Federal Industries CGR5048CD Operator’s Manual

E1954

01-05-10

INSTALLATION & OPERATIONS INSTRUCTIONS

Self-Contained & Remote Refrigerated Models

Including Dual Zone & Cold Deli Models

& Non-Refrigerated Displays

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 [phone] Fax: [phone]

CONTENTS

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

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

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

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

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

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

Removing Case From Shipping Skid .......................................................................................... 5

Grill Removal..............................................................................................................................6

Condensate Evaporator...............................................................................................................7

Cleaning......................................................................................................................................7

Trim Kits Installation

Exterior Trim ..............................................................................................................................7

Interior Trim................................................................................................................................8

Refrigeration Installation (Refrigerated units)

Self Contained Models................................................................................................................ 9

Remote Models...........................................................................................................................9

ELECTRICAL INFORMATION & GROUNDING............................................................................. 11

OPERATING INSTRUCTIONS.............................................................................................................12

Controls..................................................................................................................................... 12

Shelves......................................................................................................................................12

Rear Package Shelf ...................................................................................................................12

Doors......................................................................................................................................... 12

Placing Product Into Case......................................................................................................... 13

SHELVING INSTALLATION & REMOVAL.................................................................................14-15

Shelves and shelf light quantity................................................................................................16

SHELF INSTALLATION........................................................................................................................16

Wire Shelves.............................................................................................................................16

Glass Shelves ............................................................................................................................ 17

Metal Shelves............................................................................................................................17

MAINTENANCE...................................................................................................................................... 18

Shelf Light Replacement......................................................................................................18-19

Top Light Replacement............................................................................................................. 20

PERIODIC MAINTENANCE................................................................................................................. 21

Cleaning Condenser Coil Filter............................................................................................21-22

Cleaning Condenser Coil..........................................................................................................23

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

Daily Cleaning .......................................................................................................................... 24

Weekly Cleaning....................................................................................................................... 25

Interior Cleaning..................................................................................................................25-26

Exterior Cleaning......................................................................................................................27

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

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

Special Service Situations.........................................................................................................29

SALE & DISPOSAL.................................................................................................................................29

Owner Responsibility................................................................................................................ 29

REFRIGERATION & ELECTRICAL DATA .................................................................................30-31

MAIN WIRING DIAGRAMS ............................................................................................................32-37

LIGHT WIRING DIAGRAMS ..........................................................................................................38-49

REPLACEMENT PARTS ..................................................................................................................50-54

.......................................................................................................................7

.................................................................................9

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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

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.

DANGER

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.

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 [phone] / WI Phone [phone]

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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) 356­4206 for replacements.

CAUTION

RISK OF ELECTRIC

SHOCK DISCONNECT

POWER BEFORE

SERVICING UNIT.

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

91-12340

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CAU T IO N
HAZARDOUS MOVING PARTS
DO NOT OPERATE UNIT WITH
DISPLAY PANS REMOVED.

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.

INSTALLATION INSTRUCTIONS

Locating the Display Case

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.

The condenser air inlet is located at the rear of the case. Do not block this inlet and do not
locate the air inlet near a source of heat.

Removing Case From Shipping Skid
CAUTION: Do not push against the top glass, front glass, end glass, doors or

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

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. If your case is supplied with plastic end panels, remove them by lifting them in an upward
direction. Set these end panels aside to be reinstalled after case is placed in proper position.

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

- 5 -

5. Use the lifting handles located in each end of the case and lift case off of skid and into
required position.

6. Level and square the case as needed by adjusting the leg leveler in each corner of base. (Use
the wrench provided.) (The case must be level for proper drainage of defrost condensate to
the condensate evaporator and allow for proper alignment of front glass.) The 50”, 59”, &
77” cases also have a set of leg levelers in the center. These must be adjusted so the base is
flat.

The leveled case must be sealed to the floor using a NSF Listed Sealant.

7.

8. If plastic end panels are required reinstall them on to case. Hook the key slot located on the
inside of the end panel down over screws located on each end of case.

Grill Removal (Refrigerated Units)

DANGER: Electric shock hazard. Do not operate unit with panels

removed.

There is a removable slotted panel at the rear of the case. The panel allows access to the
condensing unit, the light ballast, the condensate pan, and the field wiring connection box.
Remove this panel to make field wiring connections. See electrical information and
grounding section of this manual before wiring case.

Note: If electrical connection has been performed, disconnect power to case before removing grill
panel.

1. Remove the rear grill panel screws from top of rear grill.

2. Tilt the top of rear grill panel outward as shown in illustration on the right.

3. Pull rear grill panel tabs up and out of slots in base of case.

2.

1. REA R GRILL
PANEL SCREWS

3. REAR GRILL
PANEL TABS

- 6 -

E1954-7

Condensate Evaporator (Refrigerated Units)

This case is furnished with an electrical condensate evaporator. Plumbing connections are
not required.

The condensate evaporator is located toward the front of the machine compartment and is
accessible from the rear of the case. After removal of rear grill panel, make sure that the
drain line has not been dislodged during shipment and that the drain trap is located
properly over the water reservoir of the condensate evaporator pan.

Cleaning

For initial setup, clean the case as outlined in the weekly cleaning section of this manual.

Trim Kits Installation

Follow the “Case Installation” procedures in this manual for each display case that is going to be
adjoined in a lined up. Additional cases must be place directly next to the adjoining end of the
first case. Push cases together as close as possible keeping the front of the cases in alignment.
Once adjoining case is in proper position complete all of the procedures outlined in the “Case
Installation” section in this manual before installing the trim kit as outlined below.

Note: The Laminated plastic end panels and end panel screws are not used on the adjoining ends
of the cases that are to be butted together.

Exterior Trim

1. Remove the (3) 8-32 screws located on rear corner of each case and set aside (If preinstalled).
These screws will be used to attach rear exterior trim strip to case. Note: For units with rear
packing shelf , These screws hold the package shelf standard to the case. The packing shelf
and packing shelf standard must be temporarily removed for installation of rear exterior trim.

EXTERIOR REAR
TRIM STRIP

REAR SCREW

E1954-11

EXTE RI O R FRONT
TRIM ST R IP

FRONT SCREW

2. Remove the adhesive liner from the inside of the rear exterior trim strip and firmly place it
over the top and down the back of case. Be sure to center rear exterior trim strip over seem
between cases and to align slots with holes in case rear (If holes are provided)

- 7 -

3. Fasten rear exterior trim strip to each case with the (3) 8-32 screws previously removed.
If no holes are provided to fasten trim strip, use the (3) #8 self-drilling screws provided.
Note: For units with rear packing shelf, Reattach rear packing shelf standard over the top of
rear exterior trim strip using the existing holes in case. Place packing shelf back on to case in
desired standard slot.

4. Use a NSF approved silicone to seal rear exterior trim strip along the top surface of case.

5. Remove the (2) screw located on the front corner of each case and set aside. These screws will
be used to attach front exterior trim strip to case. Note: For units with front package shelf,
these screws hold the package shelf to the case. The package shelf must be temporarily
removed for installation of front exterior trim.

6. Fasten front exterior trim strip to each case with the (2) 8-32 screws previously removed.
Note: For units with front package shelf, Reattach front package shelf over the top of front
exterior trim strip case with the (2) 8-32 screws previously removed.

Interior Trim

The interior trim kit is used when adjoining cases have one glass panel or no glass panel
between them.

1. On units with sliding rear doors, remove both rear doors from track by lifting doors upward
until the bottom edge of door clears the lower track. Swing the bottom of door outward and
down out of top track.
On units with rear swing doors completely open doors to allow access to interior of case.

2. Cases with no glass panels: Remove the adhesive liner from the inside of the interior trim
strip and firmly place it over the center gap between the case interiors.
Cases with one glass panel: The interior glass trim is placed in the adjoining case that does
not have an end glass panel. Remove the adhesive liner from the inside of the interior trim
strip and firmly place it against the glass trim of adjoining case with the end glass panel.

INTERIOR TRIM STRIP

E1954-12

3. Fasten interior glass trim with the stainless steel self drilling screws supplied with interior trim
kit

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Refrigeration Installation (Refrigerated units)

Self Contained Models

The self-contained models are shipped from the factory with a completely operational 134A
refrigeration system and require no modifications or adjustments upon installation.

Remote Models

The remote models are designed to use 134A refrigerant and shipped from the factory with the
evaporator coil, expansion valve, refrigerant solenoid valve and thermostat. The thermostat senses
interior case temperatures and opens and closes the refrigerant solenoid valve as needed to
maintain proper case temperatures. The condensing unit is optionally supplied from the factory
for remote location installation.

REMOTE DISPLAY CASE

EXPANSION
VALVE

REMOTE
CONDENSING
UNIT

INSTALL
LOW PRESSURE
CUTOUT

EVAPORATOR COIL

LIQUID LINE
SOLENOID
VALVE

SUCTION LINE (INSULATED)

THERMOSTAT

LIQUID LINE

INSTALL
FILTER DRIER

1. Mount condensing unit indoors as close to the remote display case as practical. The
refrigeration line should be as short as possible.

2. All refrigeration and/or electrical materials between the condensing unit and display case are
to be supplied by installing contractor.

3. Route properly sized and designed refrigeration lines from the condensing unit to the cabinet.
Horizontal suction lines should be pitched downward towards the condensing unit at least ½”
per 10’ run to aid the oil drainage. A “P” trap must be installed in the suction line at the foot
of every riser to insure oil return. Dry nitrogen should be used to flow through tubing while
brazing refrigeration lines.

4. Suction line must be insulated the entire length with armaflex (or equivalent). Do not run
liquid line inside insulation with suction line.

- 9 -

5. The filter drier, sightglass, and low-pressure control are not furnished with remote display
case models. The recommended low pressure setting for R134a refrigerant is 32# cut in and
0# cutout.

6. Leak check condensing unit, cabinet, and all connecting tubing. Cabinet and condensing unit
tubing hould be checked to insure no leaks occurred during shipping or from rough handling.
Make certain all refrigeration valves are opened and evacuate system to 500 microns. Charge
the system with refrigerant type specified on the data plates.

- 10 -

ELECTRICAL INFORMATION &
GROUNDING

This Case Must Be Grounded

DANGER: Improper or faulty hookup of electrical components in the

display case can result in severe injury or death.

Only a licensed electrician must perform all case electrical connections.

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

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

The electrical service must be grounded upon installation.

This unit is designed for permanent connection to a power source. See the electrical data plate
located at the rear of the case for proper circuit size and wire ampacity.

The electrical connection box is accessible from the rear of the case. Remove rear grill on
refrigerated models. (See “Grill Removal” in the installation section of this manual.) See
diagram below for location of the field wiring connection box.

FIELD CONNECTION COVER
FOR NONREFRIGERATED CASES

FIELD CONNECTION COVER
FOR REFRIGERATED CASES

BACK OF CASE OVERHANGS
BASE 1".

7/8" DIA. ELECTRICAL ENTRANCE
ON REAR OF CASE,
1" FROM SIDE OF BASE
1-3/4" FROM BOTTOM OF BASE

2-3/4" DIA. ELECTRICAL ENTRANCE
IN BOTTOM OF CASE,
2-3/4" FROM SIDE OF BASE,
2-1/8" FROM REAR OF BASE.

- 11 -

LIGHT SWITCH
(REFRIGERATED UNITS)

POWER SWITCH
(NONREFRIGERATED UNITS)

TEMPERATURE CONTROL
(REFRIGERATED UNITS)

E1954-8

OPERATING INSTRUCTIONS

Controls (Refrigerated Units)

Light Switch

This switch controls the power to the lighting circuit. The switch rocker is red in the “on”
position, black in the “off” position.

Temperature Control

This controls the refrigerated side by cycling the compressor/condensing unit. It has an
“off” position and the coldest setting when the knob is set all the way in the clockwise
position. Set this control at the lowest setting possible, while maintaining desired case
temperature.

Controls (Non-Refrigerated Units)

Power Switch

This switch controls the power to the lighting circuit and to the optional interior fan if
supplied. The switch rocker is red in the “on” position and black in the “off” position.

Shelves

Each display is furnished with shelves that are adjustable up and down and can be tilted in
three angular positions. See “Shelving Installation & Removal” section of this manual for
proper installation, adjustment and removal of shelving.

Rear Package Shelf (standard on Deli, optional on all other models)

The rear package shelf is removable and adjustable up and down. It can be removed or
adjusted by lifting rear package shelf up and out until the bracket is disengaged from shelf
standard. It can then be moved to desired height location and reattached.

Sliding Rear Doors

The doors can be easily removed by lifting doors upward until the bottom edge of door
clears the lower track. Swing the bottom of door outward and down out of top track.

Clean the door track frequently for easy door operation. A Very light film of lubricant,
such as PAM, will help the doors slide easily.

Swing Rear Doors

The Swing doors are not easily removable for cleaning and require no lubrication.

- 12 -

Placing Product into Case

After completing shelving installation as outlined in “Shelving Installation and Removal”
section of this manual you may begin placing product into the display case.

- Do not exceed 150 pounds of weight per shelf. Heavy product should be distributed
evenly across the entire shelving area.

- Determine desired shelving location and angle before placing product in case. Product
must be removed to readjust shelf location and angle.

(Refrigerated Models)

- Do not overhang the front of wire shelves with product. Product may overhang rear of
shelf, but allow a minimum of 1-1/2” between product and rear door. Improper clearance
in front and rear of shelf will block the refrigerated airflow and could cause product loss.

-Do not block the slots along the front or rear of the case display pan. Covering these slots
will block the refrigerated airflow and could cause product loss.

-The display pan is removable for cleaning and can become dislodged in shipment. To
ensure proper airflow and performance of the case, make sure that the display pan is
pushed completely down into evaporation tub. Check that the pan is installed properly
before placing product the display pans.

-Allow refrigerated models to run for at least two hours before placing pre chilled product
into unit. Turn temperature control to the lowest possible position that maintains required
interior cabinet temperature.

-CASE SHOULD BE STOCKED WITH PRE-CHILLED PRODUCT
ONLY.

ATTENTION:

- Federal refrigerated display cases are designed to operate in a
maximum environment of 75 DEG. F and 55% relative humidity.
Exceeding these limits could cause poor case performance and
sweating of glass panels.

- 13 -

SHELVING INSTALLATION & REMOVAL

GLAS S SHELF

GLASS SHELF
HOLDER

METAL SHELF

GLASS SHELVES

DET AIL A

(GLASS SHELF ONLY)

FEMALE SHELF
LIGHT SOCKET

SHELF BRACKET

CLEAR PLASTIC
CLIP

6-32 X 1/4 FLAT
HEAD SCREW

B

A

C

CLEAR PLASTIC CLIP

DETAIL B

(SHELF LIGHT ONLY)

SHELF LIGHT OR
FRONT SHELF SUPPORT

E1594-2

1. Turn the light switch to the off position.On units with sliding rear doors, remove both rear
doors from track by lifting doors upward until the bottom edge of door clears the lower track.
Swing the bottom of door outward and down out of top track. On units with rear swing doors
completely open doors to allow access to interior of case.

2. Insert a shelf bracket in the desired shelf standard slot on one side of case. Follow the
instruction in the illustration below. Place an additional shelf bracket in the same shelf
standard slot on the opposite end of case. Repeat for additional shelf tiers. For first time
installation it may be necessary to attach the clear plastic clips to only the shelf brackets
located on the side of the shelf light cord. Use the 6-32 x ¼ flat head screws supplied with
unit to attach clear plastic clips to the 1/8 hole on the inside of the shelf brackets. This step
may have already been performed at the factory for you. NOTE: Do not allow shelf bracket
to hit side glass

- 14 -

CLEAR PLASTIC CLIP

DETAIL C

(WIRE SHELF O NLY )

WIRE SHELF

6-32 X 1/4 FLAT
HEAD SCREW

INSTALLATION

SHELF STANDARD
TOP HOOK

1

REMOVAL

SHELF BRACKET

2

3

BOTTOM TAB

1

2

3

4

4

12° NOTCH

6° NOTCH

A.. Place shelf bracket top hook into desired shelf
standard slot.
B. Lift shelf bracket top hook to allow shelf bracket
bottom tab to clear shelf standard slot.
C. Swing shelf bracketbottom tab into shelf standard
slot.
D. Place the desired shelf bracket notch of 0, 6, or 12
degrees onto bottom of shelf standard slot.

0° NOTCH

A. Lift shelf bracket up to allow shelf bracket notch
to clear the bottom of shelf standard slot.
B. Swing shelf bracket bottom tab out of shelf
standard slot.
C. Drop shelf bracket down to allow shelf bracket top
hook to clear top of shelf standard slot.
D. remove shelf bracket top from shelf standard slot.

E1954-3

3. Hang one end of shelf light housing on the front notch of a shelf bracket and then the other
end of shelf light housing on the notch of the shelf bracket on the opposite end. Repeat for
each additional shelf tiers. NOTE: On models without shelf lights, use a shelf support instead
of a shelf light housing.

4. Push shelf light cords into clear plastic clip located on inside of shelf brackets.

5. Remove the cap from the appropriate female light sockets. If socket is not being used for a
shelf light, the cap must be plugged into socket for entire light system to operate. NOTE:
Grip each side of cap firmly and wiggle and pull cap straight out of socket. Do not roll cap
during removal.

6. Plug in each shelf light by aligning the male pins on the appropriate shelf light cord plugs with
the female light sockets and push together. NOTE: Do not roll plug during insertion.

7. Hang one end of the shelf support on to the rear notch of one shelf bracket and then on the
rear notch of the shelf bracket on the opposite side. Repeat for additional shelf tiers.

8. Place supplied shelving onto shelf supports as outlined in the appropriate “Shelf Installation”
section of this manual.

9. On units with sliding rear doors, re-install both rear doors by lifting top of door into top track
and swinging bottom of door onto bottom track. Install door labeled “inner door” first on
inner track and door labeled “outer door” second on outer track.

- 15 -

Shelves and shelf light quantity

It is not required that all shelves and shelf lights supplied with each case are used. The quantity
of shelves and shelf lights can be tailored to your specific needs. If the supplied quantity of
shelves and shelf lights are not required, cap unused female socket located in interior of the case
mullion with caps supplied. Failure to do so will prevent entire lighting system from operating.

SHELF INSTALLATION

Wire Shelves

1. For first time installation, it may be necessary to attach the clear plastic clips to each end of
the rear shelf supports. Use the 6-32 x ¼ flat head screws supplied with unit to attach clear
plastic clips to the 1/8 hole on each side of shelf support. This step may have already been
performed at the factory for you. Repeat for each rear shelf support tier. (See illustration
E1594-2 Detail C) NOTE: On 73” long shelf supports, attach (2) additional clear plastic clips
into 1/8 holes near the center of rear shelf supports.

2. With rear sliding doors removed or rear swing door open, place front of wire shelf onto front
shelf light. (On front shelf support for models without shelf lights)

3. Snap the rear of shelf into the clear plastic clips on rear shelf support.

4. Repeat 2 & 3 for each tier.

NOTE: Units with 73” long rear shelf supports uses (2) wire shelves per tier. All other units use
(1) wire shelf per tier.

- 16 -

Glass Shelves

1. For first time installation attach (2) glass shelf holders to each glass shelf. Remove backing
from tape located on flat side of glass shelf holder. Position the glass shelf holders in the (2)
far corners of glass. (See illustration E1594-2 Detail A.) Repeat for each glass shelf. This
step may have already been performed at the factory for you

NOTE: Clean area of glass where glass shelf holder is to be located with rubbing alcohol
and let air dry before installing shelf glass holder.

2. With rear sliding doors removed or rear swing doors open, place front of glass shelf onto front
shelf light. (On front shelf support for models without shelf lights.)

3. Let the rear of the glass shelf onto the rear shelf support so that the glass shelf holder straddles
the rear shelf support. If clear plastic clips were factory-installed on top of rear shelf support,
remove and discard clear plastic clips.

4. Repeat steps 2 & 3 for each tier.

NOTE: Units with 46” or longer rear shelf supports use (2) glass shelves per tier. All other units
use (1) glass shelf per tier.

Metal Shelves

1. With rear sliding door removed, or rear swing door open, place front of metal shelf on to front
shelf light. (On front shelf support on models without shelf lights.)

2. Set the rear of the metal shelf on to the rear shelf support so that the notch at each end of
metal shelf straddles the rear shelf support. If clear plastic clips were factory-installed on top
of rear shelf support, remove and discard clear plastic clips.

3. Repeat steps 2 & 3 for each tier if supplied with more than (1) tier of shelving.

- 17 -