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E1954
REV I 06/07/24
INSTALLATION & OPERATIONS INSTRUCTIONS
Self-Contained & Remote Refrigerated Models
Including Dual Zone & Cold Deli Models
KEEP THIS MANUAL FOR FUTURE REFERENCE
Engineering and technical data are subject to change without notice.
FEDERAL INDUSTRIES
Toll Free 1(800) 356-4206
& Non-Refrigerated Displays
215 Federal Avenue
WI Phone (608) 424-3331
Belleville, WI 53508
Fax: (608) 424-3234
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Table of Contents
Related Manuals for Federal CGR5048
Summarization of Contents
Introduction and Documentation
Serial Number Recording
Record the model and serial numbers of the case for easy reference.
Safety Information and Warnings
Employer Safety Responsibilities
Ensure personnel are familiar with safety information and procedures for case use.
Understanding Safety Signal Words
Defines signal words like DANGER, WARNING, CAUTION, and NOTICE in safety messages.
Pre-Installation Procedures
Shipping Damage Inspection
Inspect for shipping damage upon arrival and file freight claims.
Installation Instructions
Display Case Location
Position case away from direct sun, heat sources, and excessive air movement.
Removing Case from Shipping Skid
Procedure to safely remove the display case from its shipping skid.
Case Leveling and Grill Removal
Level the case for proper function and remove rear grill for component access.
Condensate Evaporator and Trim Kits
Information on the condensate evaporator and instructions for exterior trim kit installation.
Interior Trim Installation
Instructions for installing interior trim kits for cases with glass or no glass panels between them.
Refrigeration System Installation
Self-Contained Models
Self-contained models are pre-assembled and require no refrigeration adjustments.
Remote Models
Details components for remote models and their function in maintaining case temperature.
Remote Model Components and Setup
Information on filter drier, sight glass, and low-pressure control for remote units.
Electrical Information and Grounding
Grounding Requirements for Safety
Ensures the case is properly grounded for electrical safety, preventing shock.
Electrical Connection Procedures
Guidance for licensed electricians on wiring hookups, circuit separation, and grounding.
Operating Instructions
Controls for Refrigerated and Non-Refrigerated Units
Explains light switches, temperature control, and power switches for unit operation.
Shelves and Rear Package Shelf
Information on adjusting shelves and the rear package shelf for usability.
Sliding Rear Door Operation
Instructions for removing, cleaning, and operating sliding rear doors for easy access.
Product Placement and Environmental Limits
Guidance on stocking, weight limits, and placement for optimal airflow and performance.
Refrigerated Model Stocking and Environment
Rules for overhang, display pan, and pre-chilled product; specifies ambient limits.
Shelving Installation and Removal
Shelf Bracket and Light Assembly Installation
Steps for inserting shelf brackets and attaching shelf light assemblies and cords.
Shelf Bracket Installation Details
Detailed bracket installation, light cord connection, and rear door re-installation steps.
Shelf Support and Rear Door Re-installation
How to install shelf supports and re-install sliding rear doors after shelving.
Shelf Installation Methods
Shelf and Light Quantity Management
Guidance on using supplied shelves/lights and capping unused sockets.
Wire Shelf Installation
Steps for installing wire shelves, including attaching clips and securing shelves.
Glass Shelf Installation
Instructions for installing glass shelves, including attaching shelf holders.
Metal Shelf Installation
Steps for installing metal shelves, ensuring proper seating on supports.
Maintenance
Fluorescent Shelf Light Replacement
Procedure for replacing fluorescent shelf lights, including bulb removal.
Fluorescent Light Lens Installation
Steps for reinstalling the plastic lens into the aluminum housing of fluorescent lights.
Fluorescent Top Light Replacement
Procedure for replacing fluorescent top lights, including bulb and lens replacement.
LED Light Maintenance
LED Shelf Light Replacement
Steps for replacing LED shelf lights, including detaching and mounting new lights.
LED Top Light Replacement
Procedure for replacing LED top lights, including unplugging and mounting new LEDs.
Periodic Maintenance
Condenser Coil Filter Cleaning (Self-Contained Units)
Instructions for cleaning the reusable condenser coil filter monthly.
Condenser Coil Filter Cleaning (Longer Units)
Procedure for cleaning the condenser coil filter on 50", 59", & 77” units with filter access cover.
Condenser Coil Cleaning
Procedure for cleaning the condenser coil every 6 months or as needed.
Cleaning Instructions
Daily Interior and Glass Cleaning
Daily cleaning steps for the interior, including glass cleaning.
Front Glass Tilting for Cleaning
How to tilt the front glass for easier cleaning of interior front and side glass.
Weekly and Interior Cleaning
Recommended weekly cleaning procedure for maintaining a clean and sanitary case.
Detailed Interior Cleaning Steps
Steps for cleaning the interior, including shelves, standards, and display pan.
Interior Cleaning Details
Removing fan shroud and cleaning interior components and door tracks.
Service Information
Service Safety Precautions and Contact
Disconnect power before service; contact department for issues or parts.
Pre-Service Troubleshooting Checklist
Checklist to avoid unnecessary service calls by reviewing common issues.
Troubleshooting Case Operation, Lights, and Temperature
Checks for common issues like no power, faulty lights, or temperature problems.
Troubleshooting Glass Fogging
Checks ambient conditions and case temperature to address glass fogging.
Service, Sale, and Disposal
Special Service Situations and Owner Responsibilities
Handling refrigerant and owner duties for sale/disposal, including manual inclusion.
Refrigeration and Electrical Data
EEV Operation and Settings Adjustment
Explanation of EEV function, controller settings, and refrigerant/superheat adjustments.
Technical Specifications - Refrigeration Data
Tables of specs for non-refrigerated and self-contained models, including refrigerant and electrical data.
Technical Specifications - Remote Refrigeration Data
Table listing specs for refrigerated remote models, including refrigerant and electrical data.
Main Wiring Diagrams
120 Volt Dry Unit Wiring Diagram
Diagram for 120 Volt dry units, showing fan motor and power switch connections.
120 Volt Refrigerated Self-Contained Wiring Diagram
Wiring diagram for 120V refrigerated self-contained units, detailing components and connections.
120 Volt Refrigerated Remote Wiring Diagram (Pre 1/20)
Wiring diagram for 120V refrigerated remote units prior to 1/20, showing EEV and thermostat.
120 Volt Refrigerated Remote Wiring Diagram (Post 1/20)
Wiring diagram for 120V refrigerated remote units after 1/20, showing EEV and temperature sensor.
120 Volt Refrigerated Remote Wiring Diagram (Post 7/1/24)
Wiring diagram for 120V refrigerated remote units after 7/1/24, detailing EEV and sensors.
208-240 Volt Dry Unit Wiring Diagram
Diagram for 208-240 Volt dry units with transformer, showing fan motor and power switch.
240 Volt Refrigerated Self-Contained Wiring Diagram
Wiring diagram for 240V refrigerated self-contained units with transformer.
240 Volt Refrigerated Remote Wiring Diagram
Diagram for 240V refrigerated remote units with transformer, showing EEV and sensors.
Fluorescent Light Wiring Diagrams (Before 1/2019)
Diagram 1: Fluorescent Lights (No Shelf Light)
Diagram for fluorescent lights (F017T8, etc.) without shelf light.
Diagram 2: Fluorescent Lights with Standard Shelf Light
Diagram for fluorescent lights with standard shelf lights, showing top and shelf lamp.
Diagram 2: Fluorescent Lights (Optional No Shelf)
Diagram for fluorescent lights with optional no shelf lights, showing top lamp.
Diagram 3: Fluorescent Lights with Multiple Shelf Lights
Diagram for fluorescent lights with standard shelf lights, showing multiple lamp configs.
Diagram 3: 5042DZ Fluorescent Lights with Shelf Lights
Diagram for 5042DZ models with standard shelf lights, showing multiple lamp configs.
Diagram 3: 7742 Fluorescent Lights with Shelf Lights
Diagram for 7742 models with standard shelf lights, showing multiple lamp configs.
Diagram 4: Fluorescent Lights with Standard Shelf Lights
Diagram for fluorescent lights with standard shelf lights, showing four lamp configurations.
Diagram 4: 7748 Fluorescent Lights with Shelf Lights
Diagram for 7748 models with standard shelf lights, showing four lamp configurations.
Diagram 2: 5042DZ/5048DZ Fluorescent Lights (No Shelf)
Diagram for 5042DZ/5048DZ models with optional no shelf lights.
Diagram 4: 5042DZ/5048DZ Fluorescent Lights (Standard)
Diagram for 5042DZ/5048DZ models with standard shelf lights, showing four lamp configs.
Diagram 4: DZH Fluorescent Lights with Shelf Lights
Diagram for 3660DZH, 5060DZH, 5960DZH with standard shelf lights.
Diagram 4: 7760DZH Fluorescent Lights with Shelf Lights
Diagram for 7760DZH models with standard shelf lights, showing four lamp configurations.
LED Light Wiring Diagrams (After 1/2019)
LED Shelf Light Wiring Diagram
Diagram for LED shelf lights, including anti sweat heater and power supply.
LED Light Wiring Diagram Configuration
Detailed diagram for LED lights, showing top and shelf light configurations.
Replacement Parts - Self-Contained Refrigeration
Self-Contained Refrigeration System Component List
Table of parts for self-contained refrigeration systems, including condensing unit details.
Replacement Parts - Remote Refrigeration
Remote Refrigeration System Component List
Table of parts for remote refrigeration systems, including coil, valve, and heater.
Replacement Parts - Fluorescent Lighting
Fluorescent Light Electrical Component List
Table listing electrical components for fluorescent lights, including part numbers.
Replacement Parts - Glass Components (Before 11/1/2020)
Glass Component List (Pre 11/1/2020)
Table of glass component part numbers for models before 11/1/2020.
Replacement Parts - Glass Components (After 11/1/2020)
Glass Component List (Post 11/1/2020)
Table of glass component part numbers for models after 11/1/2020.
Replacement Parts - Door & Shelf Components
Door and Shelf Component Part Numbers
Table listing part numbers for door and shelf components for various models.
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