Federal Industries CD3628 Installation Manual

E2660

Revised 3/26/10

INSTALLATION & OPERATIONS INSTRUCTIONS

Self-Contained & Remote Refrigerated Models

& Non-Refrigerated Counter Displays

(Service & Self-Serve)

KEEP THIS MANUAL FOR FUTURE REFERENCE

Engineering and technical data are subject to change without notice.

FEDERAL INDUSTRIES 215 Federal Avenue Belleville, WI 53508 Toll Free 1(800) 356-4206 WI Phone (608) 424-3331 Fax: (608) 424-3234

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CONTENTS

INTRODUCTION.................................................................................................................................................................3

WARNING LABELS & SAFETY INSTRUCTIONS........................................................................................................4

PRE-INSTALLATION PROCEDURES.............................................................................................................................5

Inspection For Shipping Damage .......................................................................................................................5

GENERAL ELECTRICAL & GROUNDING ...................................................................................................................5

INSTALLATION INSTRUCTIONS ...................................................................................................................................5

Locating The Display Case.................................................................................................................................5

Removing Case From Shipping Skid & General Installation ......................................................................... 5-6

Cleaning..............................................................................................................................................................6

Dry CD Model Installation.......................................................................................................................................6

Cabinet Preparation ............................................................................................................................................6

Cord Options .................................................................................................................................................. 6-7

Refrigerated CRR Self Contained Model Installation..............................................................................................7

Cabinet Preparation ............................................................................................................................................7

Cord Options ......................................................................................................................................................8

Refrigerated CRB Self Contained Model Installation..............................................................................................8

Cabinet Preparation ........................................................................................................................................ 8-9

Cord Options ......................................................................................................................................................9

Refrigerated CRR Remote Model Installation .......................................................................................................10

Cabinet Preparation ..........................................................................................................................................10

Cord Options ....................................................................................................................................................10

Connect Remote Refrigeration Lines & Evaporator Condensate Drain ............................................................11

Refrigerated CRB Remote Model Installation .......................................................................................................11

Cabinet Preparation ..........................................................................................................................................11

Cord Options ....................................................................................................................................................12

Connect Refrigeration Lines..............................................................................................................................12

Refrigeration Installation (Refrigerated units)........................................................................................................13

Self Contained Models .....................................................................................................................................13

Remote Models.................................................................................................................................................13

Case Line Up Installation.......................................................................................................................................14

Top Joining Bracket..........................................................................................................................................14

Bottom Pedestal Joining ...................................................................................................................................15

END PANEL INSTALLATION ........................................................................................................................................16

SHELVING INSTALLATION & REMOVAL ................................................................................................................17

Shelf Brackets & Supports.......................................................................................................................... 17-18

Shelves and shelf light quantity........................................................................................................................18

Wire Shelf Installation......................................................................................................................................18

Glass Shelf Installation.....................................................................................................................................19

Metal Shelf Installation ....................................................................................................................................19

DOOR REMOVAL INSTRUCTION ................................................................................................................................20

OPERATING INSTRUCTIONS .......................................................................................................................................21

Controls ............................................................................................................................................................21

Shelves..............................................................................................................................................................21

Rear Package Shelf...........................................................................................................................................21

Placing Product Into Case.................................................................................................................................22

MAINTENANCE ................................................................................................................................................................23

Shelf Light Replacement ..................................................................................................................................23

Top Light Replacement (All Service and Dry Self-Serve) ...............................................................................23

Top Light Replacement (Refrigerated Self-Serve) ...........................................................................................23

PERIODIC MAINTENANCE ...........................................................................................................................................24

Cleaning Condenser Coil..................................................................................................................................24

CLEANING INSTRUCTIONS ..........................................................................................................................................24

Daily Cleaning............................................................................................................................................ 24-25

Weekly Cleaning ........................................................................................................................................ 25-26

SERVICE INFORMATION ..............................................................................................................................................27

Pre-Service Checklist ................................................................................................................................. 27-28

Special Service Situations.................................................................................................................................28

SALE & DISPOSAL...........................................................................................................................................................28

Owner Responsibility .......................................................................................................................................28

REFRIGERATION & ELECTRICAL DATA.................................................................................................................29

WIRING DIAGRAMS.................................................................................................................................................. 29-31

PARTS............................................................................................................................................................................32-33

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INTRODUCTION

Thank you for purchasing a Federal Industries display case. This manual contains important instructions for installing and servicing the Curved Glass and Hi-Volume Refrigerated (including Dual Zone & Cold Deli) and Non-Refrigerated Display Cases. A repair parts list and wiring diagram are also included in the manual. Read all of these documents carefully before installing or servicing your case.

Read this manual before installing your case. Keep this manual and refer to it before doing any service on the equipment. Failure to do so could result in personal injury or damage to the case.

NOTICE

Installation and service of the electrical components in the case must be performed by a licensed electrician.

The portions of this manual covering components contain technical instructions intended only for persons qualified to perform electrical work.

Improper or faulty hookup of electrical components in the case can result in severe injury or death. All electrical wiring hookups must be done in accordance with all applicable local, regional, or

national standards.

DANGER

SERIAL NUMBER

Record the model and serial numbers of the case for easy reference. Always refer to both model and serial numbers in your correspondence regarding the case. Case Model__________________________ Serial Number______________________ Condensing Unit Model________________ Serial Number______________________

This manual cannot cover every installation, use, or service situation. If you need additional information, call or write us:

WARRANTY/TECHNICAL SERVICE DEPARTMENT

Federal Industries

215 Federal Avenue

Belleville, WI 53508

Toll Free (800) 356-4206 / WI Phone (608) 424-3331

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WARNING LABELS & SAFETY INSTRUCTIONS

This is the safety-alert symbol. When you see this symbol on your case or in the manual, be alert to the potential for personal injury or damage to your equipment.

Be sure you understand all safety messages and always follow recommended precautions and safe operating procedures.

NOTICE TO EMPLOYERS

You must make sure that everyone who installs, uses, or services your case is thoroughly familiar with all safety information and procedures.

Important safety information is presented in this section and throughout the manual. The Following signal words are used in the warning and safety messages:

DANGER: Severe injury or death will occur if you ignore the message. WARNING: Severe injury or death can occur if you ignore the message. CAUTION: Minor injury or damage to your case can occur if you ignore the message. NOTICE: This is important installation, operation, or service information. If you ignore the

message, you may damage your case.

The warning and safety labels shown throughout this manual are placed on your Federal

Industries case at the factory. Follow all warning label instructions. If any warning or safety labels become lost or damaged, call our customer service department at 1(800) 356-4206 for replacements.

CAUTION

RISK OF ELECTRIC

SHOCK DISCONNECT

POWER BEFORE

SERVICING UNIT.

91-12340

This label is located on the back of the display case. This label is located below the display pan.

CAUTION HAZARDOUS MOVING PARTS DO NOT OPERATE UNIT WITH DISPLAY PANS REMOVED.

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PRE-INSTALLATION PROCEDURES

Inspection for Shipping Damage

You are responsible for filing all freight claims with the delivering truck line. Inspect all cartons and crates for damage as soon as they arrive. If damage is noted to shipping crates, cartons, or if a shortage is found, note this on the bill of lading (all copies) prior to signing.

If damage is discovered when the case is uncrated, immediately call the delivering truck line and follow up the call with a written report indicating concealed damage to your shipment. Ask for an immediate inspection of your concealed damage item. Crating material must be retained to show the inspector from the truck line.

GENERAL ELECTRICAL & GROUNDING

DANGER:

display case can result in severe injury or death.

-All models are supplied with a power cord that is properly sized to the amperage requirements of the case. See the electrical data plate located on the rear left interior of the case for the proper circuit size for each case.

- The cord is factory installed protruding from the bottom rear corner of the case (see the “Cord Options” section of this manual that pertains to your model case for alternate location.). If factory installed cord must be relocated for desired application the electrical work must be performed by a licensed electrician.

-A separate circuit for each display case is recommended to prevent other appliances on the same circuit from overloading the circuit and causing malfunction.

-All electrical wiring hookups must be done in accordance with all applicable local, regional, or national electrical standards

Improper or faulty hookup of electrical components in the

INSTALLATION INSTRUCTIONS

General Display Case Location

The case should be located where it is not subjected to the direct rays of the sun, heating ducts, grills, radiator, or ceiling fans, nor should it be located near open doors or main door entrances. Also, avoid locations where there are excessive air movement or air disturbances. Allow at least 6” of clearance from end of case to any walls or partitions.

Removing Case From Shipping Skid and General Installation

CAUTION:

door frames when removing the case from the skid or moving the case. Case damage or glass breakage could result.

Do not push against the top glass, front glass, end glass, doors or

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1. Remove crate top and sides and note missing or damaged items as explained in the pre-installation

procedures outlined above.

2. Move the case as near as possible to the final location and before removing it from the shipping skid.

3. Remove the (4) brackets that secure the case to the shipping skid.

4. Prepare cabinet according to instructions in this section that pertain to your model.

5. Lift the case off of skid and into required position. Only lift the case from the frame channels located on

each end of the case

6. Fasten each case to cabinet with the (4) #12 screws supplied.

7. Rout electrical cord according to instructions in this section that pertain to your model.

ase must be sealed to the counter using a NSF listed sealant.

8. Install end panels.

Cleaning

For initial setup, clean the case as outlined in the “Weekly Cleaning” section of this manual.

Dry CD Model Installation Cabinet Preparation

The CD models require (2) ½”dia. case fastening holes to be drilled through the counter top surface to attach case to counter. Use the diagram below for hole placement location. IMPORTANT: When placing cases in a line up the number of end panels used will be different. The cut out and hole placement dimension will need to be adjusted for each particular line up circumstance. See LINE UPS INTALLATION section of this manual.

35.0 (36" UNIT)

47.0 (48" UNIT)

31.0 (36" UNIT)

43.0 (48" UNIT)

CUSTOMER SIDE

FRONT

3.03

(2) 1/2" DIA MTG. HOLES

29.0

CASE TOP VIEW

1/4" END PANELS

1-1/2" HOLE FOR CORD STANDARD OPT.1

11/16 DOOR HANDLE CLEARANCE

CORD OPTIONS

CORD OPTION1: The electrical cord is shipped from the factory protruding from the bottom rear corner of the cases base. A 1-1/2”dia. hole must be drilled through the counter for the power cord clearance. See diagram below for hole placement location. CORD OPTION 2:An additional electrical cord connection hole is provided in the rear control panel next to the case’s controls. A 1-1/2”dia hole through the counter is not required for this option. NOTE: Only a licensed electrician must perform the electrical work required to move the cord to this optional position.

2.76

1.53

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DANGER:

Electric shock hazard. Do not operate unit with panels removed.

1. Remove the (8) screws holding the rear frame panel located under the door track and also remove

the 7/8” hole plug located next to the controls in the control panel.

2. Disconnect the power cord connections and move the cord and cord strain relief from the bottom hole in the frame channel to the hole in the control panel and reconnect power cord. Plug bottom hole in frame channel with the 7/8” hole plug removed from the control.

3. Reinstall the rear frame panel.

Refrigerated CRR Self Contained Models Cabinet Preparation

The CRR Self Contained models have a large condenser compartment hanging from the rear of the unit that contains the condenser/condensate evaporator unit. This compartment hangs off the rear edge of the counter. The rear of the counter must be open to allow space for this compartment. The countertop top should be flush with countertop back and the first top 8” of cabinet back must be flat with no doors.

IMPORTANT: The condenser air inlet and discharge louvers are located in the rear of the case. Do not block these louvers and do not locate them near a source of heat. Clearance of 8” minimum must be maintained for condenser air exchange. (2) ½”dia. case fastening holes will need to be drilled through the counter top surface to attach case to counter with ¼” X 2” screws provided. Use the diagram below for hole placement location. IMPORTANT: When placing cases in a line up the number of end panels used will be different. The cut out and hole placement dimension will need to be adjusted for each particular line up circumstance. See LINE UPS INTALLATION section of this manual.

DANGER:

Case must be fastened to counter and counter must be fastened to floor.

29.00

5.21 /

6.71 SS

36.0 (36"UNIT)

48.0 (48" UNIT)

31.0 (36"UNIT)

43.0 (43"UNIT) FRONT

CASE TOP VIEW

EDG OF COUNTER TOP

CUTTING BOARD

25.25 MIN.

IMPORTANT: UNIT MUST BE FASTENED TO COUNTER AND CABINET MUST BE FASTENED TO FLOOR

(2) 1/2" DIA MTG. HOLES

21.93

3/4" END PANELS

CORD LOCATION STANDARD OPT.1

COUNTER TOP MUST BE FLUSH WITH REAR OF CABINET.

10.0

DOORS ON REAR OF CABINET MUST BE

10.0" FROM COUNTER TOP SURFACE

TYPICAL CABINET CRB MODELS

FRONT

CUSTOMER SIDE

CORD LOCATION OPT.2 1-1/2" DIA HOLE

12.87 (36 UNIT)

18.87 (48 UNIT)

2.75

BACK

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CORD OPTIONS

CORD OPTION 1: The electrical cord is shipped from the factory protruding from the A 2-3/4” hole located in the bottom rear corner of the condensing compartment and does not require a hole to be drilled into the cabinet. (You may need to reach up into 2-3/4” hole to retrieve cord.) CORD OPTION 2: The power cord can also be allowed to drop into counter interior space. This option does not require any rewiring of the case, but does require a hole to be drilled into the back of cabinet.

1. Before placing the case onto the counter remove the (6) screws holding the condenser cover and remove the condenser cover.

2. There is a 2-3/4” hole in the lower corner of the compartment and a 2-3/4”hole plug in the compartment back. Remove the 2-3/4” plug from the back hole and place it into the bottom hole.

3. Install and fasten the case onto the counter.

4. Drill a 1-1/2” hole through the counter back in the location of the 2-3/4” hole for power cord to be dropped into cabinet compartment.

5. Reinstall the condenser cover and the (6) screws. OPTION 3: An electrical cord connection hole is provided in the rear control panel next to the controls. A 1-1/2”dia hole through the counter is not required for this option. NOTE: Only a licensed electrician must perform the electrical work required to move the cord to this optional position.

1. Before or after the case has been installed onto the counter remove the (6) screws holding the condenser cover and remove the condenser cover.

2. Remove the (4) screws holding the rear frame panel located under the door track. Loosen the (4) screws holding the cutting board under each end of the cutting board. Tilt and lift the rear panel out from behind the cutting board.

3. Remove the 7/8” hole plug located next to the controls in the control panel. Disconnect power cord connections and move cord and cord strain relief from bottom hole in frame channel to the 7/8” hole in the control panel. Reconnect power cord and plug bottom in frame channel with the 7/8” hole plug removed from the control panel.

4. Reinstall the condenser cover and the rear frame panel and retighten the cutting board mounting screws.

DANGER:

Electric shock hazard. Do not operate unit with panels removed.

Refrigerated CRB Self Contained Models Cabinet Preparation

The CRB Self Contained models have a large condenser compartment hanging from the bottom of case that contains the condenser/condensate evaporator unit. This compartment hangs inside the cabinet compartment. The interior of the cabinet must be open to allow space for this compartment and air movement. The countertop must be cut to allow the case’s base and condenser compartment to drop into the cabinet interior. Use the diagram below for cutout dimensions. The condenser air inlet and discharge louvers are located on each side of the case condenser compartment. The cabinet interior must have a divider that isolates intake and the exhaust sides of the condenser air. The provided gasket must be attached to case in divider location to insure a seal between the air intake and air discharge sides of condenser compartment. The Louvers provided must also be installed on each side of these compartments for required condenser outside cabinet air exchange. The louvers can be installed in either the front or the rear of the cabinet, as long there is a min. of 8”air space (drawing shows louvers in rear for reference only). The cabinet compartment must not be used for storage or air restriction may occur. (2) ½” dia. case fastening holes will need to be drilled through the counter top surface to attach case to counter with ¼” X 2” screws provided. Use the diagram below for hole placement location.

IMPORTANT: Federal Industries reserves the right to deny warranty if the cabinet is not divided internally and the cabinet louvers not installed properly, blocked or located near a source of heat.

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IMPORTANT: When placing cases in a line up the number of end panels used will be different. The cut out and hole placement dimension will need to be adjusted for each particular line up circumstance. See LINE UP INTALLATION section of this manual.

1.5

DISCHARGE GRILL (PROVIDED) LOCATED AS SHOWN 95 SQ. IN. MINIMUM OF AIR OPENING

BASE OF UNIT MUST SIT INTO OPENING AS SHOWN.

CONDENSER HOUSING, DO NOT MOUNTGRILL BEHIND CONDENSER HOUSING

33.5 (36)

32.8 (36)

44.8 (48)

45.5 (48)

26.9

TYPICAL COUNTER CUT OUT

GRILLS CAN BE INSTALLED ON EITHER FRONT OR BACK OF CABINET. (FRONT SHOWN)

SEAL WITH GASKET

14.25 /

15.50 SS

GASKET

1/2" O HOLE TO FASTEN CASE TO COUNTER WITH 1/4" X 2" SCREWS PROVIDED

SECTION AA

INTAKE GRILL(PROVIDED) LOCATED AS SHOWN 95 SQ.IN. MINIMUM OF AIR OPENING

CORD OPTION 1: The electrical cord is shipped from the factory protruding from the bottom rear corner of the base and will fall through the required cut in counter. After the case has been installed and fastened onto the counter, plug cord into a proper power source. CORD OPTION 2: An additional electrical cord connection hole is provided in the rear control panel next to the case’s controls. A 1-1/2”dia hole through the counter is not required for this option. NOTE: Only a licensed electrician must perform the electrical work required to move the cord to this optional position.

DANGER:

1. Remove the (8) screws holding the rear frame panel located under the door track and also remove

the 7/8” hole plug located next to the controls in the control panel.

3. Reinstall the rear frame panel.

Electric shock hazard. Do not operate unit with panels removed.

CENTER DIVIDER, MUST BE SEALED (GASKET PROVIDED)

Refrigerated CRR Remote Models:

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Cabinet Preparation

The CRR remote sets directly on top of the counter and refrigeration and evaporator condensate drain lines must run through the counter top surface. The evaporator condensate drain must runs to a floor drain and refrigeration lines to a remote condenser unit (2) ½”dia. case fastening holes will need to be drilled through the counter top surface to attach case to counter with ¼” X 2” screws provided. A 2-1/2”dia. hole will also need to be drilled through counter top for refrigeration lines and evaporator condensate tube connections. Use the diagram below for hole placement location. IMPORTANT: When placing cases in a line up the number of end panels used will be different. The cut out and hole placement dimension will need to be adjusted for each particular line up circumstance. See LINE UP INTALLATION section of this manual.

36.0 (36" UNIT)

47.0 (48" UNIT)

31.0 (36" UNIT)

43.0 (48" UNIT)

FRONT

3.03

CUSTOMER SIDE

(2) 1/2" DIA MTG. HOLES

3/4" END

29.0

CASE TOP VIEW

PANELS

2-1/2" HOLE REFRIGERATION AND EVAPORATOR CONDENSATE DRAIN

1-1/2" HOLE FOR CORD

3.0

22.62

11/16 DOOR HANDLE

3.26

STANDARD OPT.1

1.53

CLEARANCE

CORD OPTIONS

CORD OPTION 1: The electrical cord is shipped from the factory protruding from the bottom rear corner of the cases base. A 1-1/2”dia. hole must be drilled through the counter for the power cord clearance. See diagram below for hole placement location. CORD OPTION 2: An additional electrical cord connection hole is provided in the rear control panel next to the case’s controls. A 1-1/2”dia hole through the counter is not required for this option. NOTE: Only a licensed electrician must perform the electrical work required to move the cord to this optional position.

1. Remove the (8) screws holding the rear frame panel located under the door track and also remove the 7/8” hole plug located next to the controls in the control panel.

3. Reinstall the rear frame panel.

DANGER:

Electric shock hazard. Do not operate unit with panels removed.

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