Related Manuals for Zero Zone HYBRID
Summary of Contents for Zero Zone HYBRID
- 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 This 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 Manual.
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Page 3: Table Of Contents
Table of Contents ZERO ZONE WARRANTY ....................... IV ƒ Limited Warranty ........................IV ƒ Extended Warranties ......................... IV ƒ Length of Extended Warranty ....................IV ƒ Product Not Manufactured By The Seller ................. IV ƒ Limitation and Exclusion of Warranties ..................IV PLANNING ............................ -
Page 4: Zero Zone Warranty
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 it’s “Service and Installation”... -
Page 5: Planning
ƒ Add auxiliary fans to dissipate heat ƒ Use louvered case shrouds ƒ Use an alternate shroud height; Zero Zone Engineering must be contacted ƒ ELECTRICAL Is there suitable voltage? ƒ Is the appropriate circuit breaker installed and available in the store power panel? ƒ... -
Page 6: Delivery
DELIVERY Case Delivery Through 80" Door OVERALL CASE DEPTH IS 40 1/8" Temperature Probe Wires Remove bracket from back of case. Pull quick connect lines away and down from case. Reposition quick connect lines and reinstall bracket, once through doorway. ATTENTION FORK TRUCK OPERATOR! 2-Door 24"... -
Page 7: Setting The Case
SETTING THE CASE Contents Shipped Inside of Case Pump and Pan Assembly ƒ Condensate Evaporation Pan ƒ Hat Channels with 1", 1.75" or 2.5" Bases ƒ Setting the Case - Contents Shipped Inside of Case • 3... -
Page 8: Positioning Hat Channels
SETTING THE CASE Positioning Hat Channels Position hat channels with tape up. ƒ For 3 and 4-door cases, (as shown above left), the center hat channel needs to be angled ƒ 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. -
Page 9: Dividers Between Cases
SETTING THE 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 of dividers are factory-installed prior to shipping. Setting the Case - Dividers Between Cases • 5... -
Page 10: Mechanical
MECHANICAL Once in Final Location 2 to 5-Door Shown If electrical box was removed for entry, put back into position. 6 • Mechanical - Once in Final Location... -
Page 11: Setting The Condensing Unit
MECHANICAL Setting the Condensing Unit Locate quick connects on the back of the case. Place condensing unit with quick connects facing the back of the case. Avoid scratching the front of the case. Mechanical - Setting the Condensing Unit • 7... -
Page 12: Quick Connect Fittings
MECHANICAL Quick Connect Fittings THIS IS THE MOST IMPORTANT PORTION OF THE HYBRID INSTALL Align and pre-lubricate the couplers before connecting. Start with hand tightening. Tighten coupling connections with a wrench until seated or a definite resistance is felt. Mark a line on the swivel nut and unit. -
Page 13: Coupling Insulation
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 be provided. Mechanical - Coupling Insulation • 9... -
Page 14: Electrical/Control
ELECTRICAL/CONTROL Electrical Connections Cooler Electrical Box Freezer Electrical Box Case Conduit Case power (top electrical box) brought from condensing unit electrical ƒ box. 2-5 door cases receive 208V 4-wire service; 115/208V-1PH-60HZ; red ƒ and black power, white neutral, green ground. Whip for 1-door cases receive 115V 3-wire service;... -
Page 15: Carel Controller Sensor Wires
ELECTRICAL/CONTROL Carel Controller Sensor Wires Sensor wires are found on back of the case. ƒ Temperature (Discharge Air) probe located in false ceiling ƒ Evap (Defrost Term) probe located in coil. ƒ One sensor bulb is factory installed in medium temp case. Probe ƒ... -
Page 16: Plumbing
We supply a trap support that is field mounted to the case. The drain trap must be level. The drain trap should be primed with water after installation. Note (if applicable): Typically Hybrid cases are equipped with a condensate collection and removal system which includes a collection pan, pump, float switch, condensate evaporation pan with heater element, and connecting tubing. -
Page 17: Trim Out
TRIM OUT Installing Drain, Pump & Pan Drain Pan Assembly 2 to 5-Door Drain Trap Assembly Place the drain pan assembly as shown (Fig. 1). Glue drain-trap assembly to drain. Attach drain assembly to case with screws provided (Fig. 2), except on 1-door which comes pre-attached. Install PVC drain-trap extension/stop (Fig. - Page 18 TRIM OUT Installing Drain, Pump & Pan 14 • Trim Out - Installing Drain, Pump & Pan...
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Page 19: Enclosed Pump
Fasten bracket to front of foamed fl oor. SP-5187 Rev B ZERO ZONE, INC. • 800-247-4496 • ZERO-ZONE.COM © 2015 Zero Zone, Inc. All Rights Reserved. • FEB 2015 Enclosed Pump - CB121LSUL Pump with Brackets • 15 MN-13-A... - Page 20 ENCLOSED PUMP CB121LSUL PUMP WITH BRACKETS CB121LSUL Pump with Brackets Installation Place clear vinyl tube (from pump kit) over inlet to pump tank. Fasten into place using hose clamp (provided in pump kit). SP-5187 Rev B 16 • Enclosed Pump - CB121LSUL Pump with Brackets 2 •...
- Page 21 ENCLOSED PUMP CB121LSUL PUMP WITH BRACKETS Installation CB121LSUL Pump with Brackets Prime and glue PVC elbow to case drain lateral. PVC elbow needs to be angled downward. On 4 and 5-door cases, the pump should be installed to the right of the case lateral. On 1, 2, and 3-door cases, the pump should be installed to the left of the case lateral. On 1-door cases, the clear vinyl tubing will need to be cut to fi...
- Page 22 ENCLOSED PUMP CB121LSUL PUMP WITH BRACKETS Installation CB121LSUL Pump with Brackets Attach discharge line to pump outlet. Plug pump into outlet receptacle. Prime pump. Note that you will see the water level in the clear tube. The clear tube and pump tank now create the drain trap for the case SP-5187 Rev B 18 •...
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Page 23: Trim Out
TRIM OUT Setting the Condensate Evaporation Pan Place the Condensate Evaporation Pan on top of the case. 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.) Plug into rear of condensing unit electrical box. -
Page 24: Bumper & Kickplate
TRIM OUT Bumper & Kickplate Install Tinnerman clip to each bumper support (over the round hole). Base Kickplate Tinnerman Clip For VMC cases, Tinnerman clip is installed onto the base. For case-to-case connection, align both bumpers and splice plate before fastening. 20 •... -
Page 25: Shroud Assembly
TRIM OUT Shroud Assembly FRONT SHROUD TO SIDE SHROUD ORIENTATION AND FASTENING Front View Front Shroud Brackets None needed on 2-door, use one on 3 & 4-door, and use two on 5-door. Back View Side Shroud Brackets One at each shroud side. Trim Out - Shroud Assembly •... -
Page 26: Operation
OPERATION Start-Up Turn on the case by turning on the store circuit breaker or optional case disconnect. ƒ There will be a slight delay before the compressor starts. ƒ Set the time clock on the controller. ƒ The case fans can cycle for as long as 30 minutes (unless the case goes into defrost). ƒ... -
Page 27: Turning The Lights On & Off
OPERATION Turning the Lights On & Off The on/off switch for the LED lights are located at the top of the inside door frame in the right-hand door of each case. Case Joints Look at bumpers to determine where cases are joined together. The on/off light switch is located on the left mullion in the right-hand door of each case. -
Page 28: Automatic Hold-Open Doors
OPERATION Automatic Hold-Open Doors Hold-Open Engaged Hold-opens for doors are 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 remain open. -
Page 29: Maintenance
MAINTENANCE Solid Shelf Installation & Removal INSTALLATION: Determine the correct shelving location. While lifting the front of the shelf up at a slight angle, insert the shelf tangs into the slots in the shelf standards at the back of the case, making sure the shelf is level left to right. -
Page 30: Wire Shelf Installation & Removal
MAINTENANCE Wire Shelf Installation & Removal INSTALLATION: Determine the correct bracket and shelving location. While lifting the front of one bracket up at a slight angle, insert the shelf bracket tangs into the slots in the shelf standard at the back of the case. Continue lowering the shelf bracket until the shelf bracket is held securely by the standard. -
Page 31: Bottom Electrical Box Wire Colors (Vzch/Vcch Only)
MAINTENANCE Bottom Electrical Box Wire Colors (VZCH/VCCH Only) **VLCH/VMCH do not use a bottom electrical box Anti-Sweat Heat: ƒ Purple Wires: Perimeter ƒ Red Wires: Mullion ƒ Orange Wires: Doors ƒ Lighting: ƒ Brown & Black Wires ƒ Defrost Heaters - Low Temp Only (2): ƒ... -
Page 32: Instructions For Condensate Removal Systems With Condensate Evaporation Pan
MAINTENANCE Instructions for Condensate Removal Systems with Condensate Evaporation Pan Stores without floor drains are using the Condensate Removal System with a Condensate Evaporation Pan. This is a tray located under the kickplate with a submersible pump that will pump the water to the top of the case and into a Condensate Evaporation Pan. The Condensate Evaporation Pan has a float switch that will power its heater when the water rises. -
Page 33: Refrigeration Cleaning & Maintenance
MAINTENANCE Refrigeration Cleaning & Maintenance The medium and low temp cases should be thoroughly cleaned routinely to maintain a clean appearance. Use bleach solution to wipe out the inside of the case. Wash down all glass doors with glass cleaner. The case drain should be regularly cleared of debris and price tags to prevent clogging. -
Page 34: Carel Controller Programming Instructions
NOT want 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. Note: Zero Zone should be contacted before working on changing settings. To be completed by a trained person only. ZERO ZONE, INC. • 800-247-4496 • ZERO-ZONE.COM ©... -
Page 35: Carel Controller Low Temp Codes
Carel label on top of the electrical box cover on top of the case. ZERO ZONE, INC. • 800-247-4496 • ZERO-ZONE.COM © 2015 Zero Zone, Inc. All Rights Reserved. • MAR 2015 2 • Carel Controller - Programming Instructions Maintenance - Carel Controller Low Temp Codes •... -
Page 36: Carel Controller Medium Temp Codes
Defrost time minute 2 65-0704 Rev F ZERO ZONE, INC. • 800-247-4496 • ZERO-ZONE.COM © 2015 Zero Zone, Inc. All Rights Reserved. • MAR 2015 32 • Maintenance - Carel Controller Medium Temp Codes Carel Controller - Programming Instructions • 3... -
Page 37: Carel Controller Basic Operations
The water removal system has a maximum capacity of two gallons. When cleaning the interior of the case, do not use more than this amount of liquid. *Please consult the Zero Zone Service Department on case defrost characteristics for non-standard defrost settings. 4 • Carel Controller - Basic Operations... -
Page 38: Silencing The Carel Temperature Alarm
MAINTENANCE CAREL CONTROLLER Silencing the Temperature Alarm Silencing the Carel Temperature Alarm Press [Prg] Button to silence the alarm The button used to silence the alarm ([Prg] button) is located on the controller on the front of the case above the right-hand door. If the alarm sounds, push the [Prg] button which will reset the alarm and silence it for one hour. -
Page 39: Conditions That Trigger The Carel Alarm
MAINTENANCE CAREL CONTROLLER Conditions that Trigger the Alarm Conditions that Trigger the Carel Alarm Your LOW TEMP case has two defrosts programmed per day, one at 8:00 AM and one at 8:00 PM. A typical defrost lasts one hour. Your MEDIUM TEMP case has two defrosts programmed per day, one at 8:00 AM and one at 8:00 PM. -
Page 40: Condensing Unit Pressure Switch Settings
MAINTENANCE Condensing Unit Pressure Switch Settings ADJUSTABLE DUAL PRESSURE CONTROL (USED FOR COOLERS AND FREEZERS) Low pressure cut in/differential (PSI): 30/20 ƒ High pressure cut out/differential (PSI): 350/60 ƒ FIXED PRESSURE CONTROLS (USED FOR COOLERS) Low pressure cut in/out (PSI): 35/15 ƒ... -
Page 41: Options
Secure the metal screen to the case ceiling with (3) #8-18 x 1/2" hex, tek screws. Make necessary adjustment to metal screen to fit properly. For more detailed instructions, please contact Zero Zone. Options - Sound Attenuation Kit & Balloon Guard • 37... -
Page 42: End Close-Off
OPTIONS End Close-Off Cases ordered with end close-off panels will receive either 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 conditions over 75°F and 55 relative humidity. -
Page 43: Shroud Frame Assembly
OPTIONS Shroud Frame Assembly 1. Locate the painted lower 2. Working from left to right 3. Secure with self-tapping 4. Complete. shroud of the appropriate (facing the case), position sheet metal screws (three length. (Note: Shroud sides the lower shroud by placing per piece). - Page 44 OPTIONS Shroud Frame Assembly (Cont.) 17. Locate the last shroud side, 18. Locate two shroud support 19. While positioning the shroud 20. At the insulated divider position as shown, and brackets and secure at the top. sides plumb, secure the location, install two support secure with sheet metal support brackets to the case...
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Page 45: Special Louvered Shroud Design
OPTIONS Special Louvered Shroud Design Lineup with no shrouds. Install 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 case. Aligning the shroud support channel with the side shroud. - Page 46 OPTIONS Special Louvered Shroud Design (Cont.) Align the case divider partition (2.5" side forward) with the shroud support channel. Fasten the case divider partition to the top of the insulated divider panel using 3 screws. Attach 1 shroud support to case divider partition and case, using pre-drilled hole in the case divider partition, near the rear of the case.
- Page 47 OPTIONS Special Louvered Shroud Design (Cont.) Align the shroud support channel with the case divider partition. Use 5 screws and fasten to the top of the ceiling. Align case divider partition (2.5" side towards rear of case) with the shroud support channel. Fasten case divider to ceiling using 3 screws.
- Page 48 OPTIONS Special Louvered Shroud Design (Cont.) 10. Install right side shroud 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 1 shroud supports to the side shroud and case. Note: It is recommended 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).
- Page 49 OPTIONS Special Louvered 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 with shrouds installed. There will be one upper shroud per case.
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Page 50: Optional Disconnect Installation
OPTIONS Optional Disconnect Installation Optional disconnect shipped loose (inside case) and wired to condensing unit distribution block on site by installer. Customer Power Optional Disconnect Power to Condensing Unit Distribution Block 46 • Options - Optional Disconnect Installation... -
Page 51: Manager's Emergency Guide
This is the high temperature alarm code (HI). Other codes may also be displayed. (See above for other codes) ZERO ZONE, INC. • 800-247-4496 • ZERO-ZONE.COM © 2015 Zero Zone, Inc. All Rights Reserved. • FEB 2015 Manager’s Emergency Guide • 47 MN-07-B... - Page 52 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. • 800-247-4496 • ZERO-ZONE.COM © 2015 Zero Zone, Inc. All Rights Reserved. • MAR 2015 MN-01-H...