Loading...
HomeMy WebLinkAboutPRODUCT INFORMATIONE„ Y _ E ESi � n" F 'r��e � •8m. �. va ��an... :.•. a �,+ee 8 °a�$:=� d . • ' . . PCB S`# d.•e. q•. v v vv+A� °,�,�e.'d 9°°. v a v- v v��a e8. vv � °a2 x P I EIZC:F N` CASE`CL05ED m NSF Et4 �s Intertek ZERO ZONE WARRANTY.................................................................. 1 INTRODUCTION.............................................................................. 2 ■ Important User Information........................................................ 2 ■ Manufacturer............................................................................2 ■ Intended Use............................................................................ 2 ■ Display Case Models.................................................................. 2 ■ Delivery Inspection.................................................................... 3 ■ Packaging................................................................................ 3 ■ Location...................................................................................4 INSTALLATION............................................................................... 5 ■ Leveling...................................................................................5 MOVING CASES............................................................................ 10 LINEUP ASSEMBLY....................................................................... 12 DRAINLINE................................................................................. 16 BUMPER AND KICKPLATE............................................................. 17 ■ Installing End Kickplate........................................................... 17 ■ Installing Bumper...................................................................17 ■ Under Case Return Air Flow Assembly Instructions ..................... 19 GENERAL INFORMATION.............................................................. 20 ■ Cleaning.............................:...................................................20 ■ Shelf Location........................................................................ 20 ■ Shelves..................................................................................20 ■ Loading the Case.................................................................... 20 ■ Light Switch........................................................................... 21 ■ Case Thermometer..................................................................21 ■ Service...................................................................................21 REFRIGERATION........................................................................... 23 ■ General..................................................................................23 ■ Low Temp............................................................................... 26 ■ Medium Temp......................................................................... 28 ELECTRICAL................................................................................. 29 ■ General..................................................................................29 ■ Low Temp............................................................................... 32 ■ Medium Temp......................................................................... 36 DEFROSTING................................................................................ 39 ■ Low Temp............................................................................... 39 ■ Low Temp/Medium Temp.........................................................43 ■ Medium Temp......................................................................... 44 A;; in 111111i 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). The obligation under this warranty shall be limited to repairing or exchanging any part, or parts, without charge, FOB Factory, and which is proven to the satisfaction of Zero Zone's 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 such manufacturer's warranty to the'seller. Any products sold on an "AS IS" basis shall not be covered by this warranty. ��i���1�IFT���i�i i :11•��I':�9 In addition to the standard limited warranty, forfurther consideration, the Company will extend to the original purchaser, 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 it's "Service and Installation" instructions. Any compressor warranty may be extended for an additional four (4) years but such extension must be purchased prior to shipment to be effective. In those instances on manufactured systems where factory installed "Zero Zone Oil Management Systems" are purchased the original limited warranty shall be extended automatically to two (2) years total and purchased extended warranties shall be extended automatically for a total of six (6) years from the date of factory shipment. This warranty is only for the compressor and not for any other associated parts of the refrigeration system. The written Warranty, if any, provided by the manufacturer of any pad 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. IMPORTANT USER INFORMATION Copyright © 2013 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, 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. If any questions or problems arise, call Zero Zone at800-247-4496. Any change to a Zero Zone product made during the installation, startup, 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. l iT11d1 fi l l y!(ta iIIT 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. Always install Zero Zone products on a level surface. The information contained in this manual pertains to Zero Zone Display Cases, which include the following: DISPLAY CASE MODELS LOW -, RVZC30 RMZC24 RVZC30T2 3RMZC30WA RVZC30BB 3RVZC30WAT2 RVZC30T2BB RVCC30 RMCC24 RVCC30T2 3RMCC30WA RVCC30BB 3RVCC30WAT2 RVCC30T26B INTRODUCTION DISPLAY CASE MODELS (CONT.) 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. Potential case features include: • Brushless D.C. electronic motors, PSC*, or shaded pole fan motors* • T-8 fluorescent lamps* • LED lighting • Standard -energy*, low -energy, or no -energy doors These display cases were designed and tested using the following industry standards • ASHRAE Standard 72-2005 — Method of Testing Commercial Refrigerators and Freezers (ANSI Approved) - • AHRI 1200 — Performance Rating of Commercial Refrigerated Display Merchandisers and Storage Cabinets (ANSI Approved) • UL 471- Commercial Refrigerators and Freezers (ANSI Approved) (equipment certified by ETL) • NSF 7- Commercial Refrigerators and Freezers (ANSI Approved) (equipment certified by NSF) • DOE Compliant (All U.S. Sales) ASHRAE 72-2005 specifies the test conditions for the equipment. It includes the ambient conditions of 75OF dry bulb and 55 % RH. It also specifies the door opening requirements for the performance test. Doors are opened 6 times in 1 hour for 6seconds. The door opening test period is for 8 hours during one 24-hour performance test. As an example, a 5-door case will have 240 door openings during one 24-hour test. Consult the factory if your store exceeds these test conditions. *Not for U.S. Sales ', a ■: '.' '. These display cases were carefully factory -tested, inspected and properly packed to ensure delivery in the best possible condition. The equipment should be uncrated 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. Each case in a lineup is labeled to identify the lineup and joint. The label uses a number and letter designation. The number indicates the lineup. The letter indicates the case joint. Case joints begin with the letter A at the left most joint in the lineup when looking at the front of the lineup. The joint for two cases has the same number -letter designation (Figure 1 on page 4). Back -to -Back cases have a unique designation. The left most joint in the lineup when looking at the front of the case is labeled 1-A. The joint on the back of the case is 1-Al (Figure 1 on page 4). Insulated dividers are factory installed to separate low and medium temperature cases. They are also used to join different case models. Factory installed plexiglass dividers separate refrigeration circuits. The first case in the lineup (with the right side labeled "A") has a packet attached to the door handle that contains the manual, special instructions for installing ordered options, and touch-up paint if the cases are custom painted. Every case in the lineup has a packet attached to the door that contains the specific information for that case. The packing slip is taped to the right-hand door of each case. Bumpers and kickplates are shipped on top of the case. Shelves for the case are tiewrapped-and blocked into the individual cases. Other accessories like drain traps, drain pans, condensate evaporation pans, and hat channels are shipped in the case that require the parts. Materials for joining cases include caulk, joining bolts, splices, and T or J strips. These parts are supplied in cases that have a left -side insulated divider or no left end. The parts are bagged and taped to the coil covers. The T and J strips are tied to the shelves. 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. Out of level conditions will result in reduced performance. Wall cases (cases set with a back to a wall) and cases set back-to-back, should be positioned to allow a minimum 24' space behind the back of the unitts). This will allow necessary air to circulate behind the display case(s). Higher humidity stores with minimal air circulation require a 4' gap. Figure 1: Case label Information 2-13 2-B 2-A 2-A 1-A 1-A 1-B 1-B FRONT OF LINEUP CASE J❑INT LABELS 1-A1 1-A1 1-131 1-B1 1-A 1-A 1-B 1-B FRONT OF LINEUP BACK TO BACK CASE J❑INT LABELS LEVELING Cases must be installed perfectly level to allow efficient operation of the refrigeration coils and complete drainage of defrost water. Since a level area is seldom available, the following steps are recommended to insure a level installation. 1. Measure off and mark on floor the exact dimensions of the case lineup (Figure 2A). (Check blueprints). 2. Snap a chalk line at the locations for the front and back positions of the bases. 3. Mark locations of all joints (front and back). 4. Using a laser or transit, find the highest point along both base rail position lines. Using the high point as a reference, mark the difference directly on the floor to each joint, front and back (Figure 2B). 5. If you plan on using optional hat channels to raise the case height, place them under each pair of bases. The 3 and 4-door hat channels will be angled slightly to support the front and rear bases. (Figure 3 on page 6 and Figure 5 starting on page 7). 6. Place the required number of shims under each base or optional hat channel at each joint (front and back) to equal the highest point. 7. The RVZC30, RMZC24, RVCC30 and RMCC24, 2 through 5-door cases, have segmented bases mounted at the ends and under the center section of the case. The RVZC30 and RVCC30 1-door and RVZC30BB and RVCC30BB have full bases that run front to back and are located at the ends and under the center sections of the case. The 3RMZC30WA and 3RMCC30WA have segmented bases that run front to back. 8. Tape all shims in place (Figure 2C). Figure 4 on page 6 shows the correct orientation of shims under the base or channel. 9. Place additional support shims under all other bases or hat channels (Figure 5 starting on page 7). 10. Use a carpenter's level to check installation as you go. The case should be level from front to back and side to side. Install the case at the highest point first, if part of a lineup. Check the level on the face of the glass doors and sides of the mullions. Do not use the ceiling to check level. 11. If you've purchased seismic restraints, specific instructions for attaching those restraints are included in your document package. These instructions should be read and followed before the lineup is assembled. Figure 2: Leveling Cases Prior to Joining 0 B. Mark floor level differences VZ Shim Placement WA & BB Shim Placement C. Shim joints to equal highest points INSTALLATION LEVELING (CONY.) Figure 3: Typical Hat Channel Locations Figure 4: Shims Under Bases and Case Shims DWG. NO. SP-6003-1 REV. A Both comers of the base rims must be supported by shims _ _ ----to prevent base buckling I DWG. NO. SP-6006.1 REV. A P LEVELING (CONY.) 35 36 5/8 V2' rl/2' +1 2' iYP. O CJ A. 1-Door Case C. 24" 2-Door Case Figure 5: All Base Locations TYP 30 B. Wrap Around Case (WA) —31 3/16' /16' O 5' 1 37 7/6- n rvc D. 24" 3-Door Case YP. /2' INSTALLATION LEVELING (CONU O 59 4 2 DOOR 30' DOOR BB CASE E. 30" 2-Door Back -to -Back Case 4 1/2' 59 4 1/? Figure 5: All Base Locations (Cont.) 4 59 M. 92 1/2' 10 34B' 40 3/0' 2 L 2' Q 'TO. 3 DOOR 30' DOOR BB CASE F. 30" 3-Door Back -to -Back Case L 123' 38 3/4'— 10' TV. O L_ 5• M. 4 DOOR 30' DOOR BE CASE G. 30" 4-Door Back -to -Back -Case— - 4' M. --2 13/16' I INSTALLATION LEVELING (CONY.) Figure 5: All Base Locations (Cont.) 13/16' 62 1/8' 30 3/16' 30 5' T1P 2 DOOR 30' DOOR CASE 10' TYP. H. 30" 2-Door Case 30 30 4 DOOR 30' DOOR CASE J. 30' 4-Door Case 153 3/8' TYP. 10• 5 DOOR 30' DOOR CASE K. 30" 4-Door Case 3 DOOR 30' ➢OCR CASE I. 30" 3-Door Case MOVING CASES The Back -to -Back cases are shipped with wood planks that allow the use of pipe rollers. These wood planks should be removed after the case is moved to its final location (Figure 6 on page 11). The RVCZ and RVCC and BB cases have steel protective support plates under the ends (not under insulated dividers). These are designed to protect the end from Johnson Bar damage. Use the following methods to move the cases: RVZC30 & RMZC24 ••K LIFT FROM ✓ '-JOHNSON ✓ DOLLY ✓ ROLLERS ✓ RVZC BB ✓ ✓ ✓ ✓ ✓ RVZC WA ✓* ✓ ✓ 1-Door RVZC ✓* ✓ ✓ ✓ ✓ RVCC30 & RMCC24 ✓ ✓ ✓ ✓ RVCC BB ✓ ✓ ✓ ✓ ✓ RMCC WA ✓ ✓ ✓ 1-Door RVCC ✓* ✓ ✓ ✓ ✓ * Fork lift from rear Care should be taken when moving the cases. The doors should be secured so they cannot open while the case is moved. Only experienced certified fork truck drivers should use fork trucks to move the cases. The case should only be lifted off the floor as high as necessary for transport. The fork truck should be driven slowly avoiding any abrupt motions or bumps. The cases have steel protective support plates under the ends (not under insulated dividers). These are designed to protect the end panel from J-bar damage. Care should be taken when moving the cases. The doors should be secured so they cannot open while the case is moved. Only experienced 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, avoiding any abrupt motions or bumps. The following forklift dimensions must be maintained to avoid damaging the case when it is lifted: 2-DOOR CASES Forks must extend from 26• to no more than 30" under the case. 3-DOOR CASES Use 48" long forks! Forks must extend from 39" to no more than 43" under the case. 4 & 5-DOOR CASES Use 48" long forks! Fork blades wider than 4" will not fit in the bases. MOVING CASES Spacer blocks are factory installed in the end bases of 4 and 5-door cases that use 4'h° bases (Figure 7). These blocks limit the cases forward tilt while it is being lifted and must be used when lifting 4 or 5-door cases with 4'h" bases. For low shipping height applications, Zero Zone has optional expandable bases. As shipped, the base is 13/° tall. It is attached with spacers that allow the base to slide away from the bottom of the case creating a gap that allows the use of a 1'h" thick fork truck blade (Figure 8). Figure 6: Removing Wood Planks Figure 8: Expandable Base Spacers Figure 7: Wood Block Inside Base Ima LINEUP ASSEMBLY Zero Zone display cases have been engineered for continuous display. This means that any number of cases can be joined together to create a display of any desired length. The bottom of the end panel is protected with a removable steel plate. The lineup is assembled by sliding one case up to the second case and then bolting the cases together. Bolt holes for the bottom of the frame can be accessed by removing the right and left coil covers. The front and top bolt holes are visible on the steel end frame. The rear bolt holes are exposed by removing the lift -out duct on the 30' door cases and by removing pocket covers on the 24" door cases. Figure 12 on page 13 show the bolt hole locations for each case. Bolt kits and instructions are supplied with the case. Figure 9 gives instructions on applying caulk to the case joint before the cases are slid together. Once the cases have been caulked and slid together, start the joining bolts, but do not tighten them. Slide the t-strip between the door frames (Figure 11 on page 13). Begin tightening the bolts at the top rear, working down the back of the case and up the front, making sure that the front seams are flush. Bolts are not designed to pull the cases together. Two different model cases or two different temperature cases are connected using an insulated divider. Typically the divider is factory assembled to one of the cases. Two styles of divider are provided. The first style has a panel on each side with nut inserts in the panels. Each side is bolted to the end frame. Instructions for assembly of this style are given in Figure 13 on page 14. The second style divider uses a thru-bolt design. The divider is attached to one of the cases using short bolts. When the case is installed, the short bolts are removed and long bolts are reinstalled to bolt both cases together. Instructions for assembly of this style case are given in Figure 14 on page 15. Bolts are not designed to pull the cases together. For NSF case installation, the interior case seams need to be sealed using NSF approved caulk (not supplied) as shown in Figure 10 on page 13. The end panel protector support plates should be removed after the cases are set in their final position. Figure 9: Caulking Cases to be Joined DO NOT APPLY EXCESS AMOUNTS OF BUTYL SEALANT THAT WOULD CAUSE IT TO SQUEEZE ONTO END FRAME METAL AREAS. Caulk sealant used to join cases and complete the sealing requirements for NSF compliance should not come in contact with butyl sealant. Apply to clean, dry surfaces free of contaminants that adversely affect adhesion and could change color of sealant joint areas over time. PROCEDURE FOR JOINING CASES These procedures are critical! Failure to follow these guidelines will result in a poorly functioning case. This is especially true of low temp cases. 1. Apply two 1/4' to 3/s" wide beads of butyl sealant, 1/z" in from the inside and outside edges of foamed insulated ceiling, rear wall, base, and door frame to be joined. Apply to only one case joint to avoid excessive amounts of butyl sealant that would squeeze out of the joint. Sealant is not applied to the structural steel end frames. After cases are joined, caulk the top and back exterior seams (if possible) at this time. 2. _ When joining ends_of cases, caulk sealant should be applied in the same manner for joints. 7,5 Figure 11: T-Strips Figure 1M Required Sealing for NSF -Approved Installations SURFACE TEMPERATURE SHOULD BE ABOVE 40°F AND FREE OF FROST. 1. Apply non porous/nonabsorbent good quality NSF approved silicon caulk sealant or (Manus Band 75-AM) after end panel is joined to case or when second case is joined with first case. 2. Apply silicon caulk -sealant bead to areas shown to meet sealant requirements for NSF approved installations. 3. Apply small beads of sealant smoothly, but do not thin or feather excessively, because it may affect adhesion. NOTE: Field caulk is applied continuously. Figure 12: Joining 24° and 30" Door Cases Joining 24" 830" Cases End frames factory installed. Exploded for clarity. a � \ DETAIL A Typ (5) Places- 0 5 4 Joining Frames Typ (4) Places 1 5 i3/8°-16 x 1° Hex Hd Cap Screw I 64-0287 22 ` 1Washers ._._........._.._..—64-0034 3 5 3/8°46Hex Nut — 60-0064 4 ` 4 410-24 x 1/2" SltTruss Hd Screw- 64-0145 5 4 ;#10-24 Nut, SltTruss Hd Shoulder 64-0146 x 66 64-0034-Pl 64-0145-P1 64-0146-P1 Caulk Case Joints Per 1&0 Manual Figure 13: Joining Insulated Dividers with Nut Inserts Insulated divider (factory attached) 2-112" Insulated Divider Joining Kit Case to be joined not shown For alli frames Caulk case joints per 1&0 manual. i 1 4 '114-20X7/8 HEX HD CAP SCR GRADE 5 2 1 -11/420X1-V2 HIX HD CAP SCR GRADE 5 1 3 5 1913Y ID X 1-1/4' OD X 093' THk WASHER 4 4 SCREW #10 X 1-1Y2PH FLTHD SMSZP • —'' -'Add for Ioining kit - - -'- - - -.. 5 25 IGALV. SHIM 2' X 6- (LEVELING CASE) .....,..,.._,.,.....L_.-..._.,_..._...._._._.._......__.. ....... .__. _-._- 64-0106 64-0106-1 - 64-0125 64-0125-1 -64-0199 84.0199-P1 64-0099 - _ ' 64-0099-1 I 41-0166 41-0166 DWG NO, SP-0397 REV.H ■ Figure 14; Joining Insulated Dividers with Thru-Bolts BOLT DETAIL FOR / )/ RIGHT INSUL DVDR LEFT OPPOSITE CASE f 3 2 DMDER CASE 2-112" INSULATED DIVIDER JOINING KIT WITH THRU BOLTING VZ TO VC VC TO VZ VZT2 TO VCT2 OR VCT2 TO VZT2 1) CAULK CASE JOINTS FOLLOWING SPI TECH BULLETIN CASE JOINING AND SEALING NSF FIELD CAULKING. 2) ALIGN OPPOSITE ENDS OF TWO CASES TO BE JOINED. 3) THERE ARE 5 BOLTS ATTACHING THE DIVIDER TO THE CASE. REPLACE EACH OF THESE BOLTS ONE AT A TIME. DO NOT REMOVE DIVIDER FROM CASE. 3a) REMOVE ONE BOLT AND ONE WASHER USED TO ATTACH 2-111 INSULATED DIVIDER PANEL. 3b) INSTALL ONE LONGER (ITEM 1) 114-20 X 3-10 GRADE 8 BOLT AND ONE (ITEM 3) WASHER IN THE SAME LOCATION AND ORIENTATION OF THE ORIGINAL BOLT. 3c) TIGHTEN TO SECURE INSULATED DIVIDER. THE BOLT WILL TIGHTEN TO THE PANEL AND THE END OF THE BOLT WILL EXTEND THRU INTO THE NEXT CASE. 3A) REPEAT UNTIL FIVE BOLTS HAVE BEEN REPLACED. 4) HAND TIGHTEN ITEM 3) WASHERS AND (ITEM 2) GRADE 8 NUTS ON OPPOSITE CASE. 5) MAKE SURE INSULATED DIVIDER IS ALIGNED WITH CASE. 6) ALTERNATELY TIGHTEN EACH BOLT EQUALLY UNTIL THE CASES ARE JOINED TOGETHER EVENLY FORMING A TIGHT SEAL BETWEEN THE DIVIDER AND THE CASE. BOLTS ARE NOT DESIGNED TO PULL CASES TOGETHER. 7) FINISH ATTACHMENT OF THE SECOND CASE FRAME WITH FOUR (ITEM 4) SCREWS. ITEM QTY DESCRIPTION ZZ PART NO. ZZ PART NO. BLACK 1 (5) BOLT HEX TAP 114-20 x 3-112" HEX HD BOLT, GRID 8 64-0406 64-0405-P7 2 (5) NUT HEX 114-20 GRID 8 64-0308 64-0308-PI 3 (10) WASHER 9132" ID 1-1/4" OD .093TK FNDR 64-0199 64-0199-PI 4 (4) SCREW #10 X 1.0" PH FLTHD SMSZP (FRAME) 64-0269 64-0269-PI ADD FOR JOINING KIT 5 (25) GALV. SHIM 2- X 6'(LEVELING CASE) SP-IN7 RE DRAIN LINE The drain is located at the center of the case in the floor pan. The drain can be reached by removing the center coil covers and then removing a fan motor. The 1° PVC drain outlet is located at the center front of the case behind the kickplate. Install the 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 factory installs a drain support at the front of the case on all 30' door cases. We supply a trap support that is field mounted to the case (Figure 15). 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 insure proper drainage. Consult your local codes for minimum requirements. Figure 15: Trap Support A Zero Zone bumper is standard on all case models and should be installed at the bottom front of the case. Various bumper styles are available (Figure 16 on page 18). The kickplate assembly is adjustable to compensate for uneven floors. The bumper end cap is factory installed on bumpers for cases with end panels that do not include Euro trim. INSTALLING END KICKPLATE (Figure 17 on page 18) The end kickplate attaches to the small black bracket attached to each side of the case with an end. The kickplate can be adjusted vertically to match the height of the floor below it. 1. Attach a Tinnerman clip to the side bumper support. 2. Place the side kickplate against the Tinnerman clip on the side bracket. 3. install the black Y4" screw through the side kickplate and into the Tinnerman clip. A scratch -awl or similar tool can be used to line up the holes. 4. The front of the side kickplate is located behind the front kickplate and attached with screws to the front kickplate. I1M'M IRIJ`iUM 11lMI 9 4 (Figure 17 on page 18) The front kickplate and bumper attaches using 1'h" screws attached to brackets located on the front of the case. The kickplate can be adjusted up and down to fit the height of the floor below it. 1. Starting from the left end of the lineup, attach a Tinnerman clip to each bumper support bracket. Locate them over the hole for the bumper. 2. Attach the kickplate splice to the right side of the kickplate using the Y4" screw in the lower hole. 3. Lean the kickplate against the bumper support bracket. 4. Hang the bumper on the case. The kickplate should be located behind the bumper. 5. Install the black 1'h" screw through the bumper, kickplate, kickplate splice, and into the Tinnerman clip. A scratch -awl or similar tool can be used to line up the holes. 6. Follow these steps to install the next bumper in the lineup. A bumper splice (provided) should be installed between the two cases. Center the splice and adjust the height so the decorative tape (if applicable) lines up. Using self -tapping screws (provided), attach the upper portion of the splice using the predrilled holes in the splice. Then with two more screws, attach the lower half. C'"W �. 1 Figure 16: Other Style Bumpers Figure 17: Installing Bumper and Kickplate DUMPER AND KICKPLATE UNDER CASE RETURN AIR FLOW ASSEMBLY INSTRUCTIONS To assemble the bumper for under case return air flow (if requested), a spacer (provided) must be inserted between the bumper and kickplate (Figure 18). The spacer is held in place with the standard black assembly screw used to attach the bumper. One 3/a° spacer is required at each screw location (2 spacers on a 2-door, 3 spacers on a 3-door, etc.). 1. To ease installation, hook the bumper to the case and position the kickplate. Then pull the bottom edge of the bumper forward, hold the spacer in place, and then insert the assembly screw through the bumper, spacer, kickplate, bumper bracket and into the Tnnerman clip. 2. With the spacers in place, air will be allowed to flow between the bumper and kickplate and then underneath the case. The target airflow rate under the case should be 50 cfm/door. Note. An optional louvered kickplate is available. Figure 18: Bumper Air Flow Side view of case Bumper 1 IAiribw Spacer (gap eNarged� for danry) 1� Airflww Floor GENERAL INFORMATION CLEANING The case and doors are cleaned prior to shipping. However, the case should be thoroughly cleaned before start-up and routinely thereafter to maintain a clean appearance. Use mild detergent and warm water (never an abrasive cleaner) to wipe out the inside of the case. Wash down all glass doors with glass cleaner. Do not use any products containing silicon on anti -fog glass coatings. Clean interior glass reduces fogging and increases visibility. The case will remain bright and sparkling with just a few minutes of cleaning each week. Internal components can be cleaned after removal of access panels. The case drain should be regularly cleared of debris and price tags. Coils may be cleaned with a garden hose or pails of water. Cases that use pump, drain pans and condensate evaporators should be cleaned with a minimum amount of water. The drain should be blocked and the water removed with a shop vacuum. Do not use high-pressure water or steam to clean the interior. 'Egim 11; • The shelves are adjustable in 1" increments on cantilever shelf cases and may be located in any position for best display advantage. • Be sure brackets are completely seated. • Wire shelf brackets are stamped with "R" for Right and "L" for left to aid installation. SHELVES Zero Zone manufactures many different styles of shelves, baskets, and product stops. The shelves and baskets are placed on the shelf brackets for shipping. Solid shelves have three parts. A solid center section and two snap -in brackets. Some of the baskets may be reversed and used as a typical shelf. The fully assembled shelves are installed in cases prior to shipping. Solid shelves can be disassembled for cleaning. A screwdriver can be used to spread the snap open to remove the brackets from the center section. The case may be loaded with merchandise after it has been operated for at least 24 hours with correct case temperature and proper control operation. While loading the shelves, leave an air space between the top of the merchandise and the shelf above it so the customer can remove the merchandise. The air space allows an air curtain on top of the product. Product should not extend beyond the front of the shelves or block the return air grill. The shelf loads are as follows: 7. ITEM 1 SHELF DESCRIPTION 22°and 24° deep MAXIMUM LOAD PER SHELF 250 lbs. 2 27' deep 400 lbs. 3 Bakery or Meat Brackets at 0° 250 lbs. at 5° 250 lbs. at 10° 1501bs. at 15' 100lbs. Some deflection may occur under higher loads. ■ 1, i.V' � LIGHT SNITCH The light switch is located inside the right-hand door. Turn the light switch off during the initial case temperature pull down to prevent the case lights from cycling off and on. Always turn the lights off when replacing lamps. CASE THERMOMETER The cases are shipped with 2 thermometers. One thermometer is factory mounted in the discharge air stream. The second thermometer is shipped loose and should be installed in the warmest product location. Specific instructions are packaged with the shipped loose thermometer. N T See Figure 33 on page 41 and Figure 35 on page 43 for the typical component layout of the 30" door case. See Figure 34 on page 41 and Figure 36 on page 43 for the typical component layout of the 24" door cases. The bumper and kickplate must be removed to gain access to the drain clean out and electrical connections. Disassemble the bumper and kickplate by removing the 2 or 3 metal screws located in the kick rail. The bumper assembly can be lifted up and removed from the case. The kickplate can be removed, exposing the electric tray cover and drain (Figure 17 on page 18). EVAPORATOR The evaporator coil, located at the rear bottom of the case, is factory assembled with distributor, expansion valve, and other refrigeration components. To inspect the coil, remove the center or left of center coil cover. A small inspection window is located at the rear of the case. To inspect the entire coil, remove the remaining coil covers and raise the evaporator cover. EXPANSION VALVE Unless otherwise specified, a superheat adjustable externally equalized thermostatic expansion valve with a removable strainer and pressure limiting charge (low temp only) is mounted to the evaporator coil. The valve is not preset. Adjust the superheat setting for maximum coil effectiveness. Typical superheat settings are between 67 and 10°F. Close coupled systems should use the higher superheat setting to minimize the chance of liquid flood back. To adjust the expansion valve, remove the right end coil cover. Remove the cap from the bottom of the valve. When looking at the valve stem end, turn the valve stem counterclockwise to decrease superheat. Turn the valve stem clockwise to increase super heat. Measure the suction line temperature at the expansion valve 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 turn at a time and allow sufficient time (20 to 30 minutes) for the valve to settle before making any further adjustments. Replace the valve stem cap after the valve superheat has been adjusted. BE CERTAIN THE VALVE STEM CAP IS WIPED DRY FIRST. 0 Caution! DISCONNECT POWER TO THE CASE BEFORE SERVICING ELECTRICAL COMPONENTS TO AVOID PERSONAL INJURY AND DAMAGE TO THE UNIT. '.�rlL�1��:L� t�� 7y:V I•� Air is circulated throughout the case with 115 volt low temperature fan motors. These motors must be operating at all times except during defrost in low temp cases. 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 factory original equipment part. SERVICE (CONI) CONDENSATE EVAPORATION SYSTEM Zero Zone remote cases can be equipped with an automatic condensate evaporation system. The system uses a pump and drain pan located behind the kickplate and a condensate evaporator pan mounted on the top of the case. Condensate water and any liquid spilled in the case drains out into the drain pan. The pump is equipped with a float that turns the pump on when there is a sufficient liquid level. Liquid is pumped through a plastic hose through a check valve and into the condensate evaporation pan. The evaporation pan is equipped with a heater and a float switch to turn on when the heater is submerged in liquid. When the heater is energized, the pan will be extremely hot and should not be touched. The pump and condensate pan should be cleaned regularly. Any spilled product should be cleaned to prevent odors. AIR CURTAIN VELOCITY Air curtain velocity is affected by stocking levels, coil frost loads, temperature and fan condition. The measurement method also affects the reading. Zero Zone recommends using an Alnor Velometer Jr., set to the 0-to-600 fpm range. Air velocity should be measured at the back edge of the discharge air honeycomb, at the center of the middle door in the case (other doors have slightly lower velocity). A typical low temp velocity reading is 400 to 500 feet per minute in a fully -packed low temp case, after the case has defrosted and pulled down to operating temperature. Air curtain velocity in a partially -packed display case is significantly lower because more air exits the back wall duct holes. In medium temp cases, the velocity should be 300 to 400 feet per minute after the case has defrosted and pulled down to temperature. FAN REMOVAL 1. Turn off power to fans. Remove coil cover. 2. Unplug fan from fan power supply plug located on the front face of the fan housing. 3. Remove the fan blade nut and fan blade. 4. Remove the two mounting bolls and remove the fan assembly from the fan housing. 5. Remove the three fan motor mounting screws from the back of the fan motor. 6. Reverse steps 1 - 5 to install. LED POWER SUPPLIES AND BALLASTS Most Zero Zone case ballasts or LED power supplies are located in the door mullion. Ballasts for the 1-door and WA, are located behind the kickplate: FLUORESCENT LIGHTING These systems use a lens to direct light output evenly across the shelves. Turn off power before servicing the lamps. The lens must be removed to access the lamp. The lens must be replaced after servicing for proper operation. Detailed information is contained in the door instruction booklet. REFRIGERATION Unless otherwise specified, the liquid and suction connections are made inside the case under the evaporator fan/coil cover. Refrigerant piping may enter the case through the front left bottom, the left rear bottom of case, or the left rear top of case. The copper pipe should not touch or rub on the edges of the sheet metal. After connections have been made, the refrigeration access hole in the case must be sealed completely with an aerosol -dispensed Urethane insulation or equivalent (i.e. Great Stuff). Penetrations made in sheet metal baffles should also be sealed (Figure 19). REFRIGERANT PIPING Figure 19: Penetration Sealing Fill in area wit - foam of er installation 0 Fill in area wit foam after installation DWG. NO. SP-6007-1 REV. A Correct refrigeration line sizing and installation is essential for proper system operation. Figure 23 on page 26, Figure 24 on page 27, and Figure 25 on page 28 are for Evolution (V) model cases. Contact the factory for line sizing for the Maximizer (M) model cases. A P-trap must be installed at the bottom of all vertical suction risers (Figure 20 on page 24). Various risers are available as a factory installed option. When two or more case sections are connected to one compressor, the main liquid and suction line for the group should be run through the cases and be brought out through the refrigeration outlet of one case only. The factory recommends one riser per circuitisystem for hot gas defrost when using top back refrigeration exit. Circuit risers are available as a factory installed option. On 30" wide door rases with suction lines over 13/s° diameter, a P-trap made with 45° elbows is required (Figure 20 on page 24). A piping chase in front of the fan shroud allows the refrigerant lines to be run through the right or left end frame. Piping should not be placed near the electric defrost heaters. The defrost heaters on the 30° door cases will grow one inch to the left of the coil when they reach operating temperature. The compressor should be installed as close as possible to the cases to reduce pressure drop. Install a shallow trap at the bottom of the riser. The best location for the liquid line drier is inside the case compartment. However, it may be installed near the compressor for easy maintenance. Install moisture indicating sight glass at the outlet end of the drier. A low pressure or temperature control can be used to control case temperature. The control should be selected with adequate contact capacity for the switching load. In rack systems, an evaporator pressure -regulating -valve may be used to control the evaporating temperature. The settings (Figure 21 on page 25) are approximate due to variations in gauge accuracy, differences in compressor efficiency, line pressure drop and superheat settings. Before making adjustments for store or stocking conditions, make sure the superheat is set. Close coupled systems typically run at the higher end of this range to avoid flood back. REFRIGERATION GENERAL (CONT.) TEMPERATURE CONTROL ADJUSTMENT When factory installed, the temperature control is located toward the right end of the case in the electrical box. The sensing bulb is located under the coil cover on the back side of -the fan shroud. It can be wired in series with the low-pressure (L.P.) control. It can also be used in a pump down system by wiring it in series with the liquid solenoid valve. A thermostat is shown in Figure 22 on page 25. Discharge air temperature probes for electronic case controllers may be installed in many different customer specified locations including, but not limited to, honeycomb, ceiling pocket cover, rear wall, and return air. LEAK-C H ECK/EVACUATION/CHARGING 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 to a minimum of 500 microns and nitrogen sweep is recommended. After the system has been thoroughly evacuated of all moisture and noncondensable gas, charge the system with the proper refrigerant, using "hi-side/low-side" charging techniques. Figure 20: 45' Elbow Suction Line Figure 21: Temperature Settings RACK SYSTEMS RACK SYSTEMS RACK SYSTEMS VZ and VZT 30" door VZ and VZT 30" door VC and VCT2 30" door Evaporator temp -70F Evaporator temp -16OF Evaporator temp +28OF - MZ 24" door and WA MZ 24" door and WA MC 24" door and WA Evaporator temp-110F Evaporator temp-18OF Evaporator temp+25OF CONDENSING UNIT CONDENSING UNIT CONDENSING UNIT VZ and VZT 30" door VZ and VZT 30" door VC and VCT2 30" door Condensing unit cut -in 35 psig Condensing unit cut -in 27 psig Condensing unit cut -in 74 psig Condensing unit cut-out 24 psig Condensing unit cut-out 16 psig Condensing unit cut-out 62 psig MZ 24" door and WA MZ 24" door and WA MC 24" door and WA Condensing unit cut -in 33 psig Condensing unit cut -in 26 psig Condensing unit cut -in 70 psig Condensing unit cut-out 21 psig Condensing unit cut-out 15 psig Condensing unit cut-out 58 psig RETURN & DISCHARGE RETURN & DISCHARGE RETURN & DISCHARGE AIR TEMPERATURE AIR TEMPERATURE AIR TEMPERATURE Return air temp cut -in +60F Return air temp cut -in -30F Return air temp cut -in 300F Return air temp cut-out OOF Return air temp cut-out -9OF Return air temp cut-out 34"F Discharge air temp cut -in +30F Discharge air temp cut -in OOF Discharge air temp cut -in 33OF Discharge air temp cut-out -30F Discharge air temp cut-out -120F Discharge air temp cut-out 370F Note: These set points may require optimization for your applications to prevent short or delayed cycling. Figure 22: Temperature control F0(ED INDICATOR BULB 6 0 2 YELLOW r®z RED � 'BLUE A B@3 6 0 31 0 DIFFERENTIAL SLIDER EXAMPLE: TO OPERATE A FREEZER @ 0°-5- SET THE DIAL TO 0° AND THE SLIDER TO A S DIFFERENTIAL REDIYELLOW CLOSE ON RISE OPEN ON DROP REDIBLUE CLOSE ON DROP_ _ OPEN ON RISE DWG. NO. SP-6008-1 REV. A REFRIGERATION Wil t, 0 Figure 23: Refrigeration Line Sizing - Frozen Foods :S[tL•IIIR-9f7tL7tl[i67i_!TtiATi�i�_�3ZT17t� Liquid Line Sizing - Electric Defrost - Up to W equivalent feet Up to 100 equivalent feet 90'F Uquld, 2-F Pressure Drop' WE Liquid, 7F Pressure Drop° Fwrated Btuh: Parroted Bauh: From IQ Liauld line 0 7,3W 1/4' 7,310 15,000 5/16' 15.010 27,WO 3/8 27.310 64.600 1/2 64,610 122AW 5/8 from L Llautltlne 0 4,970 1/4- 4,980 10,300 5/16' 10,310 18,700 3/8 18,710 44,300 1/2 44,310 83,200 5/8 ' For hat gas defrost, use a liquid tine one size larger than shown. 'For 1°F pressure tlrop, multiply rated Btuh by 1.45 before using the Liquid Une Sizing Table. 'Larger liquid One size may be used (such os 3/8), if preferred. '3/4 liquid line may be used to reduce cost. Up to 150 equivalent feet Up to WO equivalent feet WF Uquid. 7F Pressure Dmp° 90'F Uquid, 77 Pressure Drop' Formted Btu In Fasted Stuh: To Llauitl Line 3,960 114' R35510 14.900 318 35.500 1/2 66,700 5/8 II1,000 7/81 From IQ Liquid Line 0 3370 114. 3,380 6,940 5/16' 6.950 12.700 318 12.710 30.300 1/2 W.310 56,900 5/8 56,910 94,800 7/81 Uquid Correction Factors For Uquid Une Sldng Table - Use Maximum Uquld Temperature For maumum liquid temperatures other than WE. nuitipty raise Btuh by liquid correction factor before using the liquid Line $ping Table .,suns, LI,dd Temperable: 40°F 50°F 60-F ArP WE WF IW°F I10°F 120°F Uquid Correction Factor. 0.96 0.95 0.95 0.95 1 0.97 1.00 1.05 1.12 1.21 Suction Horizontal Line Sizing Up to SO equivalent feet Up to Hill equlvalent feet 90'F Uquid, 7F Pressure Drop' WE Uquld, 7F Pressure Dept Ferreted BNh: Formted Btuh: From To H rr'Up t I 0 1,7W 3M" 1,740 4,100 1/2" 4,110 7.700 5/8" 7,710 12,800 7/8' 12.810 20.3W 7/8 20,310 41,OW 14/8 41,010 71,400 1-3/8 71.410 113,000 1-5/8 Rom To Horizontal 0 1,180 3/8" 1,190 2b10 I/2" 2,820 5.280 518 - 5,290 8,780 7/8' 8,790 14,000 718 14.010 28,210 1-1/8 28,210 49,210 1-3/8 49.210 77,FC0 1-5/8 Up to 150 equivalent feet Up 10 200 equivalent feel WE Uquid. 7F Pressure Dmpt 90'F Uquid, 7F Pressure Drop' For rated Bluth IFor rated Bluh: From To Honzont 0 940 3/8" 950 2,240 1/2" 2.250 4.220 5/8" 4,230 7,030 7/8t 7.040 11.200 718 11,210 22,700 1-1/8 22,710 39,500 1-3/8 39,510 62,500 175/8 62,510 I30,000 2-1/8 ' For I°F pressure drop, multiply rated BTU by I As before using the Suction Horizontal Une Siring Table. "Larger suction horizontal line size may be used, if preferred. ' 3/4 horizontal suction line may be used to reduce cost Roer IQ H-on-ZODLCI 0 80D 3M'* 810 1,910 1/2" 1,920 3,600 5/8" 3,610 60W 7/8' 6.010 9.530 7/8 9,540 19,400 1-128 19,410 33,800 1-3/8 33810 53,500 1-5/8 53.510 112,00D 2-1/8 Uquid Correction Factors for Suction Horizontal Une Sizing Table - Use Maximum Uquid Temperature Fa ma4mum liquid tempartaes other than 9W. multiply rafee BNh by Gquid conectlon factor before using the suction H xbontol Line Sizing Table L6o9invim Uauld Te,lure: 4 F I 50-F I 6VF 70-F 8WF WE 100°F I10'F 12VF liquld Correction Factor. 0.72 0.76 0.81 0.86 0.92 I.W 1.09 1.21 1.37 Sucffon Vertical Riser Sizing Maximum Allowable Filter Size For Adequate Oil Return' 70-F Minimum Uquid Temperature, using 0.35 PSI Per 100 Feet (per 20D6 A5HRAE Handbook - Refrigeration). For rated Btuh: From Lo Vencal 1,360 2.550 1/2 2.560 4,270 5/8 4,280 6,790 5/81 6.8D0 13,900 7/8 13,910 24,WO 1-1/8 24,310 38.400 IJ/8 38,410 80,000 1-5/8 80.010 142,OW 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 fine saes are inches, refrigeration O.D. Subject to change without notice. ' If horizontal line size is smaller than specified vertical riser she, the smaller size may be used for both. 13/4 suction riser may be used to reduce pressure drop. Uquid Correction Factors for Suction Vertical Riser Sizing Table - Use MInImum Uquid Temperature Multiply rated Btuh by Gquid correction factor before using the Suction Vertical Riser Siang Table Minimum could Temperature: 4 F` I 5YF I F 70-F 80-F WE 100-F IJuIdCdnebfi.nF.CtvJ 0.84 10.88 1 0.94 1.W 107 1A6 1.27 CCR, 4/4/07 SP-0612-01. RevB REFRIGERATION LOW TEMP (CONT.) Figure 24: Refrigeration Line Sizing - Ice Cream [ZHAIF- as lif.7[ - . .F- - -eu -- - 1. -a•- 11 - Uquid Line Sizing - Electric Defrost - Up to 50 equivalent feet Up to 100 equivalent feet 9,7F Uquid, 2'F Pressure Drop' 901F Uquid, 2F Pressure Drop° Forrated Bfuh:I F Forrated Bfuh: From To Liquid Line 0 7A90 1/4' 7,100 14,600 5/16' 14,610 26,500 3/8 26,510 620800 1/2 62,810 117,000 518 From S U9Lld Line 0 4,830 1/4' 4.840 9.930 5/16' 9,940 18,200 3/8 18,210 43,100 1/2 Z.110 80.900 5/8 • For hot gas defrost, use a liquid line one size larger Ihan shown. 'For I1F pressure drop, multiply rated Blurt by 1.45 before using the Liquid Line String Table. 'Larger liquid line sae maybe used (such as 3/8), if preferred. 13/4 liquid line may be used to reduce cost. Up to 150 equivalent feet Up to 200 equivalent feet 90'F liquid. 2°F Pressure Drop' 90PF Liquid, 21F Pressure Drop' Far rated Btuh: -For rated Bfuh: Figs)434,5DO1 To Llne 04- 3.86016' 7,940/8 14,510/234,510/86d,810a To Liz; d Line0 3,270 1/4- 0 6,750 5116' 0 F 12,400 318 0 29.400 112 0 55,400 $18 0 92.100 7/81 Uquid Correction Factors for Uquid Une Sizing Table - Use Maximum Ugald Temperature Far maximum liquid temperatures other thcn9MF, multiply rated Bfuh by liquid correction factor before using the Liquid line Siang Toble 6]g4Bpymaqul TemP.at.e: 40PF 501F 601F 7TF SO1F 901F 100°F I101F 120-F Liquid CmecRgn Factor. 0.95 0.94 0.94 0.95 0.97 1.00 1.05 1.12 1.23 Suction Horizontal Line Sizlna Up to 50 equivalent feet Up to 100 equivalent feet 90oF Uquid, 21F Pressure Drops 901F Uquid, 21F Pressure Dropr Forrated Btuh: Forrated Btuh: From IS, Horizontal 0 1,420 3/8" 1,430 3.3W 1/2" 3.370 6,300 5/8" 6.310 IQS00 7/81 10,510 16,600 7/8 16,610 33.600 1-1/8 33,610 58,400 1-3/8 58.410 92300 1-5/8 From To Ho4zontal 0 970 3/8" 980 2,290 1/2" 23W 4,320 5/8" 4.330 7.180 7/81 7,190 11,400 7/8 11,410 23,100 I-)/8 23.110 40,300 I-3/8 40.310 0.700 1-5/8 63.710 132,000 2-1/8 Up to 150 equivalent feet Up to 200 equivalent feet 90PF Uquid, 21F Pressure Drops 90'F Uquid, 21F Pressure Drops For rated Btuh 1 F-F.-rrated-Btu­h-�: RO TO Horizontal 0 770 3/8" 780 1,840 I/2" 1,850 3,450 5/8" 3,460 5.750 7/81 5,760 9,120 _ 718 9,130 18.600 I-1/8 18,610 32.400 I-3/8 32410 51.2f10 1-5/8 51,210 107.0M 2-1/8 1 For I1F pressure drop, multiply rated BTU by 1.44 before using the Suction Horizontal Une Sizing Table. "Larger suction horizontal line size may be used, If preferred. 13/4 horizontal suction line may be used to reduce cost. Ia Horizontal 660 3/8" 1,560 1/2- 1 2.950 5/8" 4,910 7/81 F27710 7,790 718 15,900 wilt 27.700 IJ/8 43.830 1-5/8 91,000 2-1/8 Uquid correction Factors for Suction Horizontal Une Sizing Table - Use Maximum Uquid Temperature F. maximum d,ld temn.atues other than Wit, multiply rated Btub by loud ornecNon tact. before mine the Suction Hon.m.l Line String Table (_ty''nJrymU udb,mperot,v:l 401F 501E I 601E I 701E 1 801E 1 901E I 1001E I 1101F 120-F Liquid correction Factor 0.72 0.76 0.80 OE6 0.92 LW L10 1.22 1.38 Suction Vertical Riser Sizing Maximum Allowable Riser She For Adequate Oil Return' 701E iMnimum Uquid Temperature, using 0.35 PSI Per ITo Feet (per 2006 ASHRAE handbook - ReMgeration). For rated Btuh: From Tg 2,2802,290 3,8103820 6=6060 12.40012,410 ly--ft�2-i1,210 21.60021,610 34,30034.310 71,30071,310 127,000 It may be necessary to make adjustments to compensate far speclal situations which cause the actual Bluth to differ from the rated Bluth of the cases. All liquid line and suction Me sizes are Inches, refrigeration O.D. Subject to change without notice. • If hohzanot line sae is smaller than specified vertical rher size, the smaller size may be used for both. 13/4 suction mer may be used to reduce pressure drop. Uquid Correction Factors for Suellen Vertical Riser Sizing Table - Use Minim Liquid Temperature Multiply rated Btuh by liquid correction factor before using the Suction Vertical Riser Sizing Table ?:2Lmagwd remcemrore: 40'F 501E 601E 701E 801E 901E 1001E Uquid cmedian Factor 0.83 0.1 014 1. W 1.08 1.77 7.28 CCR.3/29/07 SP-0612- 2. Rev 8 MEDIUM TEMP 1/ Liquid Line Sizing Up to 50 equivalent feet 91PF Uquid, 2-F Pressure Drop' Forrgfec Btuh: or I. Liquid Line 0 2.750 3/16' 2,760 8.050 I/4' 8,060 16,600 5/16- 16.610 30,100 318 WA 10 71,210 1/2 Figure 25: Refrigeration Line Sizing - tl Up to 100 equivalent feet Up to 150 equivalent feet Up to 200 equivalent feet 90-F Uquitl, PF Pressure Drop' 90-F Liquid, 2'F Pressure Drop' 9PF Uquitl, 2°F Pressure Drop' For rated Stun: Fonaled Btuh: For Toted Btuh: rom To Uquitl Line 0 1,870 3/16' 1,efm 5,48D 1/4- 6,490 11,300 5/1C 11,310 20,6DO 3/8 20610 48,SW 1/2 48.810 91.700 5/8 From To Liauid Line 0 1,480 3/16' 1,490 4.360 1/4' 4,370 8,990 5/I6' 9p00 16.500 3/8 16.510 39.100 1/2 39,110 73,500 5/8 °For loF pressure drop, multiply rated Btuh by 1.45 before using the Uquitl Line Sing Table. Larger liquid One size may be used (such as 318). if preferred Llauld Line 60 3/16' 10 1/4'60 A 5/16'00 3/80 1/200 5/8 Liquid Correction Factors for Liquid Line Siring Table - Use Maximum Liquid Temperature Fwmadmum Bquid temperatures other than 90'F. bra tiplyrated BIM by liquid correction factorbefore using the Uquid Une Smng Tobte M-1- Ugvldlempermure: 40-F 1 W°F 1 60°F I 70-F I 80-F I 9PF IWF 1 110'F 120-F Liquid Conection F.cf.1 0.98 1 0.97 1 0.96 1 0.97 1 0.98 1 1.00 1 1.04 1 I.09 1 1.17 Suction Horizontal Line String Up to 50 equivalent feet Up to IM equivalent feet 90PF Liquid, 2'F Pressure Drop' 90'F Uquitl, 7F Pressure Drop° Forrated Btuth 1 F-F.Mt­ed-Btu-h-1: From i0 I Horizonte 0 1.970 5/16" 1,980 3,580 3/8 3,590 8.460 1/2 8,470 15.900 5/8 15,910 26.300 71V 26,310 41,6D0 718 41,610 84,OD0 1-1/8 From To Hy3gL 0 1,350 5116" 1,360 2,450 3/8 2460 5,810 1/2 5,820 10,900 518 10,910 18,100 7/8t 18, 110 28,700 718 28,710 M.000 1-1/8 Up to 150 equivalent feel Up to 200 equivalent feel 9PF Uquld, TF Pressure Drop: 9fPF Liquid, 2'F Pressure Drop' For latetl 9tuh: For rated Bfuh: tycig To Horizontal 0 1.080 5/16" I A90 1,960 3/8 1,970 4,650 1/2 4,660 8,740 5/8 6.750 14.600 7/8t 14,610 23,100 7/8 23,110 46,700 1-1/8 46,710 81.300 "/8 From To HortavIini 0 920 5/Ir 930 1,670 3/8 1,6 3,970 1/2 3,980 7.470 518 7,480 12.500 718' 12.510 19,700 7/8 19,710 40000 1-1/8 40.010 69.600 1-3/8 For I'F pressure drop, mutiipiy rated Bfuh by 1.M before using the Suction Horizontal Une Sizing Table. "Larger suction hortic ntal Me size maybe used if preferred. '3/4 horizontal suction One may be used to reduce cost. Liquid Correction Factors for Suction Horizontal Line Sizing Table - Use Maximum Liquid Temperature Formaximum Bquld temperatures other Irian 90-F, multiply rated Bluth by (quid conectlon factwbeiore using the suction Horizontal Line Sizing Table Mai mum uamdremaerahwe: 40-F I 50-F 1 60-F 1 70°F 1 80-F 9PF 100-F I10-F 1201F Uquid Conection F..t.1 0.74 1 0.78 1 0.82 1 0.87 1 0.93 1 1.00 1.08 1.19 1.32 Suction Vertical Riser Sizing Maximum Allowable Riser Size For Adequate OR Return* 7PF Minimum Uquid Temperature, using 0,35 PSI Per I00 Feet (per 2006 ASHRAE Handbook - Refrigeration) Forraled Btuh: From To I Vertical 480 880 5116 890 2A90 318 2.100 3,950 1/2 3,960 6.590 5/8 6.6D0 10,500 5/8' 10,510 21,300 7/8 21.310 37 0 1-1/8 37.310 59,100 IJ/8 It may be necessary to make adjustments to compensate for special situations which cause the actual Blunt to differ from the rated Btuh of the cases. All liquid line and suction One sizes are Inches, refrigeration O.D. Subject to change without notice. • If horizontal tine size is smaller than specifetl vertical deer size, the smaller size may be used far both. 314 suction nser may be used to reduce pressure drop. - Uquid Conection Factors for Suction Vertical Riser Sldng Table - Use Minimum Liquid Temperature Multiply rated Btuh by Liquid correction factor before acing the Suction Vertical Riser Sling Table tlWmum Liquid Temperature: dD-F SPF 60-F 70-F BTF 9PF IW Uquid Conection Tocfar. 0.85 0.89 0.94 1.00 1.07 1 1.15 1.24 CCR. 1013107 SP-0612-1 I. Rev B 0 Caution! DISCONNECT POWER TO THE CASE BEFORE SERVICING ELECTRICAL COMPONENTS TO AVOID PERSONAL INJURY AND DAMAGE TO THE UNIT. Figure 26 on page 32 for 30" and 24" door cases shows the typical wiring diagram for a low temperature case equipped with electric defrost. Figure 27 on page 33 shows the typical wiring diagram for a low temperature case equipped with hot gas defrost. Figure 30 on page 36 shows the typical wiring diagram for a medium temperature case. Each case is provided with a wiring diagram located in the electric box that shows the exact wiring of the case. There are many control options available for multiple case defrost systems. Wiring diagrams and instructions can be obtained by contacting Zero Zone's Service Department. External wiring should be sized according to the amperage rating stamped on the serial plate. The serial plate is located on the ceiling inside the left-hand door. Typical electrical values are shown on specification sheets for each of these cases in the bag attached to the case or are available at www.zero-zone.corn. All internal wiring has been done at the factory. Cases with standard wiring have their control wires terminated in the electrical compartment located behind the kick rail at the right end of the case. A terminal block has been used to simplify field connections. An electrical box is mounted on the top of the unit for cases equipped with the optional top mount electrical connections. All wiring must comply with the National Electrical Code and all local codes. After installation of the equipment, correct operation of the electrical circuits and controls and defrost operation and termination should be verified. All operating voltages and amperages should be measured and recorded. OPTIONAL ELECTRICAL WIRING Single Point Connection (Low Temp) The "single point" connection system is designed to reduce the time required to install and wire one display case with one condensing unit. Figure 28 on page 34 is a typical diagram for this system. All of the display case controls, including the disconnect switch and the electronic case controls are installed behind the kickplate and prewired. The liquid line solenoid valve is installed in the liquid line and wired. The power to operate the display case is connected at the case disconnect switch. The power to operate the condensing unit is connected in the condensing unit control panel. There are no interconnecting wires between the condensing unit and display case. The controls operate the system as a pump down defrost. When the display case begins defrost, the liquid line solenoid valve, fans and anti -sweat heaters are de -energized. The defrost heaters are energized. The compressor continues to run and pumps down the coil. The compressor cycles off on its low-pressure control. If there is any residual liquid left in the coil, the suction line pressure will rise and the compressor may turn on and pump down the coil. The liquid line solenoid is energized at the end of the defrost cycle and the defrost heaters are de -energized. The suction line pressure rises and the compressor starts. When the low temperature evaporator reaches operating temperature, the fans and anti -condensate door heaters are energized. ELECTRICAL GENERAL (CONY.) ' Single Point Connection (Medium Temp) The "single point" connection system is designed to reduce the time required to install and wire one display case with one condensing unit. Figure 31 on page 37 is a Typical diagram forthis system. All of the display case controls, including the disconnect switch and electronic case controls, are installed behind the kickplate and prewired. The liquid line solenoid valve is installed in the liquid line and wired. The power to operate the display case is connected at the case disconnect switch. The power to operate the condensing unit is connected in the condensing unit control panel. There are no interconnecting wires between the condensing unit and display case. The controls operate the system as a pump down defrost. When the display rase begins defrost, the liquid line solenoid valve is de - energized. The fans and anti sweat heaters remain energized during defrost. The compressor continues to run and pumps down the coil. The compressor cycles off on its low-pressure control. If there is any residual liquid left in the coil, the suction line pressure will rise and the compressor may turn on and pump down the. coil. The liquid line solenoid is energized at the end of the defrost cycle. The suction line pressure rises and the compressor starts. Master Satellite Connection (Low Temp) The "master satellite" connection system allows one condensing unit to be connected to multiple cases. Figure 29 on page 35 shows a typical diagram for this system. All of the display case controls, including the disconnect switch, time clock, temperature control, and defrost temperature control, are installed behind the kickplate and prewired. The liquid line solenoid is prewired but is not installed in the liquid line. The power to operate each display case is connected at each case's disconnect switch. The power to operate condensing unit is connected at the condensing unit. There are no interconnecting wires between the condensing unit and display case. There are interconnecting wires that need to be connected between the cases. The liquid line solenoid valve needs to be installed in the common liquid line before the liquid is distributed to the cases. The controls operate the system as a pump down defrost. When the display case begins defrost, the liquid line solenoid valve, fans and anti -sweat heaters are de -energized. The defrost heaters are energized. The compressor continues to run and pumps down the coil. The master case contains the time clock. Interconnecting case wiring allows the master case to control the satellite cases. When defrost is initiated in the master case, it sends an electrical signal to each case to energize the defrost relay and initiate a defrost in all of the satellite cases. A second set of interconnecting wires is connected in series between each of the cases. Each case defrost heater is de - energized when the coil reaches the defrost termination temperature. An additional signal is relayed to the next case indicating that the termination temperature has been reached. When all of the cases have reached termination temperature, the defrost termination circuit is complete and the defrost is terminated. The liquid line solenoid is energized at the end of the defrost cycle and the defrost heaters are de -energized. The suction line pressure rises and the compressor starts. When the evaporator reaches operating temperature, the delay thermostat (klixons) will close, energizing the fans and anti -sweat door heaters. ELECTRICAL GENERAL(CONT) Master Satellite Connection (Medium Temp) The "master satellite" connection system allows one condensing unit to be connected to multiple cases. Figure 32 on page 38 shows a typical diagram for this system. All of the display case controls, including the disconnect switch, time clock, and temperature control, are installed behind the kickplate and prewired. The liquid line solenoid is prewired but is not installed in the liquid line. The power to operate each display case is connected at each case's disconnect switch. The power to operate the condensing unit is connected at the condensing unit. There are no interconnecting wires between the condensing unit and display case. There are interconnecting wires that need to be connected between the cases. The liquid line solenoid valve needs to be installed in the common liquid line before the liquid is distributed to the cases. The controls operate the system as a pump down defrost. When the display case begins defrost, the liquid line solenoid valve is de - energized. The compressor continues to run and pumps down the coil. The master case contains the time clock. Interconnecting case wiring allows the master case to control the satellite cases. When defrost is initiated in the master case, it sends an electrical signal to each case to initiate a defrost in all of the satellite cases. A second set of interconnecting wires is connected in series between each of the cases. The liquid line solenoid is energized at the end of the defrost cycle. The suction line pressure rises and the compressor starts. �e m _ N=R = nu OPRONO. TWERATURE CONTROL AND UOUID UNE SOLENOID VALVE CLOSE ON RISE - USE RED a minx OPEN ON DROP ME 18 GA WINE W/BWE 18 G1 FANS OPRONAL S'—SEE NOTE— HUE �DUPWII FLOAT SABCX CONCEIROE RLLIOLIE Km BOX 115h1-60 12 Gl OPE71 SOF Ca TSF SAEEIY BUT OUR TNERNOSTAT (63-0340) W/ BROWN IFABS- SET 0 BY F OPEN ON R� BROWN �BRPNN USIA DEFROST OL'IICNAL AONN m IERMIN41gN SET 0 SP HaowN ERHER (4w) DEEROSr HEATER BM 14 GA OPTIONAL BLACK 1a u LIQUID uNE KUWB SOLENOID 12P/ YUWON RuxWTIE:NIOCASE r_—HAOK--� 9 B 3 T(t) OBAY M COMRTRONS I HArac—�g DELAY PM07AIS �1 I RF1.AY 3POr L7 1 ® IB F CLOSE LIJ I fI 3 I,I}I,I,l 4 6 I , 200 2�N WIL 9 I W-0'L47 CQ NO NO mim mmm I 1 17 18 yBB� _ _ _ GSE — — — — (116h{BLACK____._____--_ L2L I I II _--L_--- BLACK--J UKUXONGHrS (DCHIB) CND FOR 24HR UGHING NUWON , —_ I- FRWE DOOR —CRII��II r I I I I {1 4IF NO KIDNN4 IS USED _ BULK UGm L—--I—I---I-------*HTE}(11Sy I_ ------------RED DEFROST( 20 N L---- I---__________—RED}NFATER irOPPNAtmPUMP- OPIIOWL)— L___--- 1--------------------_ WNTEI (12M CONDUCTORS USE ONLY COPPER I TECHNICAL OUESDON7 FOR SWCE CALL 1—BDD-247-4496 I DIAL. NO. 65-0565 REV. R I = ruKrL & WHITE .ILK = IN=R = ORA OPTIONAL TEMPERATURE CONTROL AND LIQUID LINE SOLENOID VALVE RED / YELLOW CLOSE ON RISE REPRESENTS T CA EGRESS BLUE 18 1 THRU CASE � I I � WHITE W/BLUE 78 GA EI OPTIONAL IF NO MUWO I m LIQUID LINE KUXON, WIRE I SOLENOID 120V TO TB. J2 OPTIONAL ° ° LIGHT ADJUSTABLE DEFROST CONTROL SWITCH \JLJLI FANS REDAMOW CLOSE ON RISE tK,?� KS7� RED/BLUE OPEN ON RISE NOT INCLUDED IF NO MULUON KU%ON 5 EXAMPLE: TO SENSE DEFROST COIL TEMPERATURE SET THE POINTER TO DESIRED '®x e ®o o Pet o (TEMPERATURE OF 501' AS AN EXAMPLE) W24HR.LIGHTING IONAL XON T TT (FANS) (MULLION)DELAY I, I I1I IT 1 T t 10'' F COPEN LOSE THERMOSTATS 10 F CLOSE 2 13 4 15 6 D7 18 I NOT INCLUDED WITH L— i i — I (TO TERMINAL 4 FOR 24 HR. LIGHTING) _ BLACK LIGHTS (115 V) l --r---T----I------------------ WHITE J I L___ 1__________________ BLACK L__ I }FANS (115 V) __________________ WHITE RUN WIRE INTO CASE GRND1 ________________ ______ _________ - BLACKMUWON, DOOR (115 V) I — WHOE & PERIMETER USE ONLY COPPER CONDUCTORS TECHNICAL QUESTION? FOR SERVICE CALL 1-800-247-4496 1 DIA. NO. 65-0443 REV. J LOW 4Y (CONU Figure 29: Master Satellite Wiring MILK iWNIKULLLKf CA]L - MUUNILU IN CALL b WHLN IWU GA�L� AKL GUNNLLILU IUbLIRLK , � � unv —0'1 a mnl�Mwui.vmmes I.��`I�-ryy IIII'I �II—Mil-]ii4T. __ ue'.x�e4�me.N.uu�� • J CPIIONOI € � `� ^m LOWER CASE WIRING"'-rArz iwrx - owla=.w;f v uss awx cNea wnunons rzaa¢u ouamx2 rw sev¢ cw 1-wo-m-rrse vwi w. ss-mu my o i n � rrs: ul mo rmm SATEWTE (CONTROLLED) CASE WHEN TWO CASES ARE CONNECTED TOGETHER o� rve a F III �LO II � � � ;•�^��I - .x u�.,,u per.. LOWER CASE WIRING - - us wnr crovm macrprs rcaeux alm M' ra M6 wL Few-24-4496 tvun xo. 65-.5 lav . 2 a 2 DOOR FRAME WIRE COLOR CODE LIGHT OPTIONAL OPTIONAL OPTIONAL OPTIONAL DGHT SWTICH = BLACK -BROWN U(R7T PFRINEIEit END =PURPLE W/LT SYBTCH TEDRTlEAIIID TIME CL MC Ell / 1SRT2 suN� 11 t 12 TEMPERATURE WNTIM m � 3O AIR SLIDER m R wl1rE /LT. RmE P SOLENOID Flu¢ AND) A PERIMETER = PURPLE -WHITE W/PURPLE / a OSEtRoma. xTlr MUWON = RED -WHITE W/RED 3 DOOR = ORANGE -WHITE W/ORANGE ' MITE s m m b ' 'm 6 NO 6wzw Rpm�E/ YETLOW LION -IU' FPNS= BLU RIP CORD ggj N4 fioz 1 z a 4 s � a+ roP a Usm OF CASE OWE 14 GA— \'�� OPEN orsMoP ommOUATE EVAPORATOR 115V-1-6o IDD "' MOUNTED ON swxz TO 115/ OPTIONAL TOP a CASE SIMPLY BLAN _ OPTIONAL 1 UWIO WE i POWERED B! GREENN— 4 K 4 aEMON CUSTMER OPTIONAL BIB _ TOP MOUNTED ELEC W% —aDE 18 Q— OPTIONAL m 9mULE T EVAPORATOR 0R TIES lHRURC �m ro 13 WINE W/BWE 18 CA COnOUR rm m 12 *UTEBLACK 14 OA ECITE55 THRU CASE 7,. P JUMPER •2 •3 S-TO 1B j5 fiVDK 14 GA CONDENSATE PUMP 1 4 CUSTOMER 5 6 RMCC - MOUNTED IN BOTTOM DECIRICk BOX 115V-1-w o c3 CONNECTIONS 115V AM. 14 G4-�I� OPTIONAL EVAP PAN FLOAT SWITCH �'7-�/I�BIALK» s• -m >a +z WAIE le CA 5—m 7B 18 BLACK 16 CA1 J I m 0 WHITE WHITE4G4 BLACK _—_ 4AA WHRE ,BOKOPTIONN. 62-0516 SWITCH (INA 4x4iQ-1/B BOX) s•—m 19 /1 WHITE 18 GAIT 1 DOOR SETUP I EVAP PAN 4 BOAT SWITCH 2 6 Yam# �re JIB s mAL f6 rA RECEPTACLE RECEPTACLE 2-5 DOOR STP USE ONLY COPPER CONDUCTORS TECHNICAL QUESTION? FOR SERVICE CALL 1-800-247-4498 1 DWG. NO. 65-0130 REV. Z LIGHT SWITCH = BLACK -BROWN PERIMETER END = PURPLE W/YELLOW & WHITE W/LT. PURPLE PERIMETER = PURPLE -WHITE W/PURPLE LIGHT MULLION = RED -WHITE W/RED o DOOR = ORANGE -WHITE W/ORANGE d FANS= BLU RIP CORD ¢ 3 O � BLACK - OPTIONAL GREEN - 4 X 4 WHITE - TOP MOUNTED ELEC BOX REPRESENTS J EGRESS THIRD CASE CONDUIT CUSTOMER JUMPER 7 2 } q CONNECTIONS 15V GREEN - -� -CRN. 14 GAT WHITE --- -WHITE 14 GA BLACK - - - -y\ ON - BLACK 14 CA a OFF OPTIONAL: 62-0516 SWITCH (IN A 4x42-1/8 BOX) LIGHT SWITCH m 12N LIQUID LINE SOLENOID VALVE WHITE W/BLUE 18 GA_5�_ BLUE IB (DISCHARGE AIR) 10 x 6.x 4 ELEC BOX 63-0437 & 63-0284 HARNESS TO CAREL TOP OF CASE 63-0916 �2 14- 3 15- .4 16: .5 17OPTIONAL H . CONDENSATE 6 1$ EVAPORATOR 7 115V-1-60 GREEN 8 MOUNTED ON 18 G4 .9 TOP OF CASE WHITE.. 10 I POWERED BY 1B GA -11 CUSTOMER -12 I OPTIONAL WHITE GREE LUE BLUE-BIACK P FLOAT SWITCH DUPLEX RECEPTACLE CONDENSATE PUMP & HANDY BOX IISV-1-60 GREEN 18 GAS 5-TO TS M2 WHITE 18 GA 5-TO TB #6 BLACK IB GA USE ONLY COPPER CONDUCTORS TECHNICAL QUESTION? FOR SERVICE CALL 1-500-247-4496 65-0976 REV. B ELECTRICAL MEDIUM TEMP (CONT.) Figure 32: Master Satellite Wiring SAT LLITE CONTROLLED CASE WHEN TWO OR MORE CASES ARE CONNECTED —TOGETHER DOOR FRAME MR E COL0.4 CODE OPTIONAL OPTIONAL TOM SWITCH = BJCR-FRNN PERIMETER END = PURPLE W/YELLOW Rpx� k CITE W/LT. PURPLE uwr Lull PERIMETER = PURPLE -WHITE W/PURPLE Wcx MULLION = RED-VHRE W/AEO ^^ DOOR = ORMIGE-WHITE W/ORANGE B 1b FANS= SLUT RIP CORD L, § a S • WOOL F3 & CORDENSATE oRtm EVAPORATOR Y 115V-I-fi0 YawrtO a+ 1 X 4 TOP OF CSSE P), uO,TE) I POMURED BY CUES BOx 1 CUSIONER 7�.ULVM N J TllS ATO SH4 11 J Iy51ER CASE HE cl✓aN 11G�1. BRONX 11 W '14 IB /l NIIIIEI/M I9%flfW 9—GI —@AEII II W IMSINIID EROYOPRDNAL9A0( SAIFLLIIE GS[I5)N ILWIN Blx CONRMATE NW BPTI 4� 1151-1-U MIEN 11-.16 a A 4.1.]-1/e' Wx R.T M11cx USE ONLY [OIroER COxgICIOflS TE<xmpL OOESTION? FOR SENSE CYL I-BM-20-4496 AG. NO.. 65-ORBS I✓EV. 0 1 OF 2 MASTER CONTROLLER CASE - MOUNTED IN MAS ER WHEN TWO OR MORE CASES ARE CONNECTED TOGETHER DOOR FRAME WIRE COLOR CODE OPTIONM �ffittim OPTIDNUL = WR RICCPERIMETER SOXS Lros ID - PURPLBROnE PERIMETER END = PURPLE W E UKHTNUTS Iw. �LwE k WI[ WAT. PURPLE x [�M -o11 PERIMETER = PURPLE -WHITE W/PURPLE D= RED-wxRE w/FEU qq 4 4a1 ron(xu DOOROOR = = ORANGE -WHILE W/ORAN 3 �GE ' TOP v Gs[ OPTIONAL LnXOFNNnrt n°�R6Tw L FMS= BLU RIP CORD •1 I]• &VE IB '1 14• SV-I-w 3 5 uOumm ON m w.RE BIA[N 11 W Ifi, OF E Pon}I.ID •4 ETE�MP PFW E, OPX, agT�g PURPLE M a b IB. _. 4x1 1 OPIIMIOE 1N U sox REC BOX10STHIN.17[GRE55 TNRJ fMCPER 7�� •12N1] J 4 5 6 U-VcTR fi]-Odi6CIgM x: mmRX.IT 11 GI xEi$ TO 1uSRP GSE 11 W S-TO IB 12 WMEIB GA1/6B t-To 10 Is ONJt IT a � H—GRA, VBAO/m IE —WAIR 4 46 xwTE n GNN 1OPTIONAL P y O11WLI BIAcO —BL1IX14 W PO[tUNELO SNRLN 6]-BS161N A t,ht-I/e' x5T4L[0 IRWI POx NI[WIE GY15) 80X Fl(UI SMICX y J LCNL U1 PUI /� IIN-I-60 USE MiY CWPLA [ONWttORS ITCWNIGI QIESUON? FOR SERI CLLL I-BM-247-4496 01SG. N0. M-MM REV. O 2 Oi 2 DEFROSTING IE _ it I, GENERAL Periodic defrosting to keep the coil free of frost is accomplished automatically by a time clock used in conjunction with an electric or hot gas defrost. For best results, temperature termination of defrost is strongly recommended on Zero Zone cases. DEFROST SETTINGS AND CONTROLS Electric Defrost Frequency: One electric defrost per day is recommended. Time of day: Nighttime defrosting is preferred to avoid periods of shopping or stocking. Drip Time: Electric defrost does not require any drip time because Zero Zone provides a built-in fan delay thermostat. Electric Defrost Fail-safe Times: At ASHRAE test conditions and 208 volt defrost heater operation, the typical observed VZ 30' door defrost durations are 28 minutes for ice cream and 19 minutes for frozen food. At the same conditions, the typical observed VZT2 30' door defrost durations are 39 minutes for ice cream and 26 minutes for frozen food. MZ 24' and WA defrost durations are 43 minutes. Preferred Termination: For optimal performance, Zero Zone recommends a temperature -terminated defrost, using a defrost termination thermostat or probe sensing the coil temperature. The VZ and VZT2 30' door case has the probe located at the right-hand side of the coil in the center of the bottom row of tubes The MZ 24" door and WA case has the probe located at the right- hand side of the coil in the top row of tubes. If the case is so equipped, the defrost termination temperature is 50°F. Zero Zone provides a defrost termination thermostat unless a control system defrost probe is requested. Temperature termination based on coil temperature allows the length of defrost to vary depending on how much frost is on the coil and the defrost heater voltage. Coil frost is a function of shopping patterns, stocking habits, general door maintenance and ambient temperature and humidity. More frost requires a longer defrost. A lower defrost heater voltage extends the defrost period. Alternate Termination: If it is not possible to terminate the defrost cycle based on a defrost termination thermostat or probe sensing the temperature at the coil, and the only available temperature probe is sensing the discharge air temperature, then the termination temperature should be set to 65°F, zero minutes drip time. Zero Zone electric defrost freezers are delivered with the defrost thermostat open -on -rise contacts wired in series with the defrost heaters. Unless the installer rewires the defrost thermostat, the defrost heater is de -energized when defrosting is complete. Zero Zone VZ and VZT2 30' door electric defrost freezers are�also equipped with a high -limit, snap -disc thermostat that de -energizes the defrost heater if the coil temperature exceeds 85°F to provide a secondary safety termination. Hot Gas Defrost Frequency: One hot gas defrost per day is recommended.. Time of day: Nighttime defrosting is preferred to avoid periods of shopping or stocking. Drip time: Hot gas defrost requires a 5 minute drip time. Hot Gas Defrost Fail-safe Times: Preferred Termination: For optimal performance, Zero Zone recommends a temperature -terminated defrost, using a defrost termination thermostat or probe attached to the dump line. At ASHRAE test conditions, termination ranges from 12-22 minutes. If the cases are so equipped, the defrost termination is 65°F at the dump line. Zero Zone provides a defrost termination thermostat unless a control system defrost probe is requested. N" Electric Defrost Operation The compressor stops when the defrost is initiated in a non -pump -down system. On pump -down systems, the liquid line solenoid will be de -energized when the defrost is initiated. The clock will energize the 208/230 volt defrost heater, and energize the normally closed 208/230 volt contactor or relay. This de -energizes the 115-volt fans, lights and anti -sweat heaters. If you don't have a light circuit limit thermostat, the lights will not de -energize. After the defrost period, the compressor will operate. When the coil temperature reaches +5°F, the fan, light and anti -sweat heater limit thermostats (Klixons) will close, starting the fans, lights and anti -sweat heaters. Gas Defrost Operation Several types of gas defrost methods (using time -actuated, time -terminated or temperature -terminated defrost timers) can be used to defrost the evaporator. The refrigeration system designer and installer are responsible for correct line sizing for effective gas defrost and liquid return from the freezers. Sizing and component selection depend on the type of defrost, size, and location of high side refrigeration system. Zero Zone freezers equipped for gas defrost consist of a side port distributor and a TXV check valve for coil defrost, and a suction line check valve to bypass hot gas to the serpentine coil, The serpentine coil is attached to the bottom of the pan to ensure pan and drain defrost. The timer starts the gas defrost cycle by energizing a solenoid, reversing valve, or directional valve. The gas is injected from the source into the suction line of the evaporator to be defrosted. The gas flows into the serpentine coil attached to the floor of the case and then into the evaporator. Condensed liquid leaves the evaporator through the side port distributor, through a check valve into the liquid line. (Figure 33 and Figure 34 on page 41). General Notes • The refrigeration technician should recheck coil condition after one week of retail operations to be certain that the frequency and duration of defrost is adequate for the particular store and locality. For example, if defrost voltage is below 200 volts, additional fail- safe time may be required. • When using time terminated defrost, defrost termination. thermostat should be wired in series with the defrost heater. • Defrost termination thermostats may be wired in series for multiple evaporator installations. • Defrost termination thermostats may be used as a digital input for electronic controllers. Limit Thermostat Each freezer has factory set limit thermostats (Klixons) attached to the return bends of the coil on the right end of the freezer to regulate the operation of the evaporator fans and anti -sweat door heaters. A limit thermostat is optional for the light circuit. When a limit thermostat is provided in the lighting circuit, the lights will be off during defrost. IMPORTANT! OPERATION OF THE LIMIT THERMOSTATS CAUSES THE EVAPORATOR FANS, FREEZER LIGHTS, AND ANTI -SWEAT DOOR HEATERS TO REMAIN OFF UNTIL THE COMPRESSOR IS OPERATING AND THE COIL TEMPERATURE IS BROUGHT BELOW THE THERMOSTAT CUT -IN SETTING (+5°F ). SUPERHEAT MUST BE SET CORRECTLY BY THE INSTALLING CONTRACTOR FOR PROPER THERMOSTAT OPERATION. When the freezer first operates, the fans and lights may cycle off and on a few times until coil temperature is below+5°F. The superheat must be set for proper operation. - - - The 30" door models have a high limit thermostat installed on the coil return bend, wired in series with the defrost heaters. This thermostat opens when the temperature reaches 85°F. LOW TEMP (CONI) 1 COIL COVER 2 FAN 3 FAN HOUSING 4 COIL 5 CHECK VALVE 6 SERPENTINE 7 SLHX HEAT EXCHANGER 8 TXV VALVE 9 HAND VALVE (OPTIONAL) 10 DRIER (OPTIONAL) 11 CHECKVALVE 12 OPTIONAL DEFROST TERMINATION SOLENOID 13 HOT GAS CLIP 14 DEFROST TERMINATION PROBE LOCATION 1 COIL COVER 2 FAN 3 FAN HOUSING 4 COIL 5 CHECK VALVE 6 SERPENTINE 7 SLHX HEAT EXCHANGER 8 TXV VALVE 9 HAND VALVE (OPTIONAL) 10 DRIER (OPTIONAL) 11 CHECK VALVE 12 OPTIONAL DEFROST TERMINATION SOLENOID 13 DEFROST TERMINATION PROBE LOCATION Figure 33: Coil 30" Hot Gas t 2 3 4r:k� Figure 34: Coil 24" Hot Gas DWG NO.SP-3000 REV. E W _ l_ _1 LOIN TEMP (COOT.) DEFROST HEATER ELEMENT On 30" door cases, one half of the U-shape heater is located on the front of the coil and the other half is located on the rear of the coil (Figure 35 on page 43). On 24' door cases and wrap -around cases, the heater element is located under the coil (Figure 33 on page 41). The electric wire leads are connected in the junction box behind the front kick rail. HEATER ELEMENT REMOVAL Front and rear heater location NZ and VZT2 30' door) The U-shape defrost heater has one leg located on the front of the coil and one leg located on the rear of the coil. The front heater is located approximately 1° off the floor and the rear heater is approximately 2' off the floor. The heater is secured to the coil by a number of stainless steel heater retaining clips. The heater is fastened to the floor on the right-hand side of the coil. Remove fasteners holding the heater to the floor. The U-shape defrost heater can be removed by first pulling the front leg of the retaining clip away from the coil and sliding the heater out from under the clip. The rear leg of the heater can then be removed by raising the retaining clips 2 inches at a time, working from right to left on the coil. Repeat this process until the retaining clips are free of the coil. The heater will slide up with the retaining clip. Under coil location WZ 24" and WA door). To remove the defrost element, remove the coil covers. Lift the inner coil cover upward and tip the fan housing forward. This will expose the coil. Remove both fan housing end brackets and center coil supports, then slide out the complete heater pan assembly from under the coil. Slowly lift the heater pan assembly between the coil and fan housing, turning it on edge while lifting. Heaters are installed in the reverse order of how they were removed LOW TEMPNEDIUM TEMP 1 COIL COVER 2 74 FAN 3 LIQUID LINE SUCTION LINE 5 FAN HOUSING 6 HEAT EXCHANGER 7 EXPANSION VALVE *8 HEATING ELEMENT *9 HEATER CLIP 10 DEFROST TERMINATION PROBE LOCATION *Low Temp Only 1 COIL COVER 2 FAN 3 LIQUID LINE 4 SUCTION LINE 5 FAN HOUSING 6 HEAT EXCHANGER 7 EXPANSION VALVE *8 HEATER *9 HEATER PAN 10 DEFROST TERMINATION PROBE LOCATION *Low Temp Only - - Figure 35: 30" Electric Figure 36: 24" Electric 0 0i " m"m �'I. 0 DWG NO.SP-6004-2REV. GENERAL Periodic defrosting to keep the coil free of frost is accomplished automatically by a time clock. Medium temperature cases generally, operate at temperatures that allow for off -cycle defrost. Medium temperature cases that operated at colder temperatures for fresh meat products may use electric or hot gas defrost. DEFROST SETTINGS AND CONTROLS Off -Cycle Defrost Frequency: Two off -cycle defrosts per day are recommended. Duration: Generally defrost is terminated on time with the recommended setting of 30 minutes. If temperature termination is selected, the termination temperature is set for 45°F for discharge air and coil temperature. Stocking or shopping activities during defrost may result in premature defrost termination. ELECTRIC AND HOT GAS DEFROST Follow the setting recommendations found in the Defrosting Low Temp section. DEFROST OPERATION Off -Cycle For off -cycle defrost, refrigeration to the unit is stopped either by stopping the compressor or closing the liquid line solenoid valve and allowing the compressor to pump down. During an off -cycle defrost, the fans, lights, and anti -sweat heaters remain on. Electric and Hot Gas For a description of thesedefrost types see the Defrosting Low Temp section. �• ZERO ZONE ;v For other technical support, please refer to Zero Zone Installation and Operation Manuals available on the Service page at: WWW.ZEFtO-ZONE.COM or contact the Zero Zone Service Department at: All specifications subject to change without notice. 02013 Zero Zone, Inc. ¢P�pPMENiN. F�POifC)bkgCe GPREENCHILL 4ryCFP AEFTT0P FPPyFEP MN-0 -A