposing the electric tray
cover and drain (Figure 11A).
Do not use high-pressure water or steam to clean the
interior.
Shelf Location
The shelves are adjustable in 1" increments and may be
located in any position for the best display advantage.
Be sure shelf clips or brackets are completely seated
before installing the shelf. The shelf brackets (for wire
shelves only) are stamped with “R” for Right and “L” for
left for proper orientation when installing shelves.
Evaporator
The evaporator coil, located at the bottom-rear of the
case is factory assembled with the distributor, expansion
valve, and other refrigeration components. To inspect the
coil, remove the center or left-of-center coil cover. A
small inspection port is located at the rear of the case.
To inspect the entire coil, remove the remaining coil
covers and raise the evaporator cover.
Shelves
Tyler manufactures many different styles of shelves,
baskets and product stops. The shelves and baskets are
placed on the shelf brackets. Some of the baskets may
be reversed and used as a typical shelf.
Expansion Valve
A superheat-adjustable externally equalized thermostatic
expansion valve, with a removable strainer and pressure
limiting charge, is mounted to the evaporator coil unless otherwise specified. The valve is not preset.
Adjust the superheat setting for maximum coil effectiveness. Typical superheat settings are between 6°F and
10°F. Close coupled systems should use the higher
superheat setting to minimize the chance of liquid flood
back.
Loading the Case
The case may be loaded with merchandise after it has
been operated for at least 24 hours with correct case
temperature and proper control operation. While loading
the shelves, leave an air space between the top of the
merchandise and the shelf above it so the customer can
remove the merchandise. The air space allows an air
curtain on top of the product. Product should not extend
beyond the front of the shelves or block the return air
grill.
To adjust the expansion valve, remove the right end coil
cover. Remove the cap from the bottom of the valve.
When looking at the valve stem end, turn the valve stem
counterclockwise to decrease superheat. Turn the valve
stem clockwise to increase superheat. Measure the
suction line temperature at the expansion valve-sensing
bulb and compare it to the suction temperature corresponding to the saturated pressure. Make sure that line
pressure drop is taken into account. (con’t on p.30)
The typical Cantilever shelf load is 170 lbs. with a
maximum load of 235 lbs. Note some deflection may
occur under higher loads.
Light Switch
A light switch is located inside the right-hand door. Turn
the light switch off during the initial case temperature pull
Tyler Refrigeration • Niles Michigan USA
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February 2009
Manual Part #: 10000004
Case Lineup Combinations and Length Chart
Doors in
Lineup
2 Door
Case
2
1
3
3 Door
Case
4 Door
Case
5 Door
Case
1
4
1
5
1
6
2
7
1
62.13
5 ft 2-1/8 in
92.50
7 ft 8-1/2 in
123.00
10 ft 3 in
153.38
12 ft 9-3/8 in
185.00
15 ft 5 in
1
215.50
17 ft 11-1/2 in
8
2
246.00
20 ft 6 in
9
1
1
276.38
23 ft 3/8 in
2
306.75
25 ft 6-3/4 in
338.50
28 ft 2-1/2 in
10
11
1
2
12
3
369.00
30 ft 9 in
13
2
1
399.38
33 ft 3-3/8 in
14
1
2
429.75
35 ft 9-3/4 in
3
460.13
38 ft 4-1/8 in
492.00
41 ft
15
16
4
17
3
1
522.38
43 ft 6-3/8 in
18
2
2
552.75
46 ft 3/4 in
19
1
3
583.13
48 ft 7-1/8 in
4
613.50
51 ft 1-1/2 in
20
21
4
1
645.38
23 ft 9-3/8 in
22
3
2
675.75
56 ft 3-3/4 in
23
2
3
706.13
58 ft 10-1/8 in
24
1
4
736.50
61 ft 4-1/2 in
5
766.88
63 ft 10-7/8 in
25
26
4
2
798.75
66 ft 6-3/4 in
27
3
3
829.13
69 ft 1-1/8 in
28
2
4
859.50
71 ft 7-1/2 in
29
1
5
889.88
74 ft 1-7/8 in
30
6
920.25
76 ft 8-1/4 in
31
4
3
952.13
79 ft 4-1/8 in
32
3
4
982.50
81 ft 10-1/2 in
33
2
5
1,012.88
84 ft 4-7/8 in
34
1
6
1,043.25
86 ft 11-1/4 in
35
7
1,073.63
89 ft 5-5/8 in
36
4
4
1,105.50
92 ft 1-1/2 in
37
3
5
1,135.88
94 ft 7-7/8 in
38
2
6
1,166.25
97 ft 2-1/4 in
39
1
7
1,196.63
99 ft 8-5/8 in
8
1,227.00
102 ft 3 in
40
February 2009
Total length
Total length
w/o ends (in.) w/o ends (ft. & in.)
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User Information & Service
A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
Turn the valve stem only 1/4 turn at a time and allow
sufficient time (20 to 30 minutes) for the valve to settle
before making any further adjustments. Replace the
valve stem cap after the valve super-heat has been
adjusted. BE CERTAIN THE VALVE STEM CAP IS
WIPED DRY FIRST.
operating at all times except during defrosting (lowtemperature only). Fan motors should be replaced with
motors having the same characteristics including type,
physical size, wattage and RPM.
Air-Curtain Velocities
Air-curtain velocity for freezers and coolers are affected
by stocking levels, coil frost loads, temperature and fan
condition. The measurement method also affects the
reading. Tyler recommends using an Alnor Velometer
Jr., set to the 0-to-800 fpm range. Air velocity should be
measured at the back edge of the discharge air honeycomb, at the center of the middle door in the case (other
doors have slightly lower velocity). A typical velocity
reading is 425 feet per minute (FPM) in a fully-packed
freezer (395 FPM for medium-temperature coolers), after
the freezer/cooler has defrosted and is pulled down to
operating temperature. A typical velocity reading for tall
cases is 400 FPM for freezers, and 370 FPM for coolers
under the same conditions. Air-curtain velocity in a
partially packed freezer is significantly lower because
more air exits the back wall duct holes.
! CAUTION !
DISCONNECT POWER TO THE CASE BEFORE
SERVICING ELECTRICAL COMPONENTS TO AVOID
PERSONAL INJURY AND DAMAGE TO THE UNIT.
Defrost Heater Element
On 30" door cases one heater is located on the front of
the coil and one on the rear of the coil. On wraparound
cases, the heater element is located under the coil. The
electric wire leads are connected in the junction box
behind the front kick rail.
Heater Element Removal
Defrost heaters for the electric defrost cases are located
on the front and rear face of the coil. The front heater is
located approximately 1” off the floor and the rear heater
is approximately 2” off the floor. The heater is secured to
the coil by a number of stainless steel heater retaining
clips. Heaters are fastened to the floor on the right hand
side of the coil. Remove fasteners holding the heater to
the floor.
Fan Removal
1. Turn off power to fans. Remove coil cover.
2. Unplug fan from fan power supply plug located on the
front face of the fan housing.
3. Remove the fan blade nut and fan blade.
The front heater can be removed by pulling the retaining
clip away from the coil and sliding the heater out from
under the clip.
4. Remove the two mounting bolts and remove the fan
assembly from the fan housing.
The rear heater can be removed by raising the heater
retaining clip. Raise each clip about 2 inches above the
coil working from right to left on the coil. Repeat this
process until the retaining clips are free of the coil. The
heater will slide up with the retaining clip.
5. Remove the three fan motor mounting screws from
the back of the fan motor.
To remove the defrost element for the A5FGN(T)E
Crown End, remove the coil covers. Lift the inner coil
cover upward and tip the fan housing forward. This will
expose the coil. Remove both fan housing end brackets
and center coil supports, then slide out the complete
heater pan assembly from under the coil. Slowly lift the
heater pan assembly between the coil and fan housing,
turning it on edge while lifting. Heaters are installed in
the reverse order of how they were removed.
Most Tyler case ballasts are located in the door mullion.
Ballasts for the Crown Ends are located behind the
kickplate.
6. Reverse steps 1 - 5 to install.
Ballasts for A5F(N)GN(T)E Crown Ends
Fluorescent Lighting
T8 lighting systems use a lens to direct light output
evenly across the shelves. Turn off power before
servicing the lamps. The lens must be removed to
access the lamp. The lens must be replaced after
servicing for proper operation. Detailed information is
contained in the door instruction booklet.
Evaporator Fans
Air is circulated throughout the case with 115-volt low
temperature fan motors. These motors must be
Tyler Refrigeration • Niles Michigan USA
30
February 2009
Manual Part #: 10000004
Front Edge Trim Replacement
C
The metal front edge trim is designed as a removeable
protective piece that can help protect the end panel from
receiving direct damage. In the event of damage, the
edge trim can be removed and a replacement piece
reinstalled. The following procedure demonstrates how
to replace the edge trim:
A
A. Back-out and retain the
frame screws that secure the
“J”-strip that covers the inside
edge of the trim piece. If the
door hinges on the side of the
edge trim that needs replaced,
it will be in the way of the frame
screws, and will need to be
removed first in order to access
the screws.
B. Use a razor blade to score
and remove the clear silicone
bead and then remove the Jstrip. Remove excess silicone
from the J-strip as needed.
NOTE: Take proper precautions
when using a sharp razor
blade.
D. Seat the new replacement edge trim piece by laying
the top fold of the edge trim into place first, keeping the
trim at an angle away from the panel. Then work the
piece into place by pressing both downward and inward,
applying even pressure to the trim as you work your way
down to ensure a proper seal with the tape.
D
E
B
E. Reinstall the J-strip with the screws and apply a new
bead of clear silicone to seal the J-strip to the edge trim.
C. The edge trim piece is secured to the front with a
commercial grade double-sided tape (not supplied by
Tyler). To remove the damaged trim, start at the top with
a blade or screwdriver and tap out to separate the trim
from the end panel. Continue downward by gently prying
the piece from the panel until removed. Remove any
loose debris or tape and then apply strips of doublesided tape to the front of the end panel and remove the
backing from the tape. Make sure the entire surface is
covered.
February 2009
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A5FGN(T), A5FG(T)BB, A5NGN(T), A5NG(T)BB
REVISION LOG
This log sheet is intended to track both major and minor revisions to this manual, and to describe what the
nature of the revision is. Revision identification is located in the lower right corner of the cover page.
Major revisions are lettered alphabetically, dated accordingly, and require reprinting for inclusion with the
product at shipment. Minor revisions are denoted after the major revision with a “period” followed by a sequential number, and do not require a printed update. All manuals with any revision changes will be available in
electronic PDF format on the Tyler Refrigeration website.
Content changes that determine the type of revisions are decided on a case-by-case basis by Tyler internal
management.
REVISION TYPE
DATE
MAJOR
MINOR
Feb 2009
n/a
n/a
Tyler Refrigeration • Niles Michigan USA
DESCRIPTION
RESULTS
First Edition Printing
32
February 2009
February 2009
33
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