Zero Zone CRYSTAL MERCHANDISER Manuel utilisateur

ZERO ZONE

CRYSTAL MERCHANDISER®FREEZERS

With CoolView®Doors and ChillBrite®LED Lighting

INSTALLATION & OPERATION MANUAL

COMPLIANT

66-0025 REV F •APR 2020

Table of Contents

ZERO ZONE WARRANTY.....................................................................1

INTRODUCTION....................................................................................2

INSTALLATION & OPERATION............................................................4

Delivery Inspection...........................................................................4

Packaging........................................................................................4

Location...........................................................................................4

Installation Leveling.........................................................................4

Case Movement...............................................................................5

LineupAssembly..............................................................................6

Drain Line.........................................................................................7

Condensate Evaporation System....................................................7

Trim..................................................................................................7

Kick Plates.......................................................................................7

Cleaning...........................................................................................8

Shelf Location..................................................................................8

Shelves............................................................................................8

Loading the Case.............................................................................8

Light Switch......................................................................................9

Case Thermometer..........................................................................9

GENERAL............................................................................................10

Evaporator.....................................................................................10

Expansion Valve ............................................................................10

Evaporator Fans............................................................................10

Fan Removal..................................................................................10

SERVICE..............................................................................................11

Air Curtain Velocity.........................................................................11

LED Power Supplies......................................................................11

REFRIGERATION................................................................................12

Piping Penetrations........................................................................12

Refrigerant Piping..........................................................................12

Leak Check/Evacuation/Charging..................................................12

Temperature Settings.....................................................................12

Temperature Control......................................................................12

ELECTRICAL.......................................................................................13

General..........................................................................................13

Optional Electrical Wiring...............................................................13

DEFROSTING......................................................................................15

General..........................................................................................15

Defrost Settings and Controls........................................................15

Defrost Operation...........................................................................16

General Notes................................................................................16

Limit Thermostat............................................................................16

Defrost Heater Element.................................................................17

Heater Element Removal...............................................................17

Anti-Sweat Heaters........................................................................17

ILLUSTRATIONS.................................................................................18

Case Label Information..................................................................18

Freezer to Cooler Leveling.............................................................19

Leveling Cases Prior to Joining.....................................................20

RVLC30 Base Locations................................................................21

RVLC30BB Base Locations...........................................................22

Case Squareness..........................................................................23

Shim Placement.............................................................................24

Shim Orientation............................................................................25

RVLC30BB Wood Planks...............................................................26

Spacer Block..................................................................................27

RVLC30 Caulking Instructions.......................................................28

RVLC30BB Caulking Instructions..................................................29

T-Strip ............................................................................................30

NSF Caulking Instructions.............................................................31

Drain Line.......................................................................................32

Kick Plates - Tinnerman Clips........................................................33

30" Electric Defrost........................................................................34

30" Hot Gas Defrost.......................................................................35

Electrical Box.................................................................................36

Refrigeration Line Sizing - Frozen Foods......................................37

Refrigeration Line Sizing - Ice Cream............................................38

Electric Defrost Wiring Diagram.....................................................39

Hot Gas Defrost Wiring Diagram...................................................40

Master/Satellite Wiring Diagram....................................................41

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). Zero Zone ChillBrite®LED Lighting carries a 5-year parts warranty. Zero Zone CoolView®

Doors carry a 10-year glass pack parts warranty. The obligation under this warranty shall be limited to repairing or exchanging any part, or parts,

FOB Factory, which is proven to the satisfaction of the Zero Zone 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 those manufacturer’s warranty

to the Seller.Any products sold on an “AS IS” basis shall not be covered by this warranty.

Extended Warranties

In addition to the standard limited warranty, for further consideration, the Seller will extend to the original purchaser prior to shipment, 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 its Installation & Operation Manuals and other instructions.

Length of Extended Warranty

Any compressor warranty may be extended for an additional four (4) years, but such extension must be purchased prior to shipment to be

effective.This warranty is only for the compressor and not for any other associated parts of the refrigeration system.

Product Not Manufactured by the Seller

The written warranty, if any, provided by the manufacturer of any part 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 HEREINARE EXCLUSIVEAND IN LIEU OFALL OTHER WARRANTIESAND REMEDIES WHATSOEVER,

INCLUDING, BUT NOTLIMITED TO, IMPLIED WARRANTIES OF MERCHANTABILITYAND/OR FITNESS FORAPARTICULAR PURPOSE.

ZERO ZONE WARRANTY

2 • Introduction

INTRODUCTION

Important User Information

graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written

permission of the publisher, Zero Zone, 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. Zero Zone products should only be installed by qualied,

professional refrigeration technicians. If any questions or problems arise, call Zero Zone at 800-247-4496.

Any change to a Zero Zone product made during the installation, start-up, 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.

Manufacturer

Zero Zone, Inc.

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, specications,

drawings, and data.All Zero Zone products must be leveled after being installed.

Display Case Models

The information contained in this manual pertains to the following Zero Zone display cases:

CASE MODEL DESCRIPTION DOOR SIZE & TYPE

RVLC30 Standard Case 30" x 74" CoolView®Ultra™Doors

RVLC30BB Back-to-Back Case 30" x 74" CoolView®Ultra™Doors

RVLC30IM Ice Merchandiser 30" x 74" CoolView®Ultra™Doors

Case Features

Zero Zone produces high quality refrigerated display cases using state-of-the-art components. The cases are built with the thickest insulation in

the industry and a high efciency evaporator coil. Case features include:

Brushless DC electronic motors

Zero Zone ChillBrite®LED Lighting

Zero Zone CoolView®Ultra

™Doors

Introduction • 3

INTRODUCTION

Testing Standards

These display cases were designed and tested using the following industry standards:

NSF 7 – Commercial Refrigerators and Freezers (ANSI Approved) (equipment certied by NSF)

NSF 51 – Food Equipment Materials (ANSI Approved) (equipment certied by NSF)

UL 471 – Commercial Refrigerators and Freezers (ANSI Approved) (equipment certied by ETL)

ASHRAE Standard 72 – Method of Testing Commercial Refrigerators and Freezers (ANSIApproved)

AHRI 1200 – Performance Rating of Commercial Refrigerated Display Merchandisers and Storage Cabinets (ANSIApproved)

DOE Compliant (All U.S. Sales and U.S. Territories)

ASHRAE Standard 72 species the test conditions for the equipment. It includes the ambient conditions of 75°F dry bulb and 55% RH. It also

species the door opening requirements for the performance test. Doors are opened six times in one hour for six seconds. The door opening

test period is for eight 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.

4 • Installation & Operation

Delivery Inspection

Zero Zone display cases are carefully factory-tested, inspected, and properly packed to ensure delivery in the best possible condition. The

equipment should be unwrapped and checked for damage immediately upon delivery. DAMAGE MUST BE NOTED AT TIME OF DELIVERY,

ANDALL CLAIMS FOR DAMAGES MUST BE FILED WITH THE TRANSPORTATION COMPANY, NOT WITH ZERO ZONE. The carrier will

supply necessary report and claim forms.

Do not leave, store, or hold case outdoors in direct sunlight or high ambient temperature. With the end panels on, the case is airtight;

the inside temperature of the case will increase, and the heat will be unable to escape. This could potentially cause any plastic inside

the case to deform or warp.

Packaging

Each case in a lineup is labeled to identify the lineup and joint. The label uses a two digit number designation, separated by a decimal. The

rst number indicates the case lineup. The second number indicates the case joint. Case joints begin with the number “1” at the left most joint in

the lineup when looking at the front of the lineup. The rst case in the lineup will be labeled on the right end and the second case in the lineup

will be labeled on the left end. The numbers on each end to be joined will match, as indicated in the gure below. Back-to-Back cases have a

side “A” and a side “B”. See Figure 1 on page 18.

The rst case in a lineup (with the right side labeled “x.1”) has a packet attached to the shelving that contains touch-up paint. Every case in

a lineup has a packet attached to the shelving that contains important information about the case and/or lineup and, if applicable, special

instructions for installing ordered options.

Bumpers and kickplates are shipped on top of the case. Shelves for the case are tie-wrapped and blocked into the individual cases. Other

accessories like drain traps, drain pans, condensate evaporation pans, and hat channel rails are shipped in the case that require the parts.

Materials for joining cases—including caulk, joining bolts, splices, and end ller posts—are shipped in each case to be joined.

The door is prevented from opening during shipment with the use of a door-holding shipping bracket. The bracket is screwed to the top of the

case at each door and should be removed when the case is unpacked.

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 oor under the installation is

of sufcient strength to prevent sagging. Uneven surfaces will result in reduced performance.

Cases should be set to allow a minimum 3" of space behind the back of the units. This will allow necessary air to circulate behind the

display cases and prevent condensation. Higher humidity stores with minimal air circulation require at least a 4" gap.Aminimum 2" gap is

recommended between cases on end-to-end installations.All minimum spacing requirements may increase if seismic restraints are used.

Installation Leveling

Alineup solely made of freezers should be level front to back and right to left.

When joining a freezer and cooler in a short lineup, both cases should be tilted back with an additional 3/16" of shims under the front bases

after the case is leveled. See Figure 2A on page 19. On long lineups, the tilt back on the coolers should gradually increase while working

away from the cooler/freezer joint until the last case has an additional 3/8" of shims under the front base and the tilt back on the freezers should

gradually decrease to no additional shims while working away from the cooler/freezer joint. See Figure 2B on page 19.

Cases should be set level right to left to allow complete drainage of defrost water. Since a level oor area is seldom available, the following

steps are recommended to insure a level installation. See Figure 3 on page 20.

1. Measure off and mark on oor the exact dimensions of the case lineup. (Check blueprints).

INSTALLATION & OPERATION

Installation & Operation • 5

INSTALLATION & OPERATION

2. Snap a chalk line at the locations for the front and back positions of the base rails.

3. Mark locations of all joints (front and back).

4. Using a laser level or transit, nd the highest point along both base rail position lines. Using the high point as a reference, mark the

difference directly on the oor to each joint (front and back).

5. If you plan on using optional “hat channels” to raise the case height, place them under each pair of bases. On some cases, all bases are

not directly in line from front to back. See Figure 4 on page 21 and Figure 5 on page 22 for base locations. The 3 and 4-door hat

channels will be angled slightly to support the front and rear bases because the bases themselves are not in line.

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. The

case is designed with minimal gaps between adjacent doors to provide a clean appearance. To maintain even, consistent gaps and proper

door operation, the case must be leveled front-to-back and side-to-side. Check case squareness to within 1/8". See Figure 6 on page

23. Shims should not extend beyond the front case bases or they will interfere with the installation of kick plates. Tape all shims in place.

The shims should be oriented to sit under the front and rear bends of each base.

7. The RVLC30 2-door through 5-door cases have segmented bases mounted at the ends and under the center section of the case. The

RVLC30 1-door and RVLC30BB have full bases that run front-to-back and are located at the ends and under the center sections of the

case. Place additional support shims under all other bases or hat channels, leaving no gaps taller than one shim.

8. Tape all shims in place (See Figure 7 on page 24). See Figure 8 on page 25 for the correct orientation of shims under the base or

channel.

9. If you are joining coolers to freezers, RVMC cases should be set with a slight backward tilt to offset the forward lean of a fully loaded case.

When joining a freezer and cooler in a short lineup, both cases should be tilted back with an additional 3/16" of shims under the front

bases after the case is leveled. See Figure 2A on page 19. On long lineups, the tilt back on the coolers should gradually increase while

working away from the cooler/freezer joint until the last case has an additional 3/8" of shims under the front base and the tilt back on the

freezers should gradually decrease to no additional shims while working away from the cooler/freezer joint. See Figure 2B on page 19.

10. If you’ve purchased seismic restraints, specic instructions for attaching those restraints are included in your document package. These

instructions should be read and understood before the lineup is assembled.

Case Movement

! CAUTION! DO NOT PULLON THE MULLIONS WHEN MOVING THE CASE.THE END FRAME CAN BE USED TO PUSH/PULL

THE CASE. DOLLIES MAY BE PLACEDAGAINST THE CASE BOTTOM, BUTAVOID CRUSHING THE BUMPER

SUPPORTOR DRAIN PIPE.

WHEN USINGAJ-BAR, IT MUST NOT CONTACT THE SHEET METAL OF THE BUMPER SUPPORT, BUT SHOULD

CONTACTTHE SHEET METALOF THE BOTTOM FOAMED PANEL.THE BUMPER SUPPORTWILLBE DAMAGED

IF LIFTED BYA J-BAR. BE CAREFULNOTTO PIERCETHE SHEET METALWITH THE CORNER OF THE J-BAR.

The RVLC30 and RVLC30BB cases have steel protective support plates under the ends (not under insulated dividers). These are designed to

protect the end from Johnson Bar damage. Per NSF, these must be removed after cases are set.

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 nal location (See Figure 9 on page 26).

MODEL FORKLIFT

FROM ENDS JOHNSON

BAR FURNITURE

DOLLY PIPE

ROLLERS SAFE (CASE)

JACKS

RVLC30 X X X X

RVLC30BB X X X X X

Care should be taken when moving the cases. The doors should be secured so they cannot open while the case is moved.

6 • Installation & Operation

INSTALLATION & OPERATION

Only experienced certied forklift drivers should use forklifts to move the cases. The case should only be lifted off the oor 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. Fork blades wider than 4" will not t in the

bases.

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!

Important: Fork blades wider than 4" will not t in the bases.

Spacer blocks are factory-installed in the end bases of 4 and 5-door cases that use bases taller than 3 1/2". These blocks limit the cases

forward tilt at the opposite end from the forklift while it is being lifted and must be used when lifting 4 or 5-door cases with bases taller than 3

1/2". See Figure 10 on page 27.

For low shipping height applications, Zero Zone has optional expandable bases.As shipped, the base is 1 3/4" 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 forklift blades thicker than 1 3/4".

When the case needs to move through an 80" door opening, the case is shipped with a 1" base on a wood pallet. Remove the case from the

pallet to slide the case through the 80" doorway. Drain elbow will need installation on a 1" base. Use extra thick PVC cement.

LineupAssembly

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 that must be removed after the cases are

set.

The cases will be ready for assembly after removal of the packaging material.

Case caulking instructions are shipped with every case, explaining the proper procedure for joining cases. See Figure 11 on page 28 and

See Figure 12 on page 29 for instructions.

FIELD-INSTALLED CAULK SEALANTAPPLICATION NOTES:

Butyl sealant is used to join cases and Silicone or NSF approved sealant is used for NSF compliance. Sealants should not contact one another

as this may affect adhesion or color of each.

Remove all shipping blocks applied to inside of base ends before joining cases.

Remove End protection plate located below END on outside of case.

FAILURE TO FOLLOWTHE INTENT OF CASE JOINING INSTRUCTIONS WITH SEALANTS WILLCAUSE FROST INSIDE THE CASE.

For NSF case installation compliance, the interior case seams need to be sealed using NSF approved caulk (not supplied). See Figure 14 on

page 31.

Installation & Operation • 7

INSTALLATION & OPERATION

After setting the rst case, the next case is slid into position and bolted to the rst case using four 3/8" bolts that are provided. 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 ush. Cases are not

designed to be pulled together using the joining bolts.

Alignment holes are located in the lower steel end frames. These are located 7" in from the joining holes.

Once the cases have been caulked and slid together, start the joining bolts, but do not tighten them. Slide the center extrusion (T-strip) between

the end mullions See Figure 13 on page 30. 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 ush. Cases are not designed to be pulled together using the joining bolts.

Drain Line

The drain is located at the center of the case in the oor pan. The drain can be reached by removing the coil covers and then tipping the fan

plenum towards the doors. The 1" PVC drain outlet is located at the center front of the case behind the kick plate.

The drain exits the case in the center. The bases are designed for lateral runs of drain pipe to pass through and the drain pipe must be installed

in this area. See Figure 15 on page 32. There is no room in front of the base for drain pipe because the kick plate installs directly to the front

of the bases.

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 tee, drain trap and plug are supplied with the case.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.

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 kick plate 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 oat that turns the pump on

when there is a sufcient 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 oat 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.

Trim

The cases are supplied with a 3" protective bumper. Each case has its own bumper assembly including end caps. The case was shipped with

the bumper support and snap track installed on the front of the case. The bumper may need trimming before snapping it onto the snap track.

Full height (top) trim is provided to hide the door hardware located on the top exterior of the case. The top trim is factory-installed. Joint splices

are shipped loose to be installed on-site at the upper case joints.

Kick Plates

Each case is shipped with a front kick plate. Cases with end panels receive 1 side kick plate per end. Cases that join together get a kick plate

splice.

Front and side kick plates are attached to the case bases using Tinnerman clips. The ange on the front kick plate faces forward and is at the

top. The screw (supplied) goes through the kick plate and into the Tinnerman clip. See Figure 16 on page 33.

There is a natural gap between the top of the kick plate and the underside of the case that allows 50 CFM of air return per door. If more return

air is required, contact the factory to order optional louvered kick plates.

8 • Installation & Operation

INSTALLATION & OPERATION

Cleaning

Although your Zero Zone cases are thoroghly cleaned before shipping, the cases should be thoroughly cleaned again 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 before start-up. The case drain should be regularly cleared of debris and price tags.

Internal components are easily accessed by the removal of mounting screws and sheet metal component parts. The components can be

cleaned using a mild detergent and warm water or a mild sanitizer. Once the wire racks and deck pans and are removed, the coil and drain

pan can be ushed. All food products should be removed from the case when ushing with a hose. Do not use high-pressure water or steam to

clean the interior.

UNDER CASE FLOOR CLEANING (NSF)

The oor underneath your Zero Zone display case can be cleaned by following a few simple steps:

1. Remove the fasteners that hold the bottom kick plate to the display case. The fasteners are accessed from the front of the unit.

2. With the kick plates removed, remove paper and other debris (typically price tags or receipts) from the oor.

3. Vacuum under the case to remove any dust build-up that may be present.

4. Using a mild detergent and warm water, mop underneath the unit with a clean mop.

5. When nished mopping, squeegee any remaining water underneath the unit to the oor drains to speed the drying process. Replace the

kick plates when the oor has dried.

GLASS SURFACES

Cleaning interior glass reduces fogging and increases visibility. Wipe down glass or plexiglass mirrors or ends with a glass cleaner. Do not use

any products containing silicone or anti-fog.

Shelf Location

The shelves are adjustable in 1" increments 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.

Bottom basket is shipped in a tipped-forward position, but may be rotated 180° to obtain a at position.

Shelves

Zero Zone manufactures many different styles of shelves, baskets, and product stops. Some of the baskets may be reversed and used as a

typical shelf. Shelves are strapped to the shelf brackets for shipping. The fully assembled shelves are installed in cases prior to shipping.

Solid shelves have three parts.Asolid center section and two snap-in brackets. Solid shelves can be disassembled for cleaning. Ascrewdriver

can be used to spread the snap open to remove the brackets from the center section.

Loading the Case

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 a minimum of 1" 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:

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