January 2006
INSTALLATION & SERVICE
INSTRUCTIONS
FOR
DCCG and DCSG (-D) MODELS
Dipping and Display Case
First Call for help (US and Canada):
1-800-922-1919
Soporte Tècnico y Asistencia (Mèxico):
01-800-522-1900
For a Service Network Locator and other
Information visit us at
select Worldwide Locations
P/N OII – DCCG - DCSG
January 2006
HUSSMANN - GLOVERSVILLE
TABLE OF CONTENTS CON’T
Dipping Using Guide
Loading
10
Storage
10
Lids
10
Temperature Control
Load Limits
Dipping
10 - 11
11
11
Maintenance
11
Warranty and Parts Information
12 - 13
2
INTRODUCTION, INSPECTION, SPECIFICATIONS
INSTALLATION and START UP
INTRODUCTION –
durability. The entire assembly is then
chemically treated and finished with
baked-on powder paint.
The DCSG/DCCG-4 8, 12, and 16 are
specifically designed for dipping/display
of bulk ice cream, sherbet, or frozen
yogurt. Wide glass front and one-piece
molded lids provide an unobstructed view
of the product for impulse merchandising.
Optional items include easy to use can
holder trays and dipper wells. The –D
models on -8, -12 and -16 include the
labor saving storage doors feature.
The liner is an all welded assembly of
electro zinc steel. Copper evaporator
tubing is fastened to the liner and
applying a conductive material on both
top and bottom of the tubing further
enhances maximum heat transfer. The
liner is also chemically treated and
painted with baked-on powder paint.
All models incorporate
condensing unit for easy access to all
components.
a
slide-out
INSPECTION –
Upon receipt of the cabinet, carefully
examine the crating for damage.
If
damage is found, make a note on the
delivery ticket before signing. Carefully
remove shipping crate and examine the
cabinet for “concealed” damage.
If
damage is found contact the delivering
carrier immediately and have his agent
prepare an inspection report for the
purpose of filing a claim. This is your
responsibility.
SPECIFICATIONS
CONSTRUCTION –
The base is an all welded assembly of
heavy dusty steel to provide a strong
frame on which the rest of the cabinet is
built.
The shell is formed from heavy gauge
steel, welded together as an assembly, and
then welded to the base for strength and
3
CABINET DIMENSIONS –
Cabinet
Model
DCSG/DCCG
Dimensions (inches)
Width
Outside * Inside
Length
Outside
Height Ship
Outside Wt.
Inside
-4
-8
-12
-16
25 3/8
21
43 1/8
63
25 13/16
25 13/16
25 13/16
25 13/16
21 ½
51 ¼
260
405
515
625
47 7/16
67 5/16
87 7/16
21 1/2
21 1/2
21 1/2
51 1/4
51 1/4
51 1/4
83 1/8
* -D models (with doors) outside width = 27 9/16
CABINET CAPACITIES –
Cabinet
Model
DCSG/DCCG
Cu.
Ft.
Capacity (9 1/2 dia. 3 gal cans)
Upper Display Lower Display
# of lids
-4
-8
-12
-16
3.3
4
8
12
16
-
4
8
12
1
1
2
2
8.9
14.5
20.2
(Capacities of ±D models are the same as models without doors)
ELECTRICAL DATA
Cabinet
Model
DCSG/DCCG
-4
-8
-12
-16
Compressor
Cabinet *
Nominal
Run Amps Amps
Volts
HP
L.R.
Amps
33.0
F.L.
Amps
6.4
Fuse
115
115
115
115
1/3
6.9
15
15
15
15
1/2 58.0
1/2 45.0
3/4 59.8
8.6
7.8
10.2
9.5
9.9
10.5
(electrical data of ±D models are the same as standard models)
* Includes main top heaters and condenser fan motors
Due to compressor change from semi-hermetic to hermetic these are the value changes
-8 (*hermetic)
-12 (*hermetic)
115
115
½
½
51.0
87.0
.9
7.9
8.4
12.0
15
15
* effective Aug. 2002 the DCCG/DCSG-8 compressor changed from a semi-hermetic
HATB-005E-IAA to hermetic T2155GK.
* effective Nov. 2003 the DCCG/DCSG-12 compressor changed from a semi-hermetic
KAGB-0050-IAA to hermetic J2212GK Aspera
4
equipment on the same circuit. Use a
time delay fuse or circuit breaker. The
supply circuit must be properly grounded
and conform to National and Local
Electrical Codes. Voltage, as measured at
INSTALLATION and
START UP
the
compressor
terminals
during
LOCATION –
operation, must not vary more than 5%
from cabinet serial plate rating. If a low
voltage condition exists, contact your
electrician or power company.
The location of your cabinet is important.
Make sure your selected location is NOT
in any of the following areas as it could
seriously affect the operation.
A wiring diagram is provided on the
condenser shroud for each unit.
•
•
Not in direct sunlight.
A power (ON-OFF) switch is provided on
each model. The switch is accessible
through a hole provided in the rear
(operator side) access panel
Not in the air path of heat or air
conditioning ducts.
•
Not at an exit or entrance affected by
extreme temperature change.
START UP PROCEDURE -
Allow 2 feet of clearance at the rear of the
case to allow adequate air movement
across the condenser for proper
refrigeration system performance, do not
obstruct the grille at the rear intake and
discharge. If desired, the blank off panel
behind the front (customer side) louvered
panel – may be removed for rear air
intake and front air discharge, but then
insure 2 feet of unobstructed clearance is
left at the case front.
•
Cut the band which holds the
compressor in place during shipment.
•
Make sure fan turns freely. Check for
any connections or parts that might
have loosened during shipment.
•
Start cabinet, and allow temperature
to pull down to normal level before
loading product.
Level case front to back and end to end,
shimming
where
necessary
upon
installation to assure proper operating
drains, and refrigeration system.
POWER REQUIREMENTS –
The DC models are equipped with a
three-wire grounded service core for your
protection. The cabinets are designed to
operate on 115V single-phase 60hz
current.
A
separate circuit is
recommended to prevent product loss due
to overloading or malfunction of other
5
OPERATION AND MAINTENANCE
SERVICING DATA AND
PROCEDURES
•
Raise top and canopy as an assembly
and place wood spacers between top
and cabinet.
OPERATION and
MAINTENANCE
TEMPERATURE CONTROL –
•
•
•
Remove heater from under base
frame.
The thermostat, which senses the cold
wall temperature, is located at the lower
rear right corner of the cabinet through
the access panel. It has been pre-set at
the factory to maintain product
temperatures between +10° and +4°. The
thermostat is adjustable. If other than
normal temperatures are required, adjust
the control by turning the knob clockwise
for colder and counter-clockwise for
warmer temperatures.
Disconnect spade terminal splices and
remove.
Reassemble reverse order – resistance
heater wire must be taped back into
position
DEFROSTING –
It must be recognized that accumulation
of frost on the cabinet walls does impair
DISPLAY LIGHTING –
refrigeration.
Daily scraping of the
All models are equipped with fluorescent
light fixtures installed in the canopy. An
ON-OFF switch is located in the right
service side of the canopy and is so
labeled.
interior walls with a plastic scraper will
extend the length of time between
complete defrosting.
Most installations will require a complete
defrosting every seven to ten days.
Usually the best time to defrost is at the
close of business so the cabinet will be
regulated for the start of the next business
day.
ANTI-SWEAT HEATERS –
A resistance heater is installed in the
perimeter of the base frame of the canopy
to prevent condensation. Continuity of
the heater circuit maybe checked at the
splice located inside the ballast enclosure
in the compressor compartment.
The ice cream should be removed from
the cabinet and placed in a walk-in or
storage freezer during the defrosting
operation. A power switch for turning
the case off for defrosting is located
through the access panel.
Should the heater fail it may be replaced
by:
Defrosting may be accomplished with the
aid of a hair dryer, plastic scraper or by
merely letting the cabinet remain open
until the walls are cleared. Care should
•
Remove screws holding aluminum top
to cabinet.
6
be taken not to puncture the interior
walls or remove paint from the walls
during this procedure.
CLEANING EXTERIOR / INTERIOR –
When cleaning the exterior of the cabinet
use a soft cloth or sponge with water and
mild detergent. Rinse and wipe dry.
Be sure to disconnect power from the
cabinet prior to starting defrost
operation. After the cabinet is completely
defrosted, wash thoroughly, remove
defrost water (Hussmann dipping cases
are provided with an outside drain
located on the operator’s side of the case
base to assist you in this operation), wipe
the interior dry, and turn the power back
on.
For cleaning the interior of the product
compartment, a built-in drain has been
provided with a standard hose fitting
located at the front of the cabinet in the
base area.
Disconnect the electrical
power and allow cabinet to warm to
above freezing temperature. Use a soft
cloth or sponge with a mild detergent to
wash the interior.
Wipe dry before
Be sure to allow the cabinet to cool down
to its operating temperature before
reloading.
restarting the cabinet. Allow the cabinet
to cool down to proper temperature
before reloading product.
CONDENSING UNIT –
SERIAL PLATE LOCATION –
The condensing unit is mounted on a
slideout base, accessible by removing the
One serial plate is located on the interior
left wall of the cabinet, and a second one
in the condensing unit compartment.
Both contain all pertinent information
such as model, serial number, amperage
rating, refrigerant type and charge, etc.
Specific charges are DCSG/DCCG-4 16
oz.,DCSG/DCCG-8 29 oz., DCSG/DCCG-
12 33 oz., and DCSG/DCCG-16 has 31
oz., all have R-404a. The “D” models
have the same charge.
rear serving side access panel.
The
condenser is of the baretube design. The
condenser fan motor draws the air
through the rear access panel, across the
compressor and discharges back out the
rear access panel unless the case has been
Field converted to front air discharge as
previously discussed in the Location
section of this manual. For this reason, if
the case is installed in a counter, provisions
must be made for the release of the
discharge air.
TEMPERATURE CONTROL
REPLACEMENT –
CLEANING THE CONDENSER –
The Ranco temperature control is located
in the compressor compartment.
To
replace, first disconnect power supply and
remove two screws holding control dial
plate. Pull capillary tube from control
well, noting length of tube removed. Push
new cap tube into well, being careful not
to kink it, and making certain it reaches
full depth of well.
To clean condenser, a soft, nylon brush
should be used to loosen dirt and lint.
Then vacuum up the dirt or blow
condenser out with a high-pressure gas
such as nitrogen. Never use a wire brush
to clean condenser tubes.
7
Replace spade connectors and reinstall
dial plate and two screws which hold
control in place.
Operational Data
The following operational data is based on lab tests, and may vary under field
conditions. The conditions shown at the non-recommended high 85°F ambient are shown
for information only and a possible reason for jobsite problems. Note that during August,
2002, the DCC/SG-8 cases changed from semi-hermetic (SH) to hermetic (H) and similarly,
during December, 2003, the DCC/SG-12 cases changed from the semi-hermetic (SH) to
hermetic (H) style compressors which operate under different pressures.
75°F
85°F
Compressor
Suction
Pressure
Head
Pressure
Suction
Pressure
Head
Pressure
Model
Compressor
Type
H
DCC/SG-4
NE2134GK
HATB-005E-
CAA
T2155GK
KAGB-005E-
IAA
9
230-240
10
260-270
DCC/SG-8 &-D
DCC/SG-8 &-D
DCC/SG-12 &-
D
DCC/SG-12 &-
D
DCC/SG-16 &-
D
SH
H
6
9
230-240
230-240
7
10
245-255
235-245
SH
H
6
10
6
235-245
230-240
270-280
7
11.5
7
250-260
260-270
280-290
J2212GK
KAAB-007E-
CAA
SH
Load Line Temperature
0 to +10°F
5 to +12°F
TROUBLE SHOOTING CHART
TROUBLE
PROBABLE CAUSE
SOLUTION
Compressor will not start,
no noise
1. Power disconnected
1. Check service cord for
proper connection
2. Replace fuse or reset
breaker
2. Blown fuse or breaker
3. Repair or replace
3. Defective or broken
wiring
4. Defective overload
5. Defective temperature
4. Replace
5. Replace control
Compressor will not start
cuts out on overload
1. Low voltage
1. Check voltage at cabinet.
Should be within 5% of
rating
2. Defective compressor
3. Defective relay
2. Replace
3. Replace
8
4. Repair or replace tube
4. Restriction pinched cap
tube
5. Restriction moisture
5. Leak check, replace drier,
evacuate and recharge
6. Allow at least 24” at front
and back of unit
6. Inadequate air over
condenser
compartment
7. Defective condenser fan
motor
7. Replace
TROUBLE
PROBABLE CAUSE
SOLUTION
High head pressure
1. Cabinet location too warm 1. Relocated cabinet
2. Restricted condenser air
flow
3. Defective condenser fan
motor
2. Clean condenser or
remove air flow restriction
3. Replace motor
4. Air or non-condensable
gases in system
4. Leak check, change drier,
evacuate and recharge
1. Reset control
Warm storage temperatures 1. Temperature control not
set properly
2. Short of refrigerant
2. Leak check, change drier,
evacuate and recharge
3. Cabinet location too warm 3. Relocate cabinet
4. Too much refrigerant
4. Purge system, change
drier, evacuate and recharge
5. Check voltage at cabinet.
Should be within 5% of
rating
5. Low voltage, compressor
cycling on overload
6. Heavy frost on side walls
6. Defrost cabinet
1. Defective control
1. Replace
Compressor runs
continuously, product too
cold
2. Control sensing element
not completely installed in
well
2. Push control sensing
element into well
3. Short on refrigerant
3. Leak check, change drier,
evacuate and recharge
Compressor runs
continuously, product too
warm
1. Short on refrigerant
1. Leak check, change drier,
evacuate and recharge
2. Inefficient compressor
2. Replace
9
DIPPING USERS GUIDE
The general success of any ice cream dipping department depends to a great extent on the
people within that department. If at all possible, a single individual should be assigned the
direct responsibility of assuring that proper operational procedures are being followed.
LOADING –
‡
Careful thought should be given to the placement of flavors within the cabinet prior to
the opening of the dipping department. Flavors with the highest sugar content (ripple,
maple syrup, and candy) require a lower temperature for dipping than vanilla. Since
temperatures will vary slightly within the cabinet, it is recommended that these flavors
be placed in the corners where maximum cooling effect from two walls can be taken
advantage of.
STORAGE –
‡
In order to assure product quality and minimum energy usage, it is important that
proper attention is given to the maintenance of product temperatures prior to placement
in the display freezer. Storage temperatures are generally maintained at –12 degrees F
to –18 degrees F. This allows for long-term storage of ice cream without deterioration.
Dipping temperatures are generally maintained at +5 degrees F to +9 degrees F, which
allows for rather limited display time before deterioration begins to occur.
‡
‡
‡
Ice cream removed from a delivery truck, walk-in freezer, or storage cabinet should be
placed in the dipping cabinet immediately.
The dipping cabinet is not designed as a hardening cabinet, and will generally only
maintain ice cream at the preset dipping temperature.
If ice cream is allowed to warm up prior to placement in the dipping cabinet,
crystallization may occur resulting in some loss of product quality.
LIDS –
‡
To conserve energy and minimize frost accumulation on the cabinet interior walls, the
lids should remain closed until the customer has made his/her choice of flavors, and
should be closed immediately once the customer has been served. Under no
circumstances should the cabinet lids be left open for extended periods of time.
10
TEMPERATURE CONTROL –
‡
The temperature control is factory set for normal dipping temperatures. If, after a week
or so of operation, it is decided that a higher or lower temperature is required, only a
qualified refrigeration mechanic should adjust the control. Other than the initial
adjustment and possibly a seasonal adjustment, no other setting should be required. If
the cabinet temperature fluctuates to any great extent, a refrigeration mechanic should
be notified. Employees should not be allowed to tamper within the control setting.
LOAD LIMITS –
·
A fully loaded cabinet will use less energy and maintain generally more even
temperatures than one that is only partially full. However, care should be taken not to
exceed the load line limits as noted on the interior cabinet walls through the use of wire
racks, stepshelving, or by stacking containers three high.
DIPPING –
‡
Much of the success of hand dipping and appeal of the stored ice cream to the customer
depends on the training of personnel in proper dipping methods. Periodic scraping of
the container sidewalls and leveling off of the ice cream is essential to avoid discoloration
and drying out of the ice cream. Scraping the container sidewalls and leveling off the ice
cream should be done lightly with the use of a spade. Start with the back of the spade
turned towards the side of the can, working from the top of the can down. Once the
walls are cleared, the top portion of the remaining ice cream should be leveled off, filling
in holes left by previous dipping.
MAINTENANCE –
·
Proper maintenance of refrigeration equipment can have a dramatic effect on the
equipment’s ability to perform, as well as power consumption and customer reaction to
your dipping operation.
‡
Hussmann equipment is designed so that a minimum amount of maintenance is
necessary. The relatively few items that do require attention should be scheduled for
specific time periods based on prevailing store conditions and cabinet usage.
11
WARRANTY –
Please read carefully to assure prompt and accurate service
Ordering Replacement Parts –
·
·
Contact your nearest Hussmann
Always specify model and serial number of
·
If correct part number is not known, give a clear description of part itself
and its function in the cabinet.
Warranty Parts Procedure –
·
·
Same as items above
Give original installation date of cabinet and, if possible, forward a copy of the
·
All shipments of in-warranty replacement parts will be invoiced from the factory until
such time as the defective part is returned and proved to be defective by our Quality
Control Department.
Contact your Hussmann Distributor for instructions on returning in-warranty parts.
Warranty parts must be returned to the factory within 30 days of date of failure to
assure proper disposition.
Lack of any of the above information may result in the shipment of the wrong part, or a
delay in shipment.
Compressor Replacement Procedure –
Replacement compressors will not be shipped from the Hussmann factory. They
may be obtained from your nearest Copeland Wholesaler.
Your wholesaler will replace, free of charge, any compressor found to be defective within
twelve months of installation, not to exceed twenty months from the date of
manufacture, as determined by the compressor serial number on the compressor serial
plate. For any defective compressor beyond the twelve or twenty month time period, a salvage
value credit will be given too partially offset the invoice for the replacement.
12
BLUE
BLUE
LAMP
LIGHT
SWITCH
RED
RED
BLK
BALLAST
WHT
CANOPY HEATER
WHT
22
24
30
26
28
6
BLK
HIGH LIMIT SWITCH
TEMPERATURE
CONTROL
BLK
23
25
31
27
29
5
COMPRESSOR
MOTOR
OVERLOAD
TERMINAL
BLOCK
C
R
S
RELAY
1
S
START
CAP.
POWER
SWITCH
POWER
CORD
CONDENSER
FAN
2
M
BLK
BLK
WHT
COMPRESSOR
USAGE: DCCG-4
WHT
TOLERANCES UNLESS OTHERWISE SPECIFIED: FRACTIONAL 1/32"
DECIMAL 0.031" ANGULAR 1° HOLE LOCATION & SPACING 1/64"
REV EO # REV DATE REV BY
115 VOLT
60 Hz
1 Ph
-
-
-
GLOVERSVILLE, NY 12078
GRN
APPROVED BY
-
EO NUMBER
-
-
-
-
-
WIRING DIAGRAM
-
DRAWN BY:
DATE DRAWN :
APPROVED BY:
JJH
01/29/2004 SHEET #
SCALE INCHES
1 OF 1
M100-2309
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