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ZERO ZONE REVEAL MERCHANDISER® OPEN MULTI-DECKS With ChillBrite® LED Lighting INSTALLATION & OPERATION MANUAL COMPLIANT 66-0057 REV E • Aug 2021 Table of Contents ZERO ZONE WARRANTY....................................................................................... 1 INTRODUCTION...................................................................................................... 2 INSTALLATION & OPERATION.............................................................................. 4 Delivery Inspection............................................................................................. 4 Packaging.......................................................................................................... 4 Location............................................................................................................. 4 Moving Cases.................................................................................................... 5 Optional Bases............................................................................................ 5 Leveling.............................................................................................................. 6 Lineup Assembly ............................................................................................... 8 Canopy Splice.................................................................................................. 10 Hand Rail Splice.............................................................................................. 10 Alternate Bumper Splice & Glass Front Splice................................................ 11 Drain................................................................................................................ 11 Kickplates......................................................................................................... 12 Bumper............................................................................................................ 12 Mirrors.............................................................................................................. 13 Night Curtains.................................................................................................. 14 Under Shelf Lights........................................................................................... 14 Canopy Lights.................................................................................................. 15 Shelves & Stocking Product............................................................................. 15 REFRIGERATION.................................................................................................. 16 Mechanical Components................................................................................. 16 Evaporator Coil & Expansion Valve........................................................... 16 Evaporator Fans........................................................................................ 16 Refrigerant Piping............................................................................................ 16 Operation Set Points........................................................................................ 18 Off-Cycle Defrost............................................................................................. 18 Case Thermometer.......................................................................................... 18 ELECTRICAL......................................................................................................... 19 General............................................................................................................ 19 MAINTENANCE..................................................................................................... 20 Cleaning........................................................................................................... 20 Under Case Floor Cleaning (NSF)............................................................ 20 When installing a Reveal Merchandiser® in a Hybrid Merchandiser™ configuration, refer to both this manual and the Hybrid Merchandiser™ Installation & Operation Manual. II ZERO ZONE WARRANTY ZERO ZONE WARRANTY Limited Warranty Zero Zone, Inc. (Seller) hereby warrants that any products manufactured by it and sold are warranted to be free from defects in material and workmanship, under normal use and service for its intended purpose, for a period of one (1) year from the date of original installation (not to exceed 15 months from the date of factory shipment). Zero Zone ChillBrite® LED Lighting carries a 5-year parts warranty. Zero Zone CoolView® Doors carry a 10-year glass pack parts warranty. The obligation under this warranty shall be limited to repairing or exchanging any part, or parts, FOB Factory, which is proven to the satisfaction of the Zero Zone Service Department to be defective. Zero Zone reserves the right to inspect the job site, installation, and reason for failure. This limited warranty does not cover labor, freight, or loss of food or product, including refrigerant loss. This warranty does not apply to motors, switches, controls, lamps, driers, fuses, or other parts manufactured by others and purchased by the Seller unless the manufacturer of these items warrants the same to the Seller, and then only to the extent of those manufacturer’s warranty to the Seller. Any products sold on an “AS IS” basis shall not be covered by this warranty. Extended Warranties In addition to the standard limited warranty, for further consideration, the Seller will extend to the original purchaser prior to shipment, a limited extended warranty on the compressor only, following expiration of the standard warranty. The Seller agrees to repair or exchange, at its option, or provide reimbursement for such exchange as directed, less any credit allowed for return of the original compressor, of a compressor of like or similar design and capacity, if it is shown to the satisfaction of Zero Zone that the compressor is inoperative due to defects in factory workmanship or material under normal use and services as outlined by Zero Zone in its Installation & Operation Manuals and other instructions. Length of Extended Warranty Any compressor warranty may be extended for an additional four (4) years, but such extension must be purchased prior to shipment to be effective. This warranty is only for the compressor and not for any other associated parts of the refrigeration system. Product Not Manufactured by the Seller The written warranty, if any, provided by the manufacturer of any part of the refrigeration unit sold by Seller to Buyer, but not manufactured by Seller, is hereby assigned to the Buyer. However, Seller makes no representation or warranty regarding the existence, validity, or enforceability of any such written warranty. Limitation and Exclusion of Warranties THE WARRANTIES SET FORTH HEREIN ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND REMEDIES WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE. DC-01-F • SEP 2019 the responsive company™ CASE DIVISION 110 N Oakridge Drive North Prairie, WI 53153 Phone: 262-392-6400 Toll Free: 800-247-4496 SYSTEMS DIVISION 6151 140th Ave NW Ramsey, MN 55303 Phone: 763-398-1996 Toll Free: 800-708-3735 Zero Zone Warranty • 1 INTRODUCTION Important User Information Copyright © 2021 Zero Zone, Inc. All rights reserved. No part of the contents of this manual may be reproduced, copied, or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of the publisher, Zero Zone, unless it is for the purchaser’s personal use. The information in this manual is subject to change without notice and does not represent a commitment on the part of Zero Zone. Zero Zone does not assume any responsibility for any errors that may appear in this manual. In no event will Zero Zone be liable for technical or editorial omissions made herein, nor for direct, indirect, special, incidental, or consequential damages resulting from the use or defect of this manual. The information in this document is not intended to cover all possible conditions and situations that might occur. The end user must exercise caution and common sense when installing, using, or maintaining Zero Zone products. Zero Zone products should only be installed by qualified, professional refrigeration technicians. If any questions or problems arise, call Zero Zone at 800-247-4496. Any change to a Zero Zone product made during the installation, start-up, or at any other time must be submitted in writing to Zero Zone for approval and be approved by Zero Zone in writing prior to commission. The product warranty is voided when any unapproved change is made to a Zero Zone product. Manufacturer Zero Zone, Inc. Display Case Division 110 N Oakridge Dr • North Prairie, WI 53153 • 800-247-4496 • www.zero-zone.com Intended Use Zero Zone products are intended to be installed and used as described in this manual and other related Zero Zone literature, specifications, drawings, and data. All Zero Zone products must be leveled after being installed. Display Case Models The information contained in this manual pertains to the following Zero Zone display cases: CASE MODEL DESCRIPTION SILL HEIGHTS ORMC82 82" Standard Multi-Deck (5-Deck) Low (L), Medium (M), or High (H) Sills ORMC87 87" Tall Multi-Deck (6-Deck) Low (L), Medium (M), or High (H) Sills ORMC75-MX 75" Meat Exclusive Multi-Deck (4-Deck) Low (L) or Medium (M) Sills ORMC80-MX 80" Meat Exclusive Multi-Deck (4-Deck) Low (L) or Medium (M) Sills ORMC80-PX 80" Produce Exclusive Multi-Deck (3-Deck) Low (L) or Medium (M) Sills ORMC82-PX 82" Produce Exclusive Multi-Deck (3-Deck) Low (L) or Medium (M) Sills Reveal Merchandiser® is a registered trademark of Zero Zone, Inc. in the United States. 2 • Introduction Introduction Case Features Zero Zone produces high quality refrigerated display cases using state-of-the-art components, including a high efficiency evaporator coil. Case features may include: Electronic fan motors Zero Zone ChillBrite® LED Lighting Alternate Bumper with Optional Glass Front Mirrors Night Curtains Quick-Connect Spray Hose Testing Standards These display cases were designed and tested using the following industry standards: NSF 7 – Commercial Refrigerators and Freezers (ANSI Approved) (equipment certified by NSF) NSF 51 – Food Equipment Materials (ANSI Approved) (equipment certified by NSF) UL 471 – Commercial Refrigerators and Freezers (ANSI Approved) (equipment certified by ETL) ASHRAE Standard 72 – Method of Testing Commercial Refrigerators and Freezers (ANSI Approved) AHRI 1200 – Performance Rating of Commercial Refrigerated Display Merchandisers and Storage Cabinets (ANSI Approved) DOE Compliant (All U.S. Sales and U.S. Territories) ASHRAE Standard 72 specifies the test conditions for the equipment. It includes the ambient conditions of 75°F dry bulb and 55% RH. Consult the factory if your store exceeds these test conditions. Introduction • 3 Installation & OPERATION INSTALLATION Operation ! CAUTION! DO NOT STAND ON TOP OF A REVEAL MERCHANDISER®. THE TOP OF THE CASE IS NOT DESIGNED TO SUPPORT THE WEIGHT OF A PERSON. Delivery Inspection Zero Zone display cases are carefully factory-tested, inspected, and properly packed to ensure delivery in the best possible condition. The equipment should be unwrapped 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 ZERO ZONE. The carrier will supply necessary report and claim forms. Do not leave, store, or hold case outdoors in direct sunlight or high ambient temperature. This could potentially cause any plastic inside the case to deform or warp. Packaging IMPORTANT: The hand rail, canopy, and honeycomb holder are shipped with protective coating. Do not remove this coating until cases are completely installed. Wooden supports are used for shipping cases without end panels. These can be removed after moving the case into position. Each case in a lineup is labeled to identify the lineup and joint. The label uses a 2-digit number designation, separated by a decimal. The first number indicates the case lineup. The second number indicates the case joint. Case joints begin with the number “1” at the left most joint in the lineup when looking at the front of the lineup. The first case in the lineup will be labeled on the right end and the second case in the lineup will be labeled on the left end. The numbers on each end to be joined will match (See Figure 1). Figure 1: Case Label Information 1.1 1.1 1.2 1.2 Front of Lineup Front of Lineup The first case in a lineup (with the right side labeled “x.1”) has a packet attached to the shelving that contains touch-up paint. Every case in a lineup has a packet attached to the shelving that contains important information about the case and/or lineup and, if applicable, special instructions for installing ordered options. 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 evaporation pans, and hat channel rails are shipped in the case that require the parts. 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. Uneven surfaces will result in reduced performance. Cases should be set to allow a minimum 3" of space behind the back of the units. This will allow necessary air to circulate behind the display cases and prevent condensation. Higher humidity stores with minimal air circulation require at least a 4" gap. A minimum 2" gap is recommended between cases on end-to-end installations. All minimum spacing requirements may increase if seismic restraints are used. Building soffits must be set back at least 6" from the front of the cases to allow access to electrical wiring on the top of the case. 4 • Installation & Operation Installation & Operation Moving Cases Various tools and equipment may be used to move cases, including, but not limited to, a forklift, a Johnson bar, a pallet jack, furniture rollers, casters, or a Rol-A-Lift. Be careful to avoid damaging the store flooring. Only certified forklift drivers should use forklifts to move the cases. The case should only be lifted off the floor as high as necessary for transport. The forklift should be driven slowly; avoid abrupt motions or bumps. Use the end frame to push/pull the case. When using a Johnson bar, only contact the sheet metal of the bottom foamed panel. Do not contact the bumper support. Be careful not to pierce the sheet metal with the corner of the Johnson bar. When using a pallet jack or furniture rollers, only place them under the floor panels. Do not place them under the bumper support or drain pipe as that will crush the components. Cases have steel protective support plates under the end panels (not under insulated dividers) to protect them from Johnson bar damage. Make sure that a forklift with the proper fork dimensions is available. Forks must be 48" long, 1 1/2" to 1 3/4" thick, and no more than 4" wide to fit the bases. Refer to the table below for instructions. CASE MODEL INSTRUCTIONS 4ORMC Forks must extend 20" to 24" under the case from either end 6ORMC Forks must extend 26" to 30" under the case from either end 8ORMC Forks must extend 39" to 43" under the case from either end 12ORMC Forks must extend 44" to 47" under the case from either end OPTIONAL BASES For low shipping height applications, Zero Zone has optional expandable bases to accommodate up to 1 3/4" thick forks (See Figure 2). To use a forklift on cases with expandable bases, raise the case with a Johnson bar and place wooden blocks under the case, allowing the base to expand enough for forks to be inserted. If a case needs to move through an 80" door opening, the case will be factory-installed with a 1" base and will be shipped on a wooden pallet. Remove the case from the pallet to slide the case through the 80" doorway. The drain elbow will be shipped loose and must be installed using extra thick PVC cement after the case is through the doorway. The 1" base will be set into an elevation kit (or "nested base") (See Figure 3). Spacer blocks (also called filler blocks) are included in the end bases of 4 and 5-door cases that use bases taller than 4 1/2". These blocks limit the case's forward tilt while it is being lifted by a forklift (See Figure 4). Figure 3: Elevation Kit for 1" Base Figure 4: Spacer Block 4 3/8" max. opening for 4' & 6' cases. 3 3/8" max. opening for 8' & 12' cases. Figure 2: Expandable Base Spacer Block(s) Installation & Operation • 5 Installation & Operation Leveling Cases should be set level right to left to allow complete drainage of defrost and condensate water. Since a level floor area is seldom available, the following steps are recommended to ensure a level installation. If your case uses seismic restraints, specific instructions for attaching seismic restraints are included in your document package. Read and understand these instructions before assembling the lineup. 1. Measure off and mark on the floor the exact dimensions of the case lineup (See Figure 5). Refer to the fixture plan or floor plan. 2. Snap a chalk line at the locations for the front and back positions of the bases. 3. Mark locations of all joints, both front and back. 4. Using a laser level or transit, find the highest point along both base position lines. Using the high point as a reference, mark the difference directly on the floor to each base, both front and back (See Figure 6). Figure 5: Measure and Mark Exact Case Outline 5. Figure 6: Mark Floor Level Difference Place enough shims under each base to equal the highest point. Shims should not extend beyond the front case bases or they will interfere with installing trim. The shims should be oriented to sit under the front and rear bends of each base. Tape all shims in place (See Figure 7). After the case is set, additional shims may need to be added at specific base locations (See Figure 8 on page 7). Figure 7: Tape Shims on the Floor Under Each Base CaCa ssee F Frroon nt t Placement Under Bases 6. The case must be leveled front-to-back and side-to-side. Ensure that the case is set square to within 1/8". Measure squareness from the top right corner to the bottom left corner, and then again from the top left corner to the bottom right corner. Measurements should be equal (See Figure 9 on page 8). Check that the case is level by setting a 4' level against the frame or intermediate standard. 7. Cases should be set with a slight backward tilt to offset the forward lean of a fully loaded case. We recommend an additional 3/8" of shims be installed under the front bases after the case is leveled. 8. se taller than one shim. Note: Total height of shims should be less than 3/4". Place additional support shims under any bases with gaps F 6 • Installation & Operation Ca ron t Installation & Operation Figure 8: Reveal Merchandiser® Base Locations Drawings are top views with bases shown under the case. Case length does not include end panels (1 1/2" wide each). 6ORMC 4ORMC 8ORMC 12ORMC Installation & Operation • 7 Installation & Operation Figure 9: Case Squareness 1. Measure squareness from top right corner of the case to the bottom left corner of the case. 2. Measure again from the top left corner of the case to the bottom right corner of the case. 3. Measurements should be equal. Difference should be no more than 1/8". Lineup Assembly Zero Zone display cases have been designed for continuous display so that multiple cases may be joined together to create a lineup of any desired length. The cases will be ready for assembly after removing the packaging material. However, do not remove the protective coating on the hand rail, canopy, and honeycomb holder at this time. A case lineup must be properly aligned, which starts with properly leveling the case (See "Leveling" on page 6). It is crucial to use a laser level to measure the high points in the floor and properly shim each base location. Before joining cases, remove all shipping blocks inside the bases and the steel support braces under the end panels. There are bolts that go up through the support plates into the underside of the foamed floor. A case must be prepared with Butyl caulk before setting the next case in the lineup. Case caulking instructions and caulk are shipped with every case (See Figure 10 on page 9). Move the next case into position and bolt it to the first case using the 4 joining bolts that are provided. Begin tightening the bolts at the top rear, working down the back of the case and to the bottom front, making sure that the case seams are flush. To align cases, use a drift pin or screwdriver on the alignment holes in the end frames, located 7" in from the joining holes. Do not pull cases together using joining bolts. For NSF case installation compliance, the interior case seams must be sealed using NSF-approved caulk (See Figure 11 on page 9). Do not allow Butyl sealant and NSF-approved caulk to contact one another as this may affect adhesion or color of each. 8 • Installation & Operation Installation & Operation Figure 10: Case Joint Caulking Instructions Figure 11: NSF Compliance Sealing IT IS CRITICAL TO FOLLOW THIS PROCEDURE TO ENSURE CASES ARE PROPERLY SEALED. Note: Apply sealant to only one case—not both cases—as excessive amounts of sealant may squeeze out of the case joint. The sealant will spread out when the cases are joined. 1. Apply 1/4" to 3/8" wide beads of Butyl caulk along the ceiling, rear wall, and base of the case where indicated by the dotted lines in the drawing. Always apply 2 beads where specified. 2. After cases are joined and tightened, caulk the top and back exterior seams, if possible, to ensure a tight seal. 3. Repeat this process between each case in the lineup. SURFACES TO BE CAULKED MUST BE CLEAN, DRY, AND FREE OF FROST (ABOVE 40ºF). Note: NSF sealant must be applied with no gaps to seal the case interior properly. 1. Cases must be properly caulked and joined before NSF caulking. Avoid using excessive Butyl caulk to prevent it from coming out of the joints because Butyl and silicone sealants will not mix. That will affect adhesion. 2. Apply NSF-approved sealant (silicone-based) in small, smooth beads where indicated by the dashed lines in the drawing. Sealant must be added between cases at case joints, between a case and an end panel, and between all access holes and cut-outs in the case end frame. Do not thin or feather excessively, as that may affect adhesion. Installation & Operation • 9 Installation & Operation Canopy Splice A ceiling alignment bracket must be field-installed to align the ceiling panels prior to canopy alignment. The canopy will come with factoryinstalled end caps on the first and last cases in a lineup. At each case joint, a canopy splice will need to be installed (See Figure 12). On cases with aluminum canopies, the factory-installed splice must be aligned in the field. Use a rubber mallet to slide the canopy splice over to the adjacent canopy until the canopies are aligned. You may need to loosen the canopy screws if canopies are not within 3/8". On cases with stainless steel canopies, the splice is shipped loose. Fit it over both canopies and screw into place. Figure 12: Ceiling Alignment Bracket and Canopy Splice (Aluminum on Left, Stainless Steel on Right) Ceiling Alignment Bracket Stainless Steel Canopy Splice Aluminum Canopy Splice Hand Rail Splice Some cases will have the standard bumper and handrail. When joining these cases, insert the front of the hand rail trim splice into the slot at the front bottom of the hand rail (See Figure 13). Form the trim piece over the hand rail and fasten it in the back (See Figure 14). Figure 13: Hand Rail Trim (Front) Figure 14: Hand Rail Trim (Back) Insert Splice into Slot Fasten in the Back 10 • Installation & Operation Installation & Operation Alternate Bumper Splice & Glass Front Splice Some cases will have the alternate bumper with optional glass front. When joining two of these cases together, special splice pieces will be provided (See Figure 15). First, hook the bumper splice over the bumper and fasten it under the bumper so it covers the seam. Next, slide the glass front splice down over the glass fronts and fasten it to the inside of the case. Figure 15: Splices for Optional Glass Front Glass Front Splice (fasten inside case) Alternate Bumper Splice (fasten in front) Drain The drain can be accessed through the drain access port in the center of the floor pan in the bottom of the case (See Figure 16). The 1 1/2" PVC drain outlet is located at the center front of the case behind the kickplate. The drain line exits the case in the center. The lateral runs of drain pipe should be installed through the bases (See Figure 17). There is no room in front of the base for the drain pipe because the kickplate installs directly to the front of the bases. Install the drain 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. The drain trap must be level. The drain trap should be primed with water after installation. The drain line must be pitched away from the case enough to ensure proper drainage. Consult your local codes for minimum requirements. The forward drain section, tee, and “R” trap are shipped loose for field installation. Figure 16: Drain Access Port Figure 17: Drain Installation Installation & Operation • 11 Installation & Operation Kickplates Each case is shipped with a front kickplate. Cases with end panels are shipped with 1 side kickplate per end panel. Cases that join together are shipped with a kickplate splice. For a standard Reveal™ case (ORMC82) or a Reveal™ Tall case (ORMC87), front and side kickplates are attached to the case bases using Tinnerman clips. Position the front kickplate so the flange is on top and facing outward. The screw (supplied)KICKPLATE goes through the kickplate and INSTALLATION 1. INSTALL TINNERMAN NUTS AT EACH BASE into the Tinnerman clip (See Figure 18). 2. INSTALL KICKPLATE END KICKPLATE FRONT A 2-piece kickplate is used on the Reveal­™ Meat Exclusive (ORMC75-MX and ORMC80-MX) and the Reveal3.™INSTALL Produce Exclusive (ORMC80-PX 4. INSERT FASTENERS TO SECURE KICKPLATES and ORMC82-PX). First, position the lower kickplate flush with the bottom of the bases and fasten it to the bases. Second, position the upper kickplate under the case and fasten it to the bases through the lower kickplate. This will create a continuous kickplate. There is a natural gap between the top of the kickplate and the underside of the Reveal Merchandiser® that allows airflow of 20 CFM/foot. If more airflow is required, contact the factory to order optional louvered kickplates (provides 60 CFM/foot). A Figure 18: Kickplate Installation BASE Base KICKPLATE END Side Kickplate Tinnerman TINNERMANClip NUT DETAIL A (ASSEMBLED) SP-6108 KICKPLATE Front FRONT DETAIL A Kickplate Fastener REV. B 1. (EXPLODED) Install Tinnerman clips at each base. Install side kickplate. REVISION2.INFORMATION No. B 3. Install front kickplate. REVISION DESCRIPTION FINISH: (PER SP-0154) (UNLESS OTHERWISE SPECIFIED) David Giese NOT TO SCALE MODELED BY: TOLERANCES: (PER SP-0457) PART WEIGHT: (IN LBS) COPYRIGHT INFORMATION THIS DRAWING AND THE INFORMATION CONTAINED WITHIN, IS THE SOLE PROPERTY OF ZERO ZONE, INC. ANY USE OF THIS DOCUMENT OR DISCLOSURE OF ITS CONTENTS; BY REPRODUCTION OR OTHER MEANS, WITHOUT THE WRITTEN CONSENT OF ZERO ZONE, INC. IS STRICTLY PROHIBITED. SCALE: DESCRIPTION: CAD DRAWING NO MANUAL REVISIONS SHEET SIZE A BY BF KICKPLATE ASSEMBLE FIELD REVEAL SP-6108 DRAWING No: DATE: 7/27/2016 SHEET: Cases are supplied with a protective bumper. Most bumpers will be factory-installed to the bumper support and snap track. If a continuous bumper is used, only the bumper support and snap track will be installed. The continuous bumper may need to be trimmed before snapping it onto the snap track. 12 • Installation & Operation DATE 6/9/2020 UNLESS OTHERWISE SPECIFIED, ALL DIMENSIONS ZERO ZONE, INC. 110 NORTH OAKRIDGE DRIVE ARE IN DECIMAL INCH NORTH PRAIRIE, WISCONSIN DRAWN BY: USA 53153 Ron Oman MATERIAL: (PER SP-0404) Bumper ECN No. fasteners to secure kickplates. 978 REMOVE4. EXTRAInsert KICKPLATE COMPONENT FROM DETAIL A. REVISION B 1 OF 1 Installation & Operation Mirrors Mirror assemblies include the mirrors, brackets, supports, and an air deflector, which are shipped together as a kit. 1. Assemble the support brackets to the mirror support. Slide the tabs on the brackets into the slots in the mirror support. Use the supplied hex screws to fasten the brackets in place (See Figure 19). Note: There will be 3 brackets and 3 screws for 36" wide mirrors or 4 brackets and 4 screws for 48" wide mirrors. 2. Install the mirror support into the shelf standards, using both the second and third slots from the top (See Figure 20). Figure 19: Support Brackets and Mirror Support Figure 20: Install Mirror Support into the Shelf Standards Add Hex Screws Install into second and third slots from the top Mirror Support Support Bracket Figure 21: Shelf Standard Slots for Air Deflector 3. 4. 5. Install the air deflector (also called a “mirror scoop”) into the shelf standards under the mirror support. Refer to the table for the correct slot, counting down from the top (See Figure 21 and Figure 22). MIRROR HEIGHT SLOT FOR AIR DEFLECTOR 8" Tall 6th Slot from Top Peel the protective coating off of the mirror. Hang the mirror from the brackets. Start by inserting it into the top and then the bottom (See Figure 23). 12" Tall 9th Slot from Top 20" Tall 16th Slot from Top Center the mirror for optimal product display. 24" Tall 19th Slot from Top Figure 22: Install Air Deflector Under Mirror Support Figure 23: Hang the Mirror, Insert Top First Air Deflector Mirror Install into shelf standards First insert into the top of the bracket, then into the bottom Installation & Operation • 13 Installation & Operation Night Curtains Cases ordered with night curtains will have factory-installed mounting brackets. A retrofit kit must be ordered from Zero Zone to install onto a case that was not ordered with night curtains. Some night curtains pull down and lock into position like roller window blinds. Other night curtains use a magnet and attach to the metal kickplate. If the night curtain has a magnet, orientate the night curtain so the magnet can attach to the case. Tip the night curtain forward into the mounting bracket and twist it until you hear a click as the brackets engage (See Figure 24). Once installed, the night curtain can be pulled down (See Figure 25). Figure 24: Install Night Curtain into the Brackets Figure 25: Night Curtain Pulled Down Under Shelf Lights 1. Position the under shelf light on the bottom of the shelf with the wire connector towards the left side of the shelf (See Figure 26). 2. Attach the under shelf light to the shelf using the two magnets that are factory-installed to the light stick. 3. After installing the shelf, plug the wire into the nearest duct pocket under the shelf (See Figure 27). 4. Bundle harness wire and place into magnetic clip. Mount magnetic clip on the side of the shelf bracket. Figure 26: Install Light Under the Shelf 14 • Installation & Operation Figure 27: Plug Into the Duct Pocket Installation & Operation Canopy Lights Canopy lights can be angled to provide the best lighting for the product. We recommend adjusting these while stocking the case. Shelves & Stocking Product Shelf location may be adjusted in 1" vertical increments in any position for best display advantage. Make sure the shelf brackets are securely seated before placing any product on the shelf. The standard shelves may be tilted down at a 10° angle. Optional shelf assemblies are available that may be tilted at 5°, 10°, or 15° angle. Bottom wire racks are available as either flat with front fence or adjustable with front fence, which can be set with a 15° angle. The case may be stocked with product after it has operated at least 24 hours with correct case temperature and proper control operation. Peg hooks require airflow baffles above each set to maintain proper product temperatures. When stocking the shelves, leave a gap between the product and the shelf above, which allows an air curtain on top of the product. Angled, tiered, or lightly stocked shelves will reduce the air curtain and may require lower evaporator temps. Product should not extend beyond the front of the shelves or bottom wire rack. Note: Do not place product on the return air grille or past the load limit line. Do not exceed shelf load capacity (See Figure 28). Do not stand on the case when stocking or adjusting shelves. Figure 28: Shelf Load Capacities SHELF TYPE Solid Shelf, Standard Duty DEPTH 22" 24" 10" 12" 14" Solid Shelf, Heavy Duty 16" 18" 20" 22" 24" BRACKET TYPE LOAD CAPACITY (LBS.) 2-Position (0°/10°) 250/150 4-Position (0°/5°/10°/15°) 250/250/150/100 2-Position (0°/10°) 250/150 4-Position (0°/5°/10°/15°) 250/250/150/100 2-Position (0°/10°) 350/275 4-Position (0°/5°/10°/15°) 350/300/275/250 2-Position (0°/10°) 350/275 4-Position (0°/5°/10°/15°) 350/300/275/250 2-Position (0°/10°) 350/275 4-Position (0°/5°/10°/15°) 350/300/275/250 2-Position (0°/10°) 350/275 4-Position (0°/5°/10°/15°) 350/300/275/250 2-Position (0°/10°) 350/275 4-Position (0°/5°/10°/15°) 350/300/275/250 2-Position (0°/10°) 350/275 4-Position (0°/5°/10°/15°) 350/300/275/250 2-Position (0°/10°) 350/275 4-Position (0°/5°/10°/15°) 350/300/275/250 2-Position (0°/10°) 350/275 4-Position (0°/5°/10°/15°) 350/300/275/250 Shelves can be ordered with 1", 2", or 3" acrylic product stops, which fit into aluminum price tag molding. Slide the product stop into the price tag molding and push it down to the bottom of the channel (See Figure 29). The channel of the price tag molding may need to be pried open with a screwdriver, but the product stop should slide in easily once started. Figure 29: Acrylic Product Stops (1" Shown) Product stop fits into the price tag molding. Installation & Operation • 15 Refrigeration REFRIGERATION Mechanical Components EVAPORATOR COIL & EXPANSION VALVE Figure 30: Expansion Valve and Schrader Valve The evaporator coil is located in the bottom of the case under the deck pans. The thermostatic expansion valve (TXV) is typically located at the end of the evaporator coil. The TXV is not preset, and superheat should be adjusted to 6-8°F. Contact Zero Zone for superheat setting if using high-glide refrigerants. To adjust the TXV, remove the far right deck pan (See Figure 30). Remove the cap from the bottom of the TXV. 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 TXV sensing bulb and compare it to the suction temperature corresponding to the saturated pressure. Make sure that line pressure drop is taken into account. Turn the valve stem only 1/4 turn at a time and allow sufficient time (20 to 30 minutes) for the TXV to settle before making further adjustments. After the superheat has been adjusted, wipe the valve stem cap dry and screw it back on. EVAPORATOR FANS Air is circulated through the display case by fans, which are located below the deck pans in the bottom of the case (See Figure 31). Air is drawn through the front return air grill and discharged out of the honeycomb at the top. The fan motors must be operating at all times. Fan motors should be replaced with motors having the same characteristics including type, physical size, lubricant temperature range, wattage, and RPM. Fan blades should be replaced with OEM parts or have the same fan pitch as the OEM fan blade. ! CAUTION! DISCONNECT POWER TO THE CASE BEFORE SERVICING ELECTRICAL COMPONENTS TO AVOID PERSONAL INJURY AND DAMAGE TO THE UNIT. 1. Disconnect power to the fan. 2. Remove the fan blade nut and fan blade. 3. Remove the mounting bolts and remove the fan assembly from the fan housing. 4. Remove the fan motor mounting screws from the back of the fan motor. 5. Replace the fan, and reverse steps 1-3 to install the cover. Restore case power. Refrigerant Piping Unless otherwise specified, the liquid and suction connections terminate inside the case under the coil cover. Refrigerant piping may enter the case through the left rear back panel or the left rear top panel of the case. Other exit options are available. The copper pipe should not touch or rub on the edges of the sheet metal. Correct refrigeration line sizing and industry standard installation practices are essential for proper system operation (See Figure 32 on page 17). After connections have been made, the refrigeration access holes or penetrations in the case must be sealed completely with an aerosol-dispensed urethane insulation or equivalent (example: Great Stuff). 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 should be done to 500 microns or less, and nitrogen sweep is recommended. After the system has been thoroughly evacuated of all moisture and non-condensable gas, charge the system with the specified refrigerant. 16 • Refrigeration Figure 31: Fans and Case-to-Case Piping Refrigeration R-404 Sizing Tables Zerofor Zone OVMC (+26°F Evaporator Temperature) Figure 32:Line R-404A Line Sizingfor Tables Zero ZoneMultideck ORMC Multi-Deck (26°F Evaporator Temperature) Liquid Line Sizing Up to 50 equivalent feet 90°F Liquid, 2°F Pressure Drop∆ For rated Btuh: From To Liquid Line ∆ Up to 100 equivalent feet 90°F Liquid, 2°F Pressure Drop∆ For rated Btuh: From To Liquid Line Up to 150 equivalent feet 90°F Liquid, 2°F Pressure Drop∆ For rated Btuh: From To Liquid Line Up to 200 equivalent feet 90°F Liquid, 2°F Pressure Drop∆ For rated Btuh: From To Liquid Line 5,280 30,720 3/8 5,280 21,010 3/8 5,280 16,790 3/8 5,280 14,310 3/8 30,730 72,750 1/2 21,020 49,900 1/2 16,800 39,960 1/2 14,320 34,110 1/2 72,760 136,380 5/8 49,910 93,740 5/8 39,970 75,160 5/8 34,120 64,210 5/8 136,390 226,300 3/4 93,750 155,790 3/4 75,170 125,030 3/4 64,220 106,890 3/4 155,800 246,590 7/8 125,040 198,070 7/8 106,900 169,440 7/8 For 1°F pressure drop, multiply rated Btuh by 1.45 before using the Liquid Line Sizing Table. Liquid Correction Factors for Liquid Line Sizing Table - Use Maximum Liquid Temperature For maximum liquid temperatures other than 90°F, multiply rated Btuh by liquid correction factor before using the Liquid Line Sizing Table Max imum Liquid Temperature: 40°F 50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F Liquid Correction Factor: 0.98 0.97 0.96 0.97 0.98 1.00 1.04 1.09 1.17 Suction Horizontal Line Sizing Up to 50 equivalent feet 90°F Liquid, 2°F Pressure Drop‡ For rated Btuh: From To Horizontal ‡ Up to 100 equivalent feet 90°F Liquid, 2°F Pressure Drop‡ For rated Btuh: From To Horizontal Up to 150 equivalent feet 90°F Liquid, 2°F Pressure Drop‡ For rated Btuh: From To Horizontal ------- Up to 200 equivalent feet 90°F Liquid, 2°F Pressure Drop‡ For rated Btuh: From To Horizontal ------- 5,280 8,350 1/2 5,280 5,730 1/2 8,360 15,640 5/8 5,740 10,760 5/8 5,280 8,630 5/8 5,280 7,380 5/8 15,650 25,950 3/4 10,770 17,880 3/4 8,640 14,360 3/4 7,390 12,280 3/4 25,960 41,010 7/8 17,890 28,290 7/8 14,370 22,740 7/8 12,290 19,460 7/8 41,020 82,770 1-1/8 28,300 57,220 1-1/8 22,750 46,030 1-1/8 19,470 39,430 1-1/8 82,780 143,860 1-3/8 57,230 95,580 1-3/8 46,040 80,190 1-3/8 39,440 68,720 1-3/8 143,870 226,880 1-5/8 95,590 157,230 1-5/8 80,200 126,700 1-5/8 68,730 108,640 1-5/8 157,240 325,130 2-1/8 126,710 262,250 2-1/8 108,650 225,030 2-1/8 For 1°F pressure drop, multiply rated Btuh by 1.44 before using the Suction Horizontal Line Sizing Table. Liquid Correction Factors for Suction Horizontal Line Sizing Table - Use Maximum Liquid Temperature For max imum liquid temperatures other than 90°F, multiply rated Btuh by liquid correction factor before using the Suction Horizontal Line Sizing Table Max imum Liquid Temperature: 40°F 50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F Liquid Correction Factor: 0.74 0.78 0.82 0.87 0.93 1.00 1.08 1.19 1.32 Suction Vertical Riser Sizing Maximum Allowable Riser Size For Adequate Oil Return* 70°F Minimum Liquid Temperature, using 0.35 PSI Per 100 Feet (per 2006 ASHRAE Handbook - Refrigeration) For rated Btuh: From To Vertical 5,280 6,590 5/8 6,600 10,500 3/4 10,510 21,300 7/8 21,310 37,300 1-1/8 37,310 59,100 1-3/8 59,110 121,880 1-5/8 121,890 215,800 2-1/8 It may be necessary to make adjustments to compensate for special situations which cause the actual Btuh to differ from the rated Btuh of the cases. All liquid line and suction line sizes are inches, refrigeration O.D. Subject to change without notice. Liquid Correction Factors for Suction Vertical Riser Sizing Table - Use Minimum Liquid Temperature Multiply rated Btuh by liquid correction factor before using the Suction Vertical Riser Sizing Table Minimum Liquid Temperature: 40°F 50°F 60°F 70°F 80°F 90°F 100°F Liquid Correction Factor: 0.85 0.89 0.94 1.00 1.07 1.15 1.24 Refrigeration • 17 Refrigeration Glycol cases typically have a balance valve located in the outlet line inside of the case. If a stop solenoid is provided, it will also be located in the outlet line. Schrader valves are provided inside the case on the right-hand side of the coil for venting and draining the system. Operation Set Points Refer to the case spec sheet for btu/h requirements and electrical requirements. Operate the case at the proper settings to maintain product temperature of 41°F or below, per food safety regulations (See Figure 33). Note: Set points based on flat shelves. Alternate shelving— such as angled or tiered shelving, peg hooks, or produce inserts—may require lower operating temperatures. Figure 33: Case Temperature Internal Control Options (R-404A) SETTING MEAT DAIRY/DELI/PRODUCE BEVERAGE Evaporator Temperature 22°F 26°F 28°F Condensing Unit Cut-In 62 psig 67 psig 71 psig Condensing Unit Cut-Out 54 psig 59 psig 62 psig Return Air Temperature Cut-In 44°F 48°F 50°F Return Air Temperature Cut-Out 40°F 44°F 46°F Discharge Air Temperature Cut-In 31°F 35°F 37°F Discharge Air Temperature Cut-Out 27°F 31°F 33°F Superheat Setting 6-8°F 6-8°F 6-8°F Note: For high-glide refrigerants, use dew point for unit sizing. Adjust evaporator pressure as needed to maintain discharge air temperatures. To receive the full benefit of high-glide refrigerant properties, the superheat may need to be lowered to 4-6°F. Contact Zero Zone with questions. Off-Cycle Defrost See Figure 34 for off-cycle defrost settings. During off-cycle defrost, refrigerant is stopped either by stopping the compressor or by closing the liquid line solenoid valve and allowing the compressor to pump down. The fans and lights remain on during off-cycle defrost. If temperature termination is selected, set the termination temperature at 45°F for discharge air and coil temperature. Note: Stocking or shopping during off-cycle defrost may cause premature defrost termination. Figure 34: Defrost Settings SETTING MEAT DAIRY/DELI/PRODUCE BEVERAGE Defrost Type Off-Cycle Off-Cycle Off-Cycle Frequency 4 Per Day 4 Per Day 4 Per Day Duration 36 Minutes 30 Minutes 30 Minutes Case Thermometer The cases are shipped with two thermometers. One thermometer is factory-mounted in the center ceiling pocket cover to sense the discharge air stream. The second thermometer is shipped loose and should be installed in the warmest product location as required by NSF. Specific field installation instructions are packaged with the thermometer that is shipped loose. 18 • Refrigeration ELECTRICAL General Standard cases have 2 electrical circuits: the fan circuit and the lighting circuit. Always refer to the wiring diagram shipped with the case (See Figure 35). Figure 35: Sample Wiring Diagram The electrical enclosure is located behind the lower trim on the right side of the case (See Figure 36). The enclosure includes the power connection and power supplies for the LED light bars. The electrical raceway allows for simple case-to-case wiring (See Figure 37). Terminal blocks are provided for supplying power for fans and lights. A ground connection can also be made inside the electrical enclosure. Optional top electrical will be located in a junction box on top of the case. The case light switch is located on the right side of the interior ceiling (See Figure 38). In coolers, 1 sensor bulb is factory installed. Temperature probe wires are white (common) and green (supply). The temperature probe (discharge air) is located in the false ceiling. Figure 36: Bottom Electrical Enclosure Figure 37: Case-to-Case Wiring Figure 38: Light Switch Electrical • 19 MAINTENANCE Cleaning Although each Zero Zone display case is thoroughly cleaned before shipping, the cases should be thoroughly cleaned again before start-up and routinely thereafter to maintain a clean appearance. With just a few minutes of cleaning each week, the case will remain in top condition. 1. Do not use high-pressure water or steam to clean the interior or any components. 2. Do not wash fan motors. A damp cloth can be used to wipe the fan motors. Cover the fan motors with a plastic bag when washing the case. 3. Wipe out the case interior using mild detergent and warm water (never an abrasive cleaner). 4. Clean windowed ends and mirrors using glass cleaner. Cleaning interior glass reduces fogging and increases visibility. Do not use any cleaning products containing silicon for anti-fog. 5. Internal components can be cleaned after removing coil covers, access panels, and sheet metal components. Use a mild detergent and warm water or a mild sanitizer. 6. If the case is equipped with a condensate pan and pump, the drain should be blocked before washing coils. Water can be removed with a shop vacuum. 7. Coils may be cleaned with a garden hose or pails of water. If the case is equipped with a condensate pan and pump, cases should be cleaned with a minimal amount of water so the evaporator, pump, and drain pans do not get overfilled. 8. The case drain should frequently be cleaned of debris to prevent clogging. If water is rising, check if the drain is clogged. UNDER CASE FLOOR CLEANING (NSF) The floor under your Zero Zone display case can be cleaned by following these steps: 1. Remove the fasteners attaching the kickplate to the case. The fasteners are accessed from the front of the unit. 2. With the kickplates removed, vacuum under the case to remove any dirt, debris, and dust build-up. 3. Mop under the unit using non-abrasive floor cleaner and warm water. 4. When finished mopping, squeegee any remaining water under the unit to the floor drains to speed up the drying process. Replace the kickplates when the floor has dried. 20 • Maintenance For other technical support, please refer to the Technical Resources page at: WWW.ZERO-ZONE.COM or contact the Zero Zone Service Department at: 800-247-4496 All specifications subject to change without notice. ZERO ZONE, INC. • 800-247-4496 • ZERO-ZONE.COM © 2021 Zero Zone, Inc. All Rights Reserved. • Aug 2021 66-0057 REV E ">
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