hussman Reach-in Merchandisers User Manual
®
IIMMPPOORRTTAANNTT
Keep in store for
future reference!
Installation &
Operation Manual
Shipped With Case Data Sheets
P/N 0387183_D
Impact Series
October 2007
Reach-in Merchandisers
Medium and Low Temperature Cases
Merchandisers
iii
P/N 0387183_D
Table of Contents
INSTALLATION
NSF Certification . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Exterior Loading . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Merchandisers Shipped With End Installed . . . . 1-2
Shipping Braces . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Remove Front Panel . . . . . . . . . . . . . . . . . . . . . . 1-2
Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installing Splashguard Brackets . . . . . . . . . . . . . 1-4
Installing Bumpers . . . . . . . . . . . . . . . . . . . . . . . . 1-5
REFRIGERATION / ELECTRICAL
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Branch Line Piping . . . . . . . . . . . . . . . . . . . . . . . 2-2
Expansion Valve Adjustment . . . . . . . . . . . . . . . 2-3
Refrigeration Thermostat . . . . . . . . . . . . . . . . . . . 2-3
Defrost Termination Thermostat . . . . . . . . . . . . . 2-5
Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Merchandiser Electrical Data . . . . . . . . . . . . . . . 2-8
Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrical Connections . . . . . . . . . . . . . . . . . . . . 2-8
Identification of Wiring . . . . . . . . . . . . . . . . . . . 2-8
Wiring Color Code . . . . . . . . . . . . . . . . . . . . . . . 2-8
DRIP PIPING AND SPLASHGUARDS
Waste Outlet and Water Seal . . . . . . . . . . . . . . . . 3-1
Installing Drip Piping . . . . . . . . . . . . . . . . . . . . . 3-1
Installing Splashguards . . . . . . . . . . . . . . . . . . . . 3-2
Sealing Splashguard to Floor . . . . . . . . . . . . . . . 3-3
START UP / OPERATION
Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Load Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Load Limit Profiles . . . . . . . . . . . . . . . . . . . . . . . 4-1
Installing FDA/NSF Required Thermometer . . .4-2
MAINTENANCE
Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cleaning Honeycomb Assemblies . . . . . . . . . . . . 5-2
Cleaning Under Merchandisers . . . . . . . . . . . . . 5-2
Removing Scratches from Bumper . . . . . . . . . . . 5-2
SERVICE
Replacing Fan Motors and Blades . . . . . . . . . . . 6-1
Replacing Electric Defrost Heaters . . . . . . . . . . 6-3
Replacing Drain Pan Heater . . . . . . . . . . . . . . . . 6-5
RLT with Gas Defrost Only: Replacing
Slave Plate Heater . . . . . . . . . . . . . . . . . . . . . . 6-6
Removing RLT Return Air Bracket . . . . . . . . . . 6-7
Replacing Lamp Ballast (other than RLT) . . . . . 6-8
Replacing RLT Lamp Ballast . . . . . . . . . . . . . . . 6-9
Servicing Vertical Lighting . . . . . . . . . . . . . . . 6-10
Servicing Doors and Frames . . . . . . . . . . . . . . 6-10
Replacing Door or Door Frame Parts . . . . . . . 6-10
Replacing Damaged Drain Fitting . . . . . . . . . . . 6-11
Repairing Aluminum Coils . . . . . . . . . . . . . . . 6-12
WARRANTY
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
© 2007 Hussmann Corporation
®
®
INSTALLATION
TOOL LIST
Unloading From Trailer:
Lever Bar (also know as a Mule,
Johnson Bar, J-bar, Lever Dolly, and pry lever)
Moving Dolly
Setting Case Line-Up:
Level, 4 ft suggested
Ratchet
1
/
4 in. Socket
5
/16 in. Socket
1
/2 in. Socket
Battery Drill/Screw Gun
Caulking Gun
10 in. Adjustable Crescent Wrench
REVISION D — SEPTEMBER 2007
1. Added front panel text and illustration, Page 1-2.
2. Clarified shimming directions, page 1-3.
3. Added RLT information throughout.
4. Added note to remove bumper protective film, Page 1-6.
5. Added information on Always*Clear™ glass, page 5-1.
6. Removed reference to Anthony doors, Page 6-5.
7. Added repairing aluminum coil, Page 6-12.
8. Changed warranty page.
9. Added Installation Tool List, page iv.
10. Added revision history, page iv.
REVISION C — JUNE 2002
1. Added NSF information,pages 1-1,4-2 through 4-4.
2. Sections 2 through 6 are completely rewritten.
3. Changed warranty to March 15,2002.
P/N 0387183_D
iv CONTENTS
NSF CERTIFICATION
These merchandisers are manufactured to meet
ANSI / National Sanitation Foundation (NSF®)
Standard #7 requirements. Proper installation is
required to maintain certification. Near the serial
plate, each case carries a label identifying the
type of application for which the case was certified.
ANSI/NSF-7 Type I – Display Refrigerator / Freezer
Intended for 75°F / 55%RH Ambient Application
ANSI/NSF-7 Type II – Display Refrigerator / Freezer
Intended for 80°F / 55%RH Ambient Application
ANSI/NSF-7 – Display Refrigerator
Intended for Bulk Produce
LOCATION
These merchandisers are designed for displaying
products in air conditioned stores where temperature is maintained at or below the ANSI/NSF-7
specified level and relative humidity is maintained
at or below 55%.
Placing refrigerated merchandisers in direct sunlight, near hot tables or near other heat sources
could impair their efficiency.
Like other merchandisers, these are sensitive to air
disturbances. Air currents passing around merchandisers will seriously impair their operation.
Do NOT allow air conditioning, electric fans,
open doors or windows, etc. to create air currents
around the merchandisers.
To prevent sweating on the exterior surfaces
of merchandisers, there must be
A MINIMUM
CLEARANCE OF
4 INCHES (102 MM) between the
merchandisers and other fixtures or walls.
Product should always be maintained at proper
temperature. This means that from the time the
product is received, through storage, preparation
and display, the temperature of the product must
be controlled to maximize the life of the product.
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.
Apparent Loss Or Damage
If there is an obvious loss or damage, it must be
noted on the freight bill or express receipt and
signed by the carrier’s agent; otherwise, carrier
may refuse claim. The carrier will supply necessary forms.
Concealed Loss Or Damage
When loss or damage is not apparent until after
equipment is uncrated, a claim for concealed
damage is made. Upon discovering damage,
make request in writing to carrier for inspection
within 15 days and retain all packing. The carrier
will supply inspection report and required claim
forms.
Reach-In
P/N 0387183_D 1-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A.
INSTALLATION
Do not walk or put heavy objects on case.
CAUTION
!
EXTERIOR LOADING
Do NOT walk on top of merchandisers or dam-
age to the merchandisers and serious personal
injury could occur. T
HEY ARE NOT STRUCTURALLY
DESIGNED TO SUPPORT EXCESSIVE EXTERNAL
LOADING
such as the weight of a person. Do not
place heavy objects on the merchandiser.
MERCHANDISERS SHIPPED WITH END INSTALLED
If the case was shipped with the end installed,
two long bolts were used to hold the shipping
brace to the end. If the shipping bolts are
reinserted after removing the brace, they will
extend into the product area and may damage
the coil. T
HEREFORE, BE SURE TO REPLACE
THESE BOLTS WITH THE SHORTER BOLTS
PROVIDED
.
Be careful not to damage the factory-installed
end while moving the merchandiser. Make sure
that tools are positioned past the end and beneath
the merchandiser’s support bar.
SHIPPING BRACES
Move the merchandiser as close as possible to its
permanent location and then remove all packaging. Check for damage before discarding packaging. Remove all separately packed accessories
such as kits and shelves.
Locate the shipping block in the
center of the heat exchanger (see
illustration), and remove it before
piping the merchandiser. This
block was installed to minimize
shipping vibration.
REMOVE FRONT PANEL
(D
OES NOT APPLY TO RLT)
Before setting case, remove the front panel as
follows: remove screws from front panel tabs,
then lift the front panel. Refer to the illustration
below. Set panel and screws aside to reinstall
once all electrical work is complete.
At completion of all electrical work, installation
contractor shall re-install the panels using care to
ensure all panels are centered and properly
fastened.
1-2 INSTALLATION
P/N 0387183_D WWW
.HUSSMANN.COM
Shipping
Block
Heat Exchanger
Top View of Merchandiser
Edge Fits Over Raceway
Tabs Fit in
Retainer Slots
Front Panel
Remove Screws
LEVELING
Merchandisers must be installed level
to ensure proper operation of the
refrigeration system and to ensure
proper drainage of defrost water.
When leveling merchandisers, use a
carpenter’s level as shown.
Metal leveling shims or wedges are
provided with each merchandiser for
use if needed.
NOTE: B
EGIN LINEUP LEVELING
FROM THE HIGHEST POINT OF THE
STORE FLOOR
.
Place shims under the rail and make
sure that they are positioned at a base
component (crossbar). This transfers
the weight directly from the loaded
case through to the floor. Placing shims
at other locations will cause uneven
distribution of weight leading to piping
leaks, as well as sagging or wracked
doors.
Reach-In
P/N 0387183_D 1-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A.
5-Door Island Shown
Bottom Front
Support
Skid/External Base
Electrical Wireway
Electrical Wireway
Shim
Here
NO SHIM
HERE
Approximately
Centered
Rear of Reach-in
Shim Here
Base
Component
Base Component
Shim Here
DOOR ADJUSTMENT
After leveling and joining the merchandisers,
adjust and level doors according to manufacturer’s
instructions shipped with each product. Factory
settings are lost due to vibration during shipment.
JOINING
Sectional construction means that two or more
merchandisers may be joined in line yielding one
long continuous display requiring only one pair
of ends. Joining kits and instructions are
shipped with each merchandiser.
To join like fixtures, a joining kit is required.
To join unlike fixtures, or like fixtures operating
at different temperatures, a 1
1
/
2 inch (38 mm)
partition kit is required. To join same
temperature fixtures on different defrost cycles,
a plexiglass partition kit is required.
A
LL JOINTS MUST BE AIR-TIGHT TO PREVENT
FORMATION OF ICE OR CONDENSATION
.
Refer to separate joining instruction shipped
with each case
INSTALLING SPLASHGUARD BRACKETS
1. Attach splashguard retainer and splashguard
retainer support to splashguard support bracket using two screws per bracket.
2. I
NSTALL SPLASHGUARD SUPPORT BRACKETS
BEFORE PIPING CASE. The leveling brackets
have a maximum extension of one (1) inch
(25 mm) for uneven floors.
DO NOT
PLACE SHIMS UNDER SPLASHGUARD
BRACKETS
.
1-4 INSTALLATION
P/N 0387183_D WWW
.HUSSMANN.COM
Splashguard
Retainer Support
Splashguard
Support Bracket
Screw
Splashguard Retainer
Bumper Retainer
Screw
Base Rail
INSTALLING BUMPERS
Offsetting the bumpers and top rails helps to
disguise the joint locations, giving the lineup a
smoother look.
Begin at the left end of the line-up. A starter
bumper is factory-installed with end kits. Insert
the internal joint trim, then add the full-length
bumper.
Align each bumper section with its retainer and
push into place, working from the end of the lineup. Install full length bumpers and internal joint
trims offset across joints. Make sure that no gaps
exist between sections. Continue installing
bumpers the length of the line up.
Do NOT install the last bumper sections at this
time. These sections will be installed in the last
step.
Once all except the last section of bumper have
been installed, refrigerate the case line-up for
at least six (6) hours. The last sections of
bumper should be kept inside a refrigerated
case or cooler during this time to allow the
bumpers to contract.
Before installing the last full-length section,
measure the remaining space. Use a miter box
and fine-tooth saw to cut last bumper to length.
Install the last section.
Reach-In
P/N 0387183_D 1-5
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A.
Merchandiser
Joint
Full Length
Bumpers
Starter
Bumper
Merchandiser
Joint
Internal Joint
Trims
Bumper
Miter Box
Remove protective film from bumpers once
installation is complete.
Optional end bumpers are factory-installed.
1-6 INSTALLATION
P/N 0387183_D WWW
.HUSSMANN.COM
Reach-In
REFRIGERANT
The correct type of refrigerant will be stamped on
each merchandiser’s serial plate which is located
on the left-hand end of the interior top liner.
REFRIGERANT PIPING
Connection Location
The refrigerant line connections are at the righthand end of the merchandiser (as viewed from
the front) beneath the display pans.
After connections have been made, seal this outlet thoroughly. Seal both the inside and the outside. We recommend using an expanding
polyurethane foam insulation.
Multiplexing
Piping of merchandisers operating on the same
refrigeration system may be run from merchandiser to merchandiser through the end frame
saddles provided for this purpose. D
O NOT
RUN
REFRIGERANT LINES THROUGH MERCHANDISERS
THAT ARE
NOT ON THE SAME REFRIGERATION
SYSTEM
as this may result in poor refrigeration
control and compressor failure.
NOTE: If Gas defrost is used, the liquid line
will need to be increased two sizes larger inside
the merchandiser area. This is necessary to ensure
even liquid drainage from all evaporators during
defrost.
Line Sizing
Refrigerant lines should be sized as shown on the
refrigeration legend that is furnished for the store
or according to ASHRAE guidelines.
Oil Traps
P-traps (oil traps) must be installed at the base of
all suction line vertical risers.
Pressure Drop
Pressure drop can rob the system of capacity. To
keep the pressure drop to a minimum, keep the
refrigerant line run as short as possible using a
minimum number of elbows. Where elbows are
required,
USE LONG RADIUS ELBOWS ONLY.
INSULATION
With GAS Defrost
The suction and liquid lines should NOT contact
each other and should be insulated separately
for a minimum of 30 ft (9144 mm) from the
merchandiser.
With OTHER Than Gas Defrost
The suction and liquid lines should be clamped or
taped together and insulated for a minimum of
30 ft (9144 mm) from the merchandiser.
With All Defrost
Additional insulation for the balance of the liquid
and suction lines is recommended wherever
condensation drippage is objectionable or the
lines are exposed to ambient conditions.
P/N 0387183_D 2-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A.
REFRIGERATION / ELECTRICAL
When brazing pipes be sure to use the
insulation blanket shipped with the
merchandiser to prevent damage to
the plastic case bottom.
Refrigeration lines are under pressure and
should be depressurized before attempting
to make any connections.
!
WARNING
CAUTION
!
BRANCH LINE PIPING
Suction Line – All Defrosts
• Pitch in direction of flow.
• May be reduced by one size at one third of case
run load and again after the second third. Do
NOT reduce below evaporator connection size.
• Suction returns from evaporators enter at the
top of the branch line.
Liquid Line – Off-time and Electric Defrost
• May be reduced by one size after one half the
case load run. Do not reduce below evaporator
connection size.
• Take-offs to evaporators exit the bottom of the
liquid line. Provide an expansion loop for each
evaporator take-off (minimum 3 in. (76 mm)
diameter).
Liquid Line – Koolgas Defrost
• Maximum of 6 evaporators per Branch System.
• Increase the liquid line size inside the case by
two sizes over the branch size.
Branch Size In Case Size
1
/2
7
/8
5
/8 11/8
7
/
8 1
3
/
8
11/81
5
/8
13/8 21/8
• Take-offs to evaporators exit the bottom of the
liquid line. Provide an expansion loop for each
evaporator take-off (minimum 3 in. (76 mm)
diameter).
2-2 REFRIGERATION / ELECTRICAL
P/N 0387183_D WWW
.HUSSMANN.COM
The following information is applicable only
for piping Hussmann merchandisers to
Hussmann refrigeration equipment.
CAUTION
!
Suction Line Return
3-In. Loop (76 mm)
Liquid Line Take Off
Koolgas Defrost Liquid Line Two Sizes Larger in Merchandiser
Electric or Offtime Defrost Liquid Line
From
Liquid
Manifold
To
Suction
Manifold
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