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ZERO ZONE HYBRID DISPLAY CASES ™ Reach-In Coolers & Freezers and Open Multi-Decks INSTALLATION, OPERATION, & MAINTENANCE MANUAL COMPLIANT 66-0034 REV H • Jan 2022...
Table of Contents INTRODUCTION ..................... 1 PLANNING ......................3 DELIVERY ....................... 4 Moving Display Case ..................4 SETTING THE CASE ....................5 Contents Shipped Inside of Case ..............5 Positioning Hat Channel Rails ................6 Dividers Between Cases ................... 7 ...
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MAINTENANCE ....................36 Cleaning ......................36 Under Case Floor Cleaning (nSF) ..............36 Using the Condensate Removal System ............37 Cleaning the Condensate Removal System ........... 37 Preventative Maintenance for Condensing Units & Evaporator Coils ..... 37 CONTROLLER OPERATION ................
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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 &...
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.
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INTRODUCTION Case Features Zero Zone produces high quality refrigerated display cases using state-of-the-art components. The cases are built with the thickest insulation in the industry and a high efficiency evaporator coil. Case features include: Brushless DC electronic motors Zero Zone ChillBrite LED Lighting ...
add auxiliary fans to dissipate heat. Use louvered case shrouds. Use an alternate shroud height (contact your Zero Zone Sales Representative). ELECTRICAL Is there suitable power supply for necessary voltage and amperage? Is the appropriate circuit breaker installed and available in the store power panel? ...
DELIVERY Moving Display Case TO GET THROUGH A DOORWAY, IT MAY BE NECESSARY TO TEMPORARILY DISMOUNT THE REFRIGERATION LINES AND THE TOP ELECTRICAL BOX. Temperature Piping Bracket Probe Wires Remove the upper electrical box by disconnecting Pull quick-connect lines away and down from the the 3 wiring connectors, then remove the 4 screws case.
SETTING THE CASE Contents Shipped Inside of Case Highlight Merchandiser Shown ® Condensate Evaporation Pan Hat Channel Rails & Pump assembly Reveal Merchandiser Shown ® Condensate Evaporation Pan Hat Channel Rails & Pump assembly Setting the Case • 5...
SETTING THE CASE Positioning Hat Channel Rails Refer to the associated remote installation & operation manual for more information about setting and leveling a display case, including base locations, optional bases, proper shimming, case squareness, case joining, and lineup assembly. Highlight Merchandiser Shown ®...
SETTING THE CASE Dividers Between Cases Clear plexi dividers separate refrigeration circuits between same temperature cases. Insulated dividers separate different temperature cases in lineups. Both types of dividers are factory-installed prior to shipping. Setting the Case • 7...
SETTING THE CASE Reveal Merchandiser Support Brace - Removal & Installation ® An 8' or 12' Reveal Merchandiser in a Hybrid configuration will be shipped with a support brace that strengthens its canopy. This ® ™ support brace can be removed in order to move the case through a low doorway; this reduces the height by ~3". The support brace must be reinstalled before the condensing unit is placed on top of the display case and before the display case is set against a wall.
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SETTING THE CASE Reveal Merchandiser Support Brace - Removal & Installation ® REMOVING THE SUPPORT BRACE Save all bolts and fasteners for reassembling the support brace after moving the display case through the doorway. Ceiling 5" Bolts 1/2" Spacer Support Washers Washers Brace...
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SETTING THE CASE Reveal Merchandiser Support Brace - Removal & Installation ® REINSTALLING THE SUPPORT BRACE Reassemble the support brace after moving the display case through the doorway. Reuse the bolts and fasteners that were removed. The support brace must be installed before the condensing unit is placed on top of the display case and before the display case is set against a wall.
SETTING THE CASE Reveal Merchandiser Support Brace - Position Components ® an 8' or 12' Reveal Merchandiser in a Hybrid configuration will be shipped with a support brace that strengthens its canopy. ® ™ Position the condensing unit, electrical box, evaporation pans, and other features around the support braces. an 8' Reveal Merchandiser uses 2 support braces.
CONDENSING UNIT CONNECTION CONDENSING UNIT CONNECTION Setting the Condensing Unit Locate quick-connect couplings on the back of the case. Place condensing unit with quick-connect couplings facing the back of the case. avoid scratching the front of the case. 12 • Condensing Unit Connection...
CONDENSING UNIT CONNECTION Quick-Connect Couplings THIS IS THE MOST IMPORTanT PaRT OF a HYBRID CaSE InSTaLLaTIOn ™ align the couplings and pre-lubricate the mating surfaces (threads and o-rings) with POE oil (supplied) before connecting them. not lubricating the mating surfaces may increase the potential for leaks. Start with hand tightening to ensure a good seal.
CONDENSING UNIT CONNECTION Insulation on Suction Line Quick-Connect a pre-cut piece of split piping insulation (supplied) will be required on each freezer suction line quick-connect coupling. Cable ties will also be provided. Wrap piping insulation around the suction line quick-connect coupling. Position the insulation so that it completely covers the quick-connect.
ELECTRICAL/CONTROL ELECTRICAL/CONTROL Case Electrical Connections - Highlight Merchandiser ® Connecting power to a Highlight Hybrid does not require opening the electrical box at any time. ™ ™ "COnn-1" carries power from the case electrical box to the case. "COnn-2" carries power from the case electrical box to the condensing unit electrical box. ...
ELECTRICAL/CONTROL Case Electrical Connections - Crystal Merchandiser ® CRYSTAL COOLER CRYSTAL FREEZER ™ ™ Wiring to Condensing Unit Wiring to Case Power runs from the store panel disconnect switch to the condensing unit electrical box and then to the case electrical box. ...
ELECTRICAL/CONTROL Case Electrical Connections - Reveal Merchandiser ® Connecting power to a Reveal Hybrid does not require opening the electrical box at any time. ™ ™ "COnn-1" carries power from the case electrical box to the case. "COnn-2" carries power from the case electrical box to the condensing unit electrical box. ...
REVISION 65-1979 NO MANUAL REVISIONS OR X.XXX AND MUST MEET Cpk ≥ 1.33. IS THE SOLE PROPERTY OF ZERO ZONE, INC. ANY USE OF THIS DOCUMENT OR DISCLOSURE OF ITS CONTENTS; BY SHEET SIZE CRITICAL DIMENSIONS DENOTED BY X.XX REPRODUCTION OR OTHER MEANS, WITHOUT THE WRITTEN OR X.XXX...
ELECTRICAL/CONTROL Condensing Unit Electrical Connections SMALL CONDENSING UNIT LARGE CONDENSING UNIT Ground Block Customer Power Black, Red, White, Green (Black, White, Green on 1-door cases) Distribution Block Case Power Black, Red, White, Green (Black, White, Green on 1-door cases) Ground Block Case Temperature Control Wire Blue...
PLUMBING Pump with Bracket Installation Instructions Parts Required: Hose clamp Vinyl tubing Cable ties P-clip clamp Vinyl tubing with PVC elbow Case drain lateral Piping support bracket Wire clamp Condensate evaporation pan ...
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PLUMBING Pump with Bracket Installation Instructions Insert the U-shaped copper pipe into the top of the discharge line and fasten into place with the supplied wire clamp. Hang the U-shaped copper over the edge of the evaporation pan. For pan sharing, set up the second discharge line the same way. Attach the overflow line to the overflow exit on the evaporation pan.
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PLUMBING Pump with Bracket Installation Instructions Place the vinyl tube with PVC elbow over the inlet to the condensate pump. Fasten into place using the supplied hose clamp. Attach vinyl tube Hose Clamp to the pump inlet 10. Use PVC primer and PVC adhesive to glue the PVC elbow to the case drain lateral. Route the vinyl tube in the correct direction and make sure it is angled downward for proper flow.
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PLUMBING Pump with Bracket Installation Instructions 11. On a Highlight Merchandiser , install the pump bracket into the holes in the foamed floor. The condensate pump will hang on the pump ® bracket with hooks that are molded into the pump. Crystal Merchandiser and Reveal Merchandiser do not use a pump bracket.
PLUMBING Dual Evaporation Pan Set Up 2 condensate evaporation pans will be installed in series on top of a Hybrid configuration of an 8' or 12' Reveal Merchandiser . The ™ ® evaporation pans and tubing should be installed before setting and shimming the case in order to access the back of the case. Parts Required: Condensing Air Flow...
PLUMBING Power the Condensate Evaporation Pan Highlight Merchandiser Electrical Box Shown ® For Highlight Merchandiser and Crystal Merchandiser , plug the condensate evaporation pan into the case electrical box. ® ® For Reveal Merchandiser , condensate evaporation pans must be powered separately by the store. ®...
PLUMBING Case Drain Line to Floor Drain (If Applicable) Drain trap to the left shown. Trap support bracket can be PVC parts can be flipped for mounted on either side for draining to the right. drains to the left or right. Highlight Merchandiser Shown Reveal Merchandiser...
PLUMBING Booster Pump Installation Instructions for installing a booster condensate pump system for a Reveal Merchandiser display case as a Hybrid Merchandiser ® ™ This system moves condensate from the display case to an overhead drain instead of a floor drain or evaporation pan. Parts Required: Booster Condensate Pump PVC drain lateral...
DRAWING AND THE INFORMATION CONTAINED WITHIN, IS SP-6108 CAD DRAWING DRAWING No: REVISION E SOLE PROPERTY OF ZERO ZONE, INC. ANY USE OF THIS NO MANUAL REVISIONS DOCUMENT OR DISCLOSURE OF ITS CONTENTS; BY SHEET PRODUCTION OR OTHER MEANS, WITHOUT THE WRITTEN...
OPERATION Controller Sensor Wires The temperature probe (discharge air) is located in the false ceiling. The evaporator probe (defrost termination) is located in the evaporator coil. In coolers, 1 sensor bulb is factory installed. Temperature probe wires are white (common) and green (supply). ...
OPERATION Start-Up Power on the case by turning on the store circuit breaker or optional case disconnect. There will be a slight delay before the compressor starts. Set the time clock on the controller to the correct time of day. See below for setting controller time. ...
OPERATION Turning the Lights On & Off The on/off switch for the LED lights are located in the right-hand door of each case. Case Joints Look at bumpers to determine where cases are joined together. The light switch is located on the front right of the false ceiling in The light switch is located on the ceiling in the right center on the right-hand door on Highlight cases and Crystal...
OPERATION Solid Shelf Installation & Removal Shelf Standards InSTaLLaTIOn: Determine desired shelving location. Lift the front of the shelf at a slight angle, keeping the shelf level left to right. Insert the shelf tabs into the slots in the shelf standards. Lower the front of the shelf while moving the shelf tabs into the standards and until the shelf is held securely by the standards.
OPERATION Wire Shelf Installation & Removal Shelf Standards INSTALLATION: Determine desired bracket and shelving location. With the first bracket, lift the front of it up at a slight angle. Insert the shelf bracket tabs into the slots in the shelf standard. Lower the front of the shelf bracket while moving the tabs into the standards and until the shelf bracket is held securely by the standard.
OPERATION Door Hold-Open Bracket Hold-Open Bracket Engaged Highlight Freezer Shown ™ To lock a door in the open position for stocking, open the door until you feel the hold-open bracket fully engage. When you let go of the door, it will remain open. To disengage the hold-open bracket, simply close the door.
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.
MAINTENANCE Using the Condensate Removal System Stores without floor drains use the condensate removal system with a condensate evaporation pan. This is a tray located under the kickplate with a 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.
30 seconds and the control will return to normal operation, discarding any changes made. Note: Zero Zone should be contacted before attempting to change settings. To be completed by trained personnel only. 38 • Controller Operation...
CONTROLLER OPERATION Carel IR33+ Low Temp Reach-In Codes 1 AND 2-DOOR LOW TEMP 3 TO 5-DOOR LOW TEMP 3-DOOR IM BOTTOM-MOUNTED COIL Factory Factory Factory Code Name Code Name Code Name LEVEL 1 LEVEL 1 LEVEL 1 Set Point Set Point Set Point Differential Differential...
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CONTROLLER OPERATION Carel IR33+ Low Temp Reach-In Codes 2 TO 5-DOOR LOW TEMP 1 AND 2-DOOR IM BOTTOM-MOUNTED COIL Factory Factory Code Name Code Name MASTER/SATELLITE LEVEL 1 SATELLITE LEVEL 1 Set Point Set Point Differential Differential High Temp alarm High Temp alarm Min Comp Time Starts Min Time Between Starts...
CONTROLLER OPERATION Carel IR33+ Medium Temp Reach-In Codes MEDIUM TEMP HYBRID ™ MEDIUM TEMP MEDIUM TEMP HYBRID ™ WITH ELEC DEFROST Factory Factory Factory Code Name Code Name Code Name LEVEL 1 LEVEL 1 LEVEL 1 Set Point Set Point Set Point Differential Differential...
CONTROLLER OPERATION Carel IR33+ Medium Temp Open Multi-Deck Codes OPEN MULTI-DECK HYBRID R-404A OPEN MULTI-DECK HYBRID R-448A ™ ™ Factory Factory Code Name Code Name LEVEL 1 LEVEL 1 Set Point Set Point Differential Differential tc.y RTC Year tc.y RTC Year tc.m RTC Month tc.m...
If this button is pressed and held for more than five seconds at start-up, it will activate the procedure for setting the default factory parameters. Contact Zero Zone before performing this procedure; it can erase your IR33+ program settings. note: PRG+ON-OFF/UP resets any alarm with manual reset if pressed together for more than three seconds.
60ºF for a low temp case. Product temperatures within the case will not rise above acceptable levels, however. Product in freezers will remain frozen. Product in coolers will remain at or below 41ºF.* *Please consult the Zero Zone Service Department on case defrost characteristics for non-standard defrost settings. Defrost Schedule REACH-IN FREEZERS 1 to 2-door freezers: 1 time per day (8:00 aM);...
CONTROLLER OPERATION Conditions that Trigger the Temperature alarm If the controller alarm sounds during the scheduled defrost times, please allow an additional one-hour recovery time before calling for service. If the alarm sounds outside of the scheduled defrost times, please review the following checklist. If all items have been checked and the case still does not work properly, submit a service request.
CONTROLLER OPERATION Carel IR33+ Verify and/or Change Parameters SET PASSWORD IN ORDER TO CHANGE PARAMETERS Press and hold [PRG] button until you see “0” flashing. Once “0” is flashing, press [UP] arrow key until you see “22”. Press [SET] key to enter the password access parameters. BELOW ARE EXAMPLES OF PARAMETERS TO CHECK ON THE CAREL IR33+ any parameter can be changed in a similar manner as long as it is listed on your program set points list attached to your case or in the Low ...
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CONTROLLER OPERATION Carel IR33+ Verify and/or Change Parameters H1 - Verify parameter H1 set to “10”. Press [UP] arrow key to move to “H1” parameter. Press [SET]. Press [UP] arrow key to set parameter to “10” if not already “10”. Press [SET].
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CONTROLLER OPERATION Carel IR33+ Verify and/or Change Parameters SETTING PARAMETERS ON THE CAREL IR33+ To set parameters, enter the password and then perform the following steps. Repeat these steps until all parameters have been changed. Press [UP] arrow key until parameter you want to see is displayed. Press [SET] to enter parameter setting Press [UP] or [DOWN] arrows to set parameter to desired setting.
Table 4-1 - XR75CX Front Panel Keys and Functions Compressor enabled 4.1. Keys and Functions 4.2. Use of LEDS Contact Zero Zone for full Dixell / Emerson manual. Flashing Anti-short cycle delay enabled 4.2. Use of LEDS Figure 4-1 - XR75CX Front Panel...
CONTROLLER OPERATION Dixell XR75CX alarm Signals 14 Alarm Signals 14 Alarm Signals 14.2. Alarm Recovery 14.2. Alarm Recovery ALARM SIGNALS ALARM RECOVERY Probe alarms P1, P2, P3, and P4 start some sec- Probe alarms P1, P2, P3, and P4 start some sec- Probe alarms P1, P2, P3, and P4 start some seconds after the onds after the fault in the related probe;...
CONTROLLER OPERATION Condensing Unit Pressure Switch Settings FIXED PRESSURE CONTROLS Note: Used for Crystal Cooler and Highlight Cooler ™ ™ Low pressure cut-in/out: 35/15 psig High pressure cut-out: 440 psig ELECTRONIC UNIT CONTROL (EUC) Note: Used for Crystal Freezer, Highlight Freezer, and Reveal Cooler...
SHROUD INSTALLATION INSTRUCTIONS Standard Shroud assembly Highlight Merchandiser - 20 1/4" Tall Standard Shroud ® CAUTION! 20 1/4" TaLL SHROUDS aTTaCH TO THE UPPER RaCEWaY COVER. DO nOT SCREW THE FROnT SHROUDS DIRECTLY InTO THE UPPER RaCEWaY aS THIS WILL CaUSE an ELECTRICaL HaZaRD. Number of Angle Brackets for Front Side Shroud Front Shrouds...
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SHROUD INSTALLATION INSTRUCTIONS Highlight Merchandiser - 20 1/4" Tall Standard Shroud ® Position the side shrouds perpendicular to the front shroud, on top of each end panel. Screw the side shrouds to the front shroud to ensure a tight fit. Screw the side shrouds into the end panel using self-tapping screws.
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SHROUD INSTALLATION INSTRUCTIONS Highlight Merchandiser - 20 1/4" Tall Standard Shroud ® Screw the shroud divider to the top of the case using self-tapping screws. Install 1 angle bracket to support the shroud divider. Mount the angle bracket to the holes on the top flange of the shroud divider, and screw the shroud divider to the top of the case.
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DRAWING No: REVISION OR X.XXX AND MUST MEET Cpk ≥ 1.33. NO MANUAL REVISIONS IS THE SOLE PROPERTY OF ZERO ZONE, INC. ANY USE OF THIS DOCUMENT OR DISCLOSURE OF ITS CONTENTS; BY SHEET SIZE CRITICAL DIMENSIONS DENOTED BY X.XX REPRODUCTION OR OTHER MEANS, WITHOUT THE WRITTEN OR X.XXX...
OPTIONS noise Reduction Kit Self-Tapping Screw DESCRIPTION QUANTITY Washer Screw Self-Tapping Screw Spring Clip U-Clip angle Bracket Rear angle Brace Front angle Brace Balloon Guard Rear Brace U-Shaped Insulation Panel Flat Insulation Panel Pre-lubricate quick- Flanges should be tight connect couplings against back of case Install Rear Brace and Condensing Unit Place the rear brace on the case top with bent flanges tight to the back of the case top.
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OPTIONS noise Reduction Kit Align the flat insulation panel with the edge of the U-shaped insulation panel as shown. Place the angle bracket against the middle of the flat insulation panel as shown. Fasten the angle bracket to the flat insulation panel using 2 screws and 2 spring clips. Use 2 self-tapping screws to fasten the angle bracket to the case top.
OPTIONS Balloon Guard Kit DESCRIPTION QUANTITY 23 1/2" x 36" Plastic Mesh 3/32" x 2 5/16" Cotter Pin Use the cotter pins to attach the plastic mesh to the condenser to prevent balloons or debris from blocking airflow to the condenser. This process varies depending on whether the condenser inlet/outlet piping is toward the back or the front of the display case.
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OPTIONS Balloon Guard Kit SCENARIO 2: CONDENSER INLET/OUTLET TOWARD THE FRONT OF CASE (3 COTTER PINS) Orient the plastic mesh with the longer side against the condenser. Clip the mesh to the far end of the condenser at the top. Repeat the previous step on the near end of the condenser.
OPTIONS Optional Disconnect Installation Optional disconnect is 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 Options • 63...