Zero Zone HYBRID, Installation, Operation & Maintenance Manual

Page 1: ...ZERO ZONE HYBRID MEDIUM LOW TEMP DISPLAY CASE Installation Operation Maintenance Manual Compliant with 2012 DOE Regulations MN 01 H MAR 2015...

Page 2: ...manual is specific to the Zero Zone Hybrid display case For standard Zero Zone display case installation and operation please refer to the Zero Zone Medium Low Temp Display Case Installation Operation...

Page 3: ...d Assembly 21 OPERATION 22 Start Up 22 Carel Controller Standard Features 22 Instructions for Setting the Time 22 Turning the Lights On Off 23 Automatic Hold Open Doors 24 MAINTENANCE 25 Solid Shelf I...

Page 4: ...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 satisfac...

Page 5: ...e store ceiling panels Add auxiliary fans to dissipate heat Use louvered case shrouds Use an alternate shroud height Zero Zone Engineering must be contacted ELECTRICAL Is there suitable voltage Is the...

Page 6: ...30 Or 4 Door 24 Cases Use 48 long forks Forks must extend from 39 to no more than 43 under the case from ends through bases 4 5 Door 30 Or 6 Door 24 Cases Use 48 long forks Forks must extend from 44 t...

Page 7: ...Setting the Case Contents Shipped Inside of Case 3 Pump and Pan Assembly Condensate Evaporation Pan Hat Channels with 1 1 75 or 2 5 Bases Contents Shipped Inside of Case SETTING THE CASE...

Page 8: ...e center hat channel needs to be angled to rest on front and back base Do not locate under drain hub For 5 door cases as shown above right there are 4 hat channels position as shown In most instances...

Page 9: ...e Case Dividers Between Cases Clear plexi dividers separate refrigeration circuits between same temp cases Insulated dividers are provided between medium temp and low temp cases in lineups Both types...

Page 10: ...6 Mechanical Once in Final Location MECHANICAL If electrical box was removed for entry put back into position 2 to 5 Door Shown Once in Final Location...

Page 11: ...he Condensing Unit 7 Mechanical 2 Place condensing unit with quick connects facing the back of the case 3 Avoid scratching the front of the case 1 Locate quick connects on the back of the case Setting...

Page 12: ...ons with a wrench until seated or a definite resistance is felt Mark a line on the swivel nut and unit Using the line as a guide tighten an additional quarter turn Sealing does not occur until no thre...

Page 13: ...Coupling Insulation 9 Mechanical Coupling Insulation One pre cut 4 piece of split insulation supplied will be required on each freezer suction side quick connect coupling as shown Wire ties will also...

Page 14: ...door cases Blue White Green Case Conduit See specific wiring diagrams shipped with your case Customer Power Black Red omitted for 1 door cases and all coolers White Green Distribution Block Ground Blo...

Page 15: ...Term probe located in coil One sensor bulb is factory installed in medium temp case Probe wires labeled Green White for Temperature Discharge Air Two sensor bulbs are factory installed in low temp ca...

Page 16: ...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 factory installs a drain support at the front of the case on all 3...

Page 17: ...trap extension stop Fig 3 4 Do not glue this component but use the screw provided This will allow the extension to be removed should the drain pan need cleaning or service Fig 4 5 Finished assembly 2...

Page 18: ...14 Trim Out Installing Drain Pump Pan Trim Out 1 2 3 4 5 6 7 Installing Drain Pump Pan...

Page 19: ...kets will be shipped inside case Prime and glue case lateral to elbow underneath case Fasten bracket to front of foamed oor CB121LSUL Pump Pump Kit CB121LSUL PUMP WITH BRACKETS Installation SP 5187 Re...

Page 20: ...Pump CB121LSUL Pump with Brackets 2 CB121LSUL Pump with Brackets Installation CB121LSUL PUMP WITH BRACKETS Installation 2 Place clear vinyl tube from pump kit over inlet to pump tank Fasten into plac...

Page 21: ...rackets into holes in the foamed oor Install the pump onto the pump brackets Pump will hang on the brackets via the hooks that are molded into the pump tank Brackets are used to lift pump off the grou...

Page 22: ...ion CB121LSUL PUMP WITH BRACKETS Installation 5 Attach discharge line to pump outlet 6 Plug pump into outlet receptacle 7 Prime pump Note that you will see the water level in the clear tube SP 5187 Re...

Page 23: ...densate Evaporation Pan on top of the case 2 Move drain line s from the back to the top of the case and hang U copper drain line over the edge of the pan Optional return line not shown 3 Plug into rea...

Page 24: ...Kickplate For case to case connection align both bumpers and splice plate before fastening Install Tinnerman clip to each bumper support over the round hole For VMC cases Tinnerman clip is installed...

Page 25: ...rim Out Front View Shroud Assembly Back View FRONT SHROUD TO SIDE SHROUD ORIENTATION AND FASTENING Front Shroud Brackets None needed on 2 door use one on 3 4 door and use two on 5 door Side Shroud Bra...

Page 26: ...isplay where xx is the last 2 digits of the year 4 Press the Down arrow once This will cycle the control to the minutes setting nxx will be shown on the display where xx is a number between 00 and 59...

Page 27: ...right hand door of each case The on off light switch is located on the left mullion in the right hand door of each case Case Joints Look at bumpers to determine where cases are joined together Note T...

Page 28: ...e found at the top of the door To lock a door in the open position for stocking continue to open the door until you feel the top hold open device fully engage When you let go of the door it will remai...

Page 29: ...ts in the shelf standards at the back of the case making sure the shelf is level left to right Lower the front of the shelf while continuing to move the shelf tabs into the standards and until the she...

Page 30: ...bracket until the shelf bracket is held securely by the standard Repeat the process for the opposite shelf bracket Make sure the shelf brackets are level left to right Place rear of shelf down and on...

Page 31: ...CH Only Anti Sweat Heat Purple Wires Perimeter Red Wires Mullion Orange Wires Doors Lighting Brown Black Wires Defrost Heaters Low Temp Only 2 Brown Wire In Series with 80 F High Limit Black Wire Defr...

Page 32: ...allon of liquid When cleaning the case do not use more than this amount of liquid The pump sits in the pan and removes water slowly Large amounts of water dumped down the drain will overflow the pan W...

Page 33: ...persons only VACUUM THE CONDENSER COIL SURFACE EVERY 3 MONTHS Annual checkup 1 Check and tighten ALL electrical connections 2 Check all wiring and insulators 3 Check contactors for proper operation a...

Page 34: ...nt to save changes you ve just made simply stop pressing buttons for 30 seconds and the control will return to normal operation discarding any changes made HOW TO CHANGE LEVEL 2 CONTROL SETTINGS 6 Pre...

Page 35: ...1 Min time between starts 5 c2 Min comp OFF 1 c3 Min comp ON 1 d0 Defrost type 4 dd Drip time 1 dn Defrost duration 100 AL Low temp alarm 20 AH High temp alarm 25 F0 Fan management 2 F1 Fan start temp...

Page 36: ...p n a tc y RTC year tc m RTC month tc d RTC day of month tc u RTC day of week tc h RTC hour tc m RTC minute MEDIUM TEMP LEVEL 2 Code Name Factory Set A2 Probe 2 con guration 0 c1 Min time between star...

Page 37: ...sic Case Operations 1 The case s condensing unit mounted on top of the case cycles off and on during normal operation When the inside of the case is warm the compressor turns on When the inside of the...

Page 38: ...truction label for the electronic control can be found af xed to the ceiling of each case inside the right hand door See Manager s Emergency Guide at the end of this manual The button used to silence...

Page 39: ...the alarm timer will reset If the case is in defrost the electronic display will read DEF Common Things to Check DEFROST AND ALARMS 1 Check the circuit breakers for the cases Tripped circuit breakers...

Page 40: ...set Built in hold restart button for 3 seconds when suction pressure is between cut in and cut out valves Electronic service menu Compressor starts and runtime for compressor Alarms HP High pressure t...

Page 41: ...notch for refrigeration piping quick connections to rear of case 3 Position large 1 piece baffle with coil opening cut out in front of U shaped box Secure in place with brace BALLOON GUARD INSTALLATIO...

Page 42: ...r 12 or 16 panels and are to be installed from the case end panel to the wall Fan Kit The fan kits are optional and are designed to prevent condensation on the wall and under the case in store conditi...

Page 43: ...utout in the lower shroud 8 Re fasten the electrical box with the same screws you removed This procedure will be duplicated at each case 9 Remove one of the two screws from the Euro trim retainer clip...

Page 44: ...Locate the galvanized shroud top rail of the appropriate length and secure it to the shroud side with two self tapping screws 23 Secure the right hand end of the shroud top rail to the insulated divi...

Page 45: ...all left side with louvers onto the case end panel Align the side shroud with the back of the case Use 3 screws and fasten to the top of the end panel Attach 2 shroud supports to the side shroud and c...

Page 46: ...er partition and case using pre drilled hole in the case divider partition near the rear of the case 5 Using 2 screws at each end of the upper shroud support fasten it to the side shroud case divider...

Page 47: ...ign case divider partition 2 5 side towards rear of case with the shroud support channel Fasten case divider to ceiling using 3 screws Attach 1 shroud support to case divider partition and case using...

Page 48: ...ed that there be two people one on each end for installing the upper shroud supports the narrow long metal pieces that are the length of the case 11 Place left end of upper shroud support onto the cas...

Page 49: ...ered Shroud Design Cont 13 Hang upper shroud onto the upper shroud support into the shroud support channel 14 Hang upper shroud onto the upper shroud support into the shroud support channel 15 Lineup...

Page 50: ...tion Options Optional Disconnect Installation Optional disconnect shipped loose inside case and wired to condensing unit distribution block on site by installer Optional Disconnect Customer Power Powe...

Page 51: ...ves and prevent a door from fully closing b Con rm that the case was not recently stocked with product Holding one of the doors open for an extended period of time as is the case when stocking will ra...

Page 52: ...tion Manuals available on the Service 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 44...