hussman INNOVATOR, INNOVATOR II User Manual
®
P/N 0425683F
September 2006
INNOVATOR
AND
INNOVATOR II
REACH-IN
GLASS DOOR
INSTALLATION
& SERVICE
MANUAL
IMPORTANT
KEEP IN STORE FOR FUTURE REFERENCE
Quality that sets industry standards!
12999 St. Charles Rock Road • Bridgeton, MO 63044-2483
U.S. & Canada 1-800-922-1919 • Mexico 1-800-522-1900
www.hussmann.com
© 2006 Hussmann Corporation
HUSSMANN CORPORATION, BRIDGETON, MO 63044-2483 U.S.A.
Table of Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Always
*Clear
™
Glass . . . . . . . . . . . . . . . . 1
Shipping Damage . . . . . . . . . . . . . . . . . . . 1
New Installations . . . . . . . . . . . . . . . . . . . 1
Adjusting Closing Torque . . . . . . . . . . . . . 1
Adjusting Door Sag . . . . . . . . . . . . . . . . . 2
Conditioning Gasket . . . . . . . . . . . . . . . . . 2
Replacing Doors . . . . . . . . . . . . . . . . . . . . 3
Replacing Door Hinge Spring . . . . . . . . . 5
Replacing Magnetic Gasket . . . . . . . . . . . 5
Restoring Gasket Seal . . . . . . . . . . . . . . . .6
Door Handle Replacement . . . . . . . . . . . . 8
Frame Heater Replacement . . . . . . . . . . . 9
Lamp Replacement (Center Mullion) . . . 11
Lamp Replacement (End Mullion) . . . . . 13
Ballast Replacement . . . . . . . . . . . . . . . . 13
Heater Harnesses . . . . . . . . . . . . . . . . . . 14
Wiring Diagrams . . . . . . . . . . . . . . . . . . 15
Replacement Parts Chart . . . . . . . . . . . . 17
Replacement Parts List . . . . . . . . . . . . . . 18
WARRANTY
Revision E
1. Added Always*Clear cleaning information, page 1.
2. Revised text for diffuser removal, pages 11 & 12.
3. Revised wiring diagrams, pages 15 & 16.
4. Added ballast change-out direction, page 24.
REVISION F
1. Added instruction for conditioning gaskets during
initial case installation, page 2.
2. Revised wiring diagrams, pages 15 & 16.
3. Added Aftermarket part numbers, pages 18 through 23.
®
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Innovator Door Installation and
Service Instruction
P/N 0425683F
iii
GENERAL
Be sure merchandisers have been leveled according to the installation instructions shipped with
the merchandiser.
The door nameplate is attached to the top of the
door, handle side, behind the magnetic gasket.
The frame nameplate is located on the top left
near the switch.
ALWAYS*CLEAR™GLASS
Hussmann recommends using a soft cloth with
isopropyl (rubbing) alcohol to clean the inside
(coated) glass surface. Isopropyl alcohol does not
freeze and evaporates without leaving residue.
Always allow the surface to dry before closing
the door. Use of abrasives may damage the
coated surface and void the warranty. Labels
(stickers) applied to the coated surface will cause
damage and void the warranty.
SHIPPING DAMAGE
All equipment should be thoroughly examined for
shipping damage before and during unloading.
This equipment has been carefully inspected at
our factory. Any claim for loss or damage must be
made to the carrier. The carrier will provide any
necessary inspection reports and/or claim forms.
NEW INSTALLATIONS
Untape the doors and remove the shipping braces
located at top and bottom of the doors.
Doors are not fine adjusted at the factory since
they will go out of adjustment during shipment.
This is normal.
ADJUSTING CLOSING TORQUE
Adjust closing torque by turning the bottom
hinge pin in the direction the door closes. Use a
1
/2 in. (13 mm) wrench. Turn the hinge pin until
the door closes on its own, usually 3 to 4 clicks or
3
/4 turn. See Figure 1.
DO NOT over-torque the hinge spring assembly.
Excessive torque (over 1 full turn) will result in
damage to the spring assembly and/or door. If
door does not close on its own after one full turn
(5 clicks), look for obstructions causing the door
to hang up.
Figure 1. Adjusting Closing Torque
Innovator Door Installation and
Service Instruction
P/N 0425683F
1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM
ADJUSTING DOOR SAG
To adjust door sag (saw-tooth effect from door to
door), loosen the two hinge plate mounting
screws using a Torx Plus no. 27 bit. Adjust hinge
plate as needed, then tighten the screws. See
Figure 2.
CONDITIONING GASKETS
The manufacturer cannot control the environment
surrounding cases during shipment. Temperature
and humidity fluctuations during shipment, as
well as excessive vibration, may promote gaps
between gasket and frame. These gaps prevent
gaskets from sealing even when correctly fitted at
the factory. This is not a warranty issue or defect.
Follow this procedure to ensure gaps close and
gaskets seal properly:
1. Remove all shipping retainers and packing
material.
2. Close each door. Use a flashlight to identify
any gaps between frame and gasket.
3. Energize all anti-sweat, fan and light circuits
for at least two hours, but not more than four
hours, prior to initiating the refrigeration cycle.
4. Monitor all gaps. If gaps remain at the end of
four hours, follow the procedure for Restoring
Gasket Seal, beginning on page 6 of this manual.
5. Initiate cooling sequence once gaps disappear.
Do not exceed 8 hours of energized circuits
without refrigeration. Doing so may cause
damage to the case and will void the warranty.
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HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM
Figure 2. Adjusting Door Sag
Loosen both
hinge plate
mounting
screws.
ATTENTION
TO ENSURE PROPER DOOR GASKET SEAL – REMOVE ALL SHIPPING
RETAINERS AND ENERGIZE ALL ANTI-SWEAT, FAN & LIGHT CIRCUITS 2
TO 4 HOURS PRIOR TO INITITATING REFRIGERATION CYCLE.
DO NOT EXCEED 8 HOURS OF ENERGIZED CIRCUITS WITHOUT
REFRIGERATION. DAMAGE OR PRODUCT FAILURE MAY OCCUR AND VOID
THE WARRANTY. DO NOT REMOVE THIS LABEL UNTIL REFRIGERATION IS
INITIATED.
Before and After Gasket Conditioning
REPLACING DOORS
1. Loosen torque on door before removing the
door. Wedge a screwdriver between the bottom of
the door and the hinge socket, then lift the door
up. This will lift the bottom hinge pin up and out
of the bottom hinge socket. Hold the hinge pin
with a 1/2 in. (13 mm) open end wrench to keep
it from spinning out and stripping the socket. See
Figure 3.
Innovator Door Installation and
Service Instruction
P/N 0425683F
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HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM
Always disconnect the electrical power at the
main disconnect when servicing or replacing
any electrical component. This includes, but is
not limited to, such items as doors, lights,
fans, heaters, and thermostats.
Lift up
Screwdriver
Figure 3. Loosening Torque on the Door
!
WARNING
2. Unscrew the two #6 Phillips screws that hold
the black plug into the side of the door as shown
in Figure 4. Remove the plug from the door.
3. Grasp the strain relief just below the cord and
pull until the heater terminal plug comes out. See
Figure 5. Note that the left end door must be
opened more than 90 degrees to access the
screws.
4. Use a flat blade screwdriver as shown in
Figure 6 to lift the door retainer over the shoulder
screw.
5. Push down the top hinge pin until it clears the
top socket using a flat blade screwdriver as
shown in Figure 7. With finger, hold the hinge
pin in the door to keep it from popping out. Tape
may be used to temporarily hold the hinge pin
once door is removed.
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HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM
Figure 4. Removing Screws to Plug
Figure 5.
Removing the Heater Terminal Plug
Remove Screws
Figure 6. Removing the Door Retainer
Door Retainer
Figure 7.
Removing the Door from the Top Hinge Pin
Top
Hinge
Pin
6. Rock the door out and pull the bottom hinge
pin out from the bottom socket.
7. Install the new door in reverse order.
8. Adjust the torque on the new door. If needed,
adjust sag.
REPLACING DOOR HINGE SPRING
The door must be removed before replacing the
door hinge spring.
Pull the hinge spring assembly out of the bottom
of the door and replace with a new assembly. See
Figure 8. Note that there are right-hand and lefthand hinge spring assemblies.
REPLACING MAGNETIC GASKET
Carefully remove the old gasket from the groove
in the back of the door, Figure 9.
The new gasket will be easier to work with if it is
at ambient temperature. Begin by lubricating the
new gasket with a mild soap and water solution.
Innovator Door Installation and
Service Instruction
P/N 0425683F
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HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM
Figure 8. Replacing Door Hinge
Spring Assembly
Figure 9. Removing Door Gasket
Gasket
Work from the corners to the centers of each side,
top and bottom. Carefully push the new gasket
into the groove at each corner, refer to Figure
10(A). Then, push the gasket into the channel at the
center of the top, bottom and each side, Figure
10(B). Avoid stretching the gasket.
Sub-divide remaining areas and push the gasket
in at those points, Figure 10(C).
Sub-divide once again and repeat pushing the
gasket in until all of the gasket is evenly seated in
the groove, Figure 10(D).
Use a soft cloth or paper towels to dry the gasket
before closing door on clean door frame.
RESTORING GASKET SEAL
Occasionally, a crimped or damaged gasket can
cause gaps in the seal (Figure 11), leading to frost
formation on the doors. Use this procedure to
close gaps and end frost formation on doors.
Locate Gaps
Normally, interior case lighting will provide
enough light to see gaps. In some cases, the only
way to see gaps is to provide a backlight as
shown in Figure 12(A). Backlight the door
mullion and look for places the light shines
between the door and gasket, Figure 12(B).
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HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM
Corners first
Middle of Door
Sub-divide Middle Locations
Sub-divide again
Figure 10.
Sequence for Installing New Gasket
(A)
(B)
(C)
(D)
Figure 11.
Improperly Installed or Damaged Gasket
Figure 12. Back-Lighting Gaps in Gasket
Back-Light
Gap
(A)
(B)
Gap
Heat the Gasket
Make sure the door is closed.
Beginning at the top of the gap,
use a heat gun or electric hair
dryer (1500-1600 watt) to heat
the gasket with a constant up
and down motion.
IMPORTANT: If a gap runs
the entire length of the door,
heat the area 4 in. (100 mm)
above and 8 in. (200 mm)
below the top-most point where
the gap starts and work in
12 in. (300 mm) increments.
If the gasket becomes shiny,
remove heat immediately as
this is an indication that the
gasket is near the melting
point.
If possible, direct the hot air
onto the gasket and also
through the gap between the
gasket and mullion. This will
help to heat both sides of the
gasket. Refer to Figure 13(A)
and (B).
As the gasket softens and
becomes pliable, the magnet in
the gasket should pull it across
the gap. As the gap closes,
move heat down to create a
zippering effect as shown in
Figure14.
If the gasket is not pulled
across the gap by the magnet,
reach around the mullion (from
the inside) and pull the gasket
skirt toward the mullion.
Innovator Door Installation and
Service Instruction
P/N 0425683F
7
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM
Gap
Back-Light
Direct the hot air through the gap
between the gasket and mullion.
Back-Light
Remember to use a constant
up and down motion when
applying heat.
Figure 13. Applying Heat to Gasket
(A)
(B)
Figure 14. Zipper Effect
(A)
(B)
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