Hussmann CW2U-138GE, CW2-BGE, CW2U-90XGE, CW2U-138XGE, CW2U-90GE Installation And Operation Manual

Shop Around
Medium T emperature
Dairy, Delicatessen and Produce
Merchandisers
Installation &
Operation Manual
Shipped With Case Data Sheets
P/N 428668A.
August, 2001
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KKeeeepp iinn ssttoorree ffoorr ffuuttuurree rreeffeerreennccee!!
®
Merchandisers
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
Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Joining Instructions . . . . . . . . . . . . . . . . . . 1-3
Install Splashguard Brackets . . . . . . . . . . . . 1-4
Offsetting Bumpers and Top Rail . . . . . . . . 1-5
Installing Partitions . . . . . . . . . . . . . . . . . . . 1-6
REFRIGERATION / ELECTRICAL
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Refrigerant Piping . . . . . . . . . . . . . . . . . . . 2-1
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Suction Line . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Liquid Line . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Refrigeration Thermostat . . . . . . . . . . . . . . 2-3
Defrost Termination Thermostat . . . . . . . . . 2-3
Defrost Sequences . . . . . . . . . . . . . . . . . . . 2-3
Merchandiser Electrical Data . . . . . . . . . . . 2-4
Electrical Connections . . . . . . . . . . . . . . . . 2-4
Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Identification of Wiring . . . . . . . . . . . . . . . 2-4
DRIP PIPING AND SPLASHGUARDS
Waste Outlet and Water Seal . . . . . . . . . . . . 3-1
Installing Drip Piping . . . . . . . . . . . . . . . . . 3-1
Installing Splashguards . . . . . . . . . . . . . . . . 3-3
Sealing Splashguard to Floor . . . . . . . . . . . 3-4
START UP / OPERATION
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Load Limits . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stocking . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Load Limit Profile . . . . . . . . . . . . . . . . . . . 4-2
Shelf Alignment . . . . . . . . . . . . . . . . . . . . . 4-2
Multideck Shelf Configuration . . . . . . . . . . 4-2
Installing Lighted Shelves . . . . . . . . . . . . . . 4-2
Installing FDA/NSF Required Thermometer 4-4
MAINTENANCE
Care and Cleaning . . . . . . . . . . . . . . . . . . . 5-1
Cleaning Mirrors . . . . . . . . . . . . . . . . . . . . 5-2
Cleaning Honeycomb Assemblies . . . . . . . . 5-3
Removing Interior Back Panels . . . . . . . . . . 5-3
Cleaning Under Merchandiser . . . . . . . . . . 5-4
Removing Scratches from Bumper . . . . . . . 5-4
SERVICE
Replacing Fan Motors and Blades . . . . . . . . 6-1
Replacing Fluorescent Lamps . . . . . . . . . . . 6-3
Replacing Lamp Holder and End Cap . . . . . 6-3
Replacing Electronic Ballasts . . . . . . . . . . . 6-4
Replacing Damaged Drain Fitting . . . . . . . . 6-5
Repairing Aluminum Coils . . . . . . . . . . . . . 6-6
WARRANTY
REVISION A
1. Added Caution box, page 2-4.
2. Revised lighted shelf installation, pages 4-2 through 4-4.
IMPORTANT
KEEP IN STORE FOR FUTURE REFERENCE
Quality that sets industry standards.
This merchandiser conforms to the
Commercial Refrigerator Manufacturers Association
Health and Sanitation Standard
CRS-S1-96.
12999 St. Charles Rock Road • Bridgeton, MO 63044 U.S.A. • (314) 291-2000 • FAX (314) 298-4767

TABLE OF CONTENTS

P/N 428668A
®
Medium T emperature
P/N 428668A 1-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

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.
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.
The exterior frames on these cases provide space for air circulation. However, in high ambient conditions, sweating may still occur. If this happens install a method of forced ventilation such as a fan ventilation kit.

Wide Island Fronts

BE SURE TO POSITION WIDE ISLAND MERCHANDISER
FRONTS PROPERLY
. The front of wide island merchandisers is readily identified by the location of the serial plate (see leveling drawing on next page). Since all electrical and refrigeration connections will be made at the front side, the fronts will need to be positioned according to the store plan layout.

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.

Concealed Loss Or Damage

When loss or damage is not apparent until after equipment is uncrated, retain all packing materials and submit a written request to the carrier for inspection, within 15 days.

INSTALLATION

Do not walk or put heavy objects on case.
CAUTION
!
1-2 INSTALLATION
P/N 428668A
EXTERIOR LOADING Do NOT walk on top of merchandisers or
damage to the merchandisers and serious personal injury could occur. THEY ARE NOT STRUCTURALLY
DESIGNED TO SUPPORT EXCESSIVE EXTERNAL LOADING such as the weight of a person. Do not
place heavy objects on the case.

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. THEREFORE, BE SURE TO REPLACE
THESE BOLTS WITH THE SHORTER BOLTS PROVIDED.
NOTE:
Be careful not to damage the factory installed end while moving the case.
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.

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. Leveling shims are provided with each merchandiser for use if needed. The shims are big enough so that you can level adjoining merchan­disers at the same time using one shim.
NOTES:
•B
EGIN LINEUP LEVELING FROM THE HIGHEST POINT OF
THE STORE FLOOR.
•If shimming two corners, check to see if a shim is needed in the center of the merchandiser. If a gap exists between the support rail of the merchandiser and the floor, a shim should be placed in the center.
Do NOT remove shipping braces until
the merchandisers are
positioned for installation.
NOTE: Do not place levels
on Display Pans or on Shelves.
!
WARNING
Levels
Rear
Serial Plate
Front of Merchandiser
Medium T emperature
P/N 428668A 1-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

JOINING INSTRUCTIONS

Sectional construction means that two or more merchandisers may be joined in line yielding one long continuous display requiring only one pair of ends.
ALL JOINTS MUST BE AIR
-
TIGHT TO PREVENT
FORMATION OF ICE OR CONDENSATION.

Prep Case

1. Check to be sure that merchandisers are level and that the factory-installed nut retainers and alignment pins are in place. Locate Joint Kit and check contents against parts list.
2. Remove shelves (if installed), display racks, pans, front shelf supports and front air grilles from the right end.
3. Remove the rear panel(s) from the right end. On multi-deck cases remove the lower back panel first. To remove a panel lift it up from its bottom edge and out. No tools are required.

Apply Gaskets

1. Insert donut gasket into the end frame horizontal recess across the bottom and up the front of one merchandiser as shown.
2. Apply the
1
/2 in. (13 mm) gasket around the
perimeter of case and across the top as shown. Be sure to overlap gaskets as sho wn. Check to be sure that there are no gaps between gasket and merchandiser.

Fasten Cases

1. Move the second merchandiser into position against the first. Match the alignment pins with the corresponding holes.
2. Fasten fronts together using cap screws, flat washers, lock washers and nuts. Tighten only until front panels touch. Do not tighten fully.
3. Use the cap screws, flat washers and lock washers provided in the joint kit to draw mer­chandisers together at rear. Do not tighten
fully.
4. Draw canopies of multi-deck wall merchandisers together by inserting threaded rod through top shoe as shown. Fasten each end with washers and nuts. Tighten only until canopies
touch.
5. Tighten joints in the order shown (A, B, C, D) until gaskets are compressed, and cases join smoothly.
Tighten in Order Shown
IMPORTANT
• Do not stretch gasket,
especially around corners.
• Do not butt gaskets;
always overlap them as shown.
• Remove paper backing
after gasket has been applied.
CW2G and CW2XG
D
A
C
B
C
1
/2 x1/2 in. Gasket
Donut Gasket
B
A
D
1-4 INSTALLATION
P/N 428668A

Seal Merchandisers

1. Apply Butyl Tape across the bottom joint. Be sure to extend the tape up the back and front of the case.
2. Use field-supplied silicone to fill any gaps between the front support brackets.

INSTALL SPLASHGUARD BRACKETS

The splashguard and brackets are shipped inside each case.
Install splashguard brackets before piping case.
Use two screws per bracket. Attach brackets every 4 feet at pre-drilled locations.
Install splashguard brackets on faceted end in locations shown.
After merchandisers have been leveled and joined, and all drip piping, electrical and refrigeration work has been completed, install the splashguards as described in Section 3.
Butyl Tape
Splashguard Bracket
Splashguard (for reference)
Two screws per bracket
Bracket at 4 ft interval
Front of CW2U-138
Medium T emperature
P/N 428668A 1-5
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)
Optional flat end: The flat end splashguard retain­er is installed last, as shown.

OFFSETTING BUMPERS AND TOP RAIL

Offsetting the bumpers and top rails helps to disguise the joint locations, giving the lineup a smoother look.
1. Do not remove factory-installed faceted bumpers or top rails on the CW2 family. Do not expose bumpers or top rails to excessive heat or direct sun as this may cause distortion of the material.
2. Remove full-length factory-installed top rails and bumpers from cases as follows:
a. To remove top rails, push rail toward the
back of the case with one hand while lift­ing the top edge with the other hand. A flat screwdriv er may be used carefully as a pry. (Refer to preceding drawing.)
b. Starting at one end, carefully peel bottom
of top rail free of the retainer and set the rail inside the case.
c. Remove bumpers by pulling bumper away
from bumper retainers.
There are no starter bumpers in the CW2 family. Full-length bumpers and top rails are installed without internal trim or fasteners.
3. Starting at the left end of the line up, install the first full-length bumper by pushing it into place, touching the faceted bumper. Make sure that no gaps exist between sections. Continue installing the bumpers the length of the line up. Do NOT install the last upper bumper section at this time. This section will be installed in the last step.
4. Return to the left end of the line up and posi­tion the top rail as shown on next page.
5. Push the bottom portion of the top rail section into the retainer. Use one hand to push the top rail toward the rear of the case while using the other hand to “snap” the top section down ov er the edge as shown.
Attach retainer
before attaching end

Optional Flat End

Splash-guard Attachment
1-6 INSTALLATION
P/N 428668A
6. Continue installing the top rails the length of the line up. Do NOT install last section at this time.
7. Once all except the last sections of the bumper and top rail have been installed refrigerate the case line up for at least six (6) hours. The last
sections of bumper and top rail should be kept inside a refrigerated case or cooler during this time. This will allow the bumpers
and top rails to contract.
8. Go to the right end of the line up and tap the top rail and bumpers to close any gaps.
9. Measure and cut last sections of top rail and bumpers. Use a miter box and fine-tooth saw to cut last bumpers and top rail to length. Install the last sections.
Note: If part of plastic top rail pops loose, remove that section of top rail and re-install according to Step 5. Trying to re-install only the popped part may not secure the top rail, and may damage the top rail, color panel and light channel.
10. Slide alignment strips between front glass sections at each joint.

CW2 End Case Only

Install the base plate as shown below when joining a CW2 end case to the lineup.

INSTALLING PARTITIONS

To join same temperature fixtures on different defrost cycles, an acrylic partition kit is required. To join unlike fixtures, or like fixtures operating at different temperatures, a 1
1
/
2 in. (38 mm) parti-
tion kit is required. Instructions for installing the partitions are included with the kit.
Bumper
End Case
Joint Base Plate
Miter Box
Medium T emperature
P/N 428668A 2-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

REFRIGERANT

The correct type of refrigerant will be stamped on each merchandiser’s serial plate. The case refrigeration piping is pressurized, leak tested and factory sealed. Before making refrigera­tion hookups, depress universal line valve to ensure that coils have maintained pressure during shipment.
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. A sticker marks the location of the connection “pod.” The installer must saw a hole through the pod to exit the case.
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. DO NOT RUN REFRIGERANT
LINES THROUGH MERCHANDISERS THAT ARE NOT ON THE SAME REFRIGERATION SYSTEM BRANCH as this may result in poor refrigeration
control and compressor failure.
Interconnecting piping inside the merchandiser must be located as shown below to allow room for lifting the hinged fan plenums and for clearance beneath the display pans. Or the interconnecting piping may be run outside the case in the raceway area shown.

Line Sizing

Refrigerant lines should be sized as shown on the refrigeration legend that is furnished for the store or according to ASHRAE guidelines. Refer to the information on the next page for branch line pip­ing of Hussmann Equipment.

Oil Traps

P-traps (oil traps) must be installed at the base of all suction line vertical risers.

REFRIGERATION / ELECTRICAL

Refrigeration lines are under pressure and should be depressurized before attempting
to make any connections.
!
WARNING
Piping Locations
Pan
Fan
Plenum
Pod
Front
Piping Locations
Piping Locations
Fan Plenum
Pan
Rear
2-2 REFRIGERATION
/ ELECTRICAL
P/N 428668A

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

The suction and liquid lines should be clamped or taped together and insulated for a minimum of 30 feet from the merchandiser. Additional insula­tion for the balance of the liquid and suction lines is recommended wherever condensation drippage is objectionable or lines are exposed to ambient conditions.

SUCTION LINE

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 the case suction line size.
Case suction lines should enter at the top of the branch line.

LIQUID LINE

May be reduced by one size after one half the case run load. Do not reduce below the case liquid line connection size.
Take-offs to case liquid lines should exit the bottom of the branch liquid line. Provide an expansion loop for each evapo­rator take-off. (Minimum 3 in. (76 mm) loop.)
Suction Line Return
Minimum Loop
3-in. (76 mm)
Liquid Line Take Off
8 Ft Case
(2438 mm)
12 Ft Case (3658 mm)

Offtime Defrost

8 Ft Case
(2438 mm)
12 Ft Case (3658 mm)
Liquid Line
Suction Line
Medium T emperature
P/N 428668A 2-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

REFRIGERATION THERMOSTAT

The bulb for the optional refrigeration thermostat is located in the discharge air of the evaporator. The optional refrigeration thermostat is located 5 ft (1524 mm) from the left-hand end, just past the raceway, on the serial plate side (front) of the merchandiser.

DEFROST TERMINATION THERMOSTAT

The standard disc type defrost termination thermostat is not adjustable. This thermostat is clamped to the suction line of the coil on the left-hand end of the serial plate side (front) of the merchandiser.

DEFROST SEQUENCES

These merchandisers require defrost cycles for proper operation. Refer to the data sheets for appli­cation data.
The Time Clock initiates defrost. The evaporator fans continue to circulate air across the evaporator coil, melting any frost build-up. Defrost can be terminated by either temperature or time.

Temperature Termination

Temperature termination should be used for the following types of installations:
1. Parallel systems with EPRs or suction stop solenoids
2. Single compressor units without pump-down cycle.

Time Termination

Should be used for the following types of instal­lations:
1. Parallel systems with thermostat and liquid solenoid.
2. Single compressor units with pump-down.
To use time termination, simply do not wire the termination thermostat.
6 ft
(1829 mm)
Rear
Standard Defrost
Termination Thermostat
Front
5 ft
(1524 mm)
Optional Refrigeration Thermostat
2-4 REFRIGERATION
/ ELECTRICAL
P/N 428668A

MERCHANDISER ELECTRICAL DATA

Merchandiser data sheets are included with this manual. The data sheets provide case electrical data, electrical schematics, parts lists and perfor­mance data. Refer to the merchandiser data sheets and case serial plate for electrical information.

ELECTRICAL CONNECTIONS

All wiring must be in compliance with NEC and local codes. All electrical connections are to be made in the electrical raceway or Handy Box.

FIELD WIRING

Field wiring must be sized for component amperes stamped on the serial plate. Actual ampere draw may be less than specified. Field wiring from the refrigeration control panel to the merchandisers is required for defrost termination thermostats and for optional refrigeration thermostats. When multiple merchandisers are on the same defrost circuit, the defrost termination thermostats are wired in series.
ALWAYS CHECK THE SERIAL PLATE FOR COMPO
-
NENT AMPERES.

IDENTIFICATION OF WIRING

Leads for all electrical circuits are identified by colored plastic bands. These bands correspond to the color code sticker (shown below) located inside the merchandiser’s raceway.

WIRING COLOR CODE

Leads for all electrical circuits are identified by a colored plastic band:neutral wire for each circuit has either White insulation or a White plastic sleeve in addition to the color band.
PINK ............REFRIG.THERMOSTAT LOW TEMP.ORANGE OR
L
IGHT BLUE..REFRIG.THERMOSTAT NORM TEMP.TAN..........LIGHTS
DARK BLUE ..DEFROST TERM.THERMOSTAT MAROON...RECEPTACLES
PURPLE........CONDENSATE HEATERS YELLOW....DEFROST HEATERS 120V
BROWN ........FAN MOTORS RED ........DEFROST HEATERS 208V
G
REEN* .......GROUND *EITHER COLORED SLEEVE OR COLORED INSULATION
ELECTRICIAN NOTE: Use copper conductor wire only.
CASE MUST BE GROUNDED
Optional T8 rail lights and
optional Quick Connect spray hose
or field-installed misting system
shall not be used together.
CAUTION
!
Medium T emperature
P/N 428668A 3-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

WASTE OUTLET AND WATER SEAL

The waste outlet is located in front of the fan plenum 6 ft (1829 mm) from the left-hand end of the merchandiser (facing case front). A water seal is supplied with each fixture. The water seal must be installed to the waste outlet to prevent air leak­age and insect entrance into the fixture.
NOTE: Water seal outlet must clear front skid rail.
A Tee, adapter, plug and street ell are also supplied with each merchandiser.

INSTALLING DRIP PIPING

Poorly or improperly installed drip pipes can seriously interfere with the merchandiser’s opera­tion and result in costly maintenance and product losses. Please follow the recommendations listed below when installing drip pipes to ensure proper installation.
1. Never use drip piping smaller than the nominal diameter of the pipe or water seal supplied with the merchandiser.
2. When connecting drip piping, the “water seal” must be used as part of the drip piping to prevent air leakage or insect entrance. Never use two water seals in series in any one drip pipe. DOUBLE WATER SEALS IN SERIES
WILL CAUSE AN AIR LOCK AND PREVENT DRAINING.
3. Pitch the drip piping in the direction of flow. There should be a minimum pitch of
1
/8in. per
ft (3 mm per 300 mm).
4. Avoid long runs of drip piping. Long runs make it impossible to provide the pitch necessary for good drainage.
5. Provide a suitable air break between flood rim of the floor drain and outlet of drip pipe. To meet code on low base merchandisers, it may be neces­sary to install a field-supplied drip pipe reducer. An alternative is to cut the last section of drip pipe at an angle.
6. Prevent drip pipes from freezing:
A. Do NOT install drip pipes in contact with uninsulated suction lines. Suction lines should be insulated with a nonabsorbent insulation material.
B. Where drip pipes are located in dead air spaces, such as between merchandisers or between a merchandiser and a store wall, provide means to prevent freezing.
Splashguard brackets MUST be installed
before piping case.

DRIP PIPING AND SPLASHGUARDS

CAUTION
!
Field Installed
Water Seal
Center of Case
Waste Outlet
Base Of Case
Front of Case
3-2 DRIP PIPING AND SPLASHGUARDS
P/N 428668A
See the case data sheet set for dimensions. Each waste outlet will be interconnected with factory installed drip piping. When unitized cases are joined, or an end case is to be joined to a lineup of CW2 models, the waste outlet can be inter­connected. A drain piping connect kit is required to change piping from front to back as shown.
Each merchandiser is supplied with a 2 in. (51mm) water seal, an adapter, a plug and a street ell. The street ell and water seal must be installed to prevent air leakage and insect entrance into the merchandiser. They should be installed as shown above.
Refrig. Outlet
Front
Access Area
Base
Front
Waste Outlet & Water Seal
Refrig. Outlet
Front
Medium T emperature
P/N 428668A 3-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

INSTALLING SPLASHGUARDS

The splashguards are shipped inside each case.
Install splashguard brackets before piping case.
After merchandisers have been leveled and joined, and all drip piping, electrical and refrigeration work has been completed, install the splashguards.
To Install splashguards:
1. Check to be sure that all splashguard brackets are level with the floor. Tighten screws.
2. Align splashguard so that slots in the top of splashguard match the tabs extending from the base of the case as shown.
3. Push splashguard up onto tabs until lower edge of splashguard swings onto bracket. Lo wer bot­tom of splashguard onto bracket tabs.
4. Install the front and back splashguards first. The left and right end angle splashguards have two pre-drilled flanges on each end. Use one screw to fasten each flange behind the front and back splashguards at pre-drilled holes.
5. Install end facet splashguard on brackets; use four screws in pre-drilled holes to fasten the end facet splashguard to the left and right end angle splashguards.
Optional flat end: The flat end splashguard is installed last, as shown.
1
2
Attach retainer
before attaching end
END SPLASHGUARD
ATTACHMENT
3-4 DRIP PIPING AND SPLASHGUARDS
P/N 428668A
SEALING SPLASHGUARD TO FLOOR IF REQUIRED by local sanitation codes, or if
desired by the customer, splashguards may be sealed to the floor using a vinyl cove base trim. The size of trim needed will depend on how much the floor is out of level.
To install the trim to the splashguard:
1. Remove all dirt, wax and grease from the area of the splashguard where adhesion will be nec­essary. This is to ensure a good and secure installation.
2. Apply a good contact cement to the cove trim and allow proper drying time according to the directions supplied with the cement.
3. Install the trim to the splashguard so that it is lying flush with the floor. D
O NOT SEAL THE
TRIM TO THE FLOOR.
4. If required by local health codes the Cove Trim may be sealed to the floor, using a sili­cone type sealer. Sealant must be removed and replaced when servicing.
Cove Trim
Cement
Splashguard
Medium T emperature
P/N 428668A 4-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

START UP

See the merchandiser's Data Sheet Set for refrigerant settings and defrost requirements. Bring merchandisers down to the operating temperatures listed on the data sheet.
Each four foot section has its own evaporator coil and pre-set non-adjustable thermostatic expansion valve (TEV). No adjustment is required. DONOT
REMOVE THE CAP ON THE
TEV
S. This cap is to be
removed only for valve disassembly. Removal of this cap during case maintenance will result in refrigerant loss unless the system is first isolated and the refrigerant recovered.
The TEV has been factory set to provide the recommended performance settings as specified on the merchandiser data sheets.

LOAD LIMITS

Each merchandiser has a load limit decal. Shelf life of perishables will be short if load limit is violated. A
T NO TIME SHOULD MERCHANDISERS BE
STOCKED BEYOND THE LOAD LIMITS INDICATED.
DO NOT BLOCK HONEYCOMB.

STOCKING

Hussmann recommends one or two shelves be used in each CW2 merchandiser section, and two or three shelves be used in each CW2X merchandiser section. Shelves for end compartments are single-position 180-degree shelves: either flat, or tilted. End compartments should not be used to display fresh-cut meat.
Product should NOT be placed in merchandisers until case is at proper operating temperature.
Proper rotation of product during stocking is necessary to prevent product loss. Always bring the oldest product to the front and set the newest to the back.
A
IR DISCHARGE AND RETURN FLUES MUST REMAIN
OPEN AND FREE OF OBSTRUCTION AT ALL TIMES to
provide proper refrigeration and air curtain perfor­mance. Do not allow product, packages, signs, etc. to block these grilles. Do not use non-approved shelving, baskets, display racks, or any accessory that could hamper air curtain performance.

START UP / OPERATION

REMOVAL OF THE TEV CAP WILL RESULT IN
REFRIGERANT LOSS UNLESS THE SYSTEM IS FIRST
ISOLATED AND THE REFRIGERANT RECOVERED
.
CAUTION
!
Glass Front
LOAD LIMIT
Return Air Path (keep clear)
Package Guard
4-2 START UP / OPERATION
P/N 428668A

LOAD LIMIT PROFILE

The illustration below shows the typical load limit area for the CW2 family of cases.

SHELF ALIGNMENT

Taped to one of the shelves of each merchandiser is a small plastic bag containing shelf alignment strips. These strips are designed to enhance the appearance of the shelves by aligning the front edge of each shelf with that of an adjacent shelf.
When installing shelves:
1. Insert one of the alignment strips into the slot behind the front edge of each shelf.
2. After all shelves are installed, slide the strip across the shelf joint wherever two shelves are adjacent. This will lock them together.

MULTI-DECK SHELF CONFIGURATION

The bottom display shelves can be adjusted to accommodate shallow or volume displays (bulky items such as hams or chickens). The upper shelves are individually mounted in 1 in. (25 mm) incre­ments and have two-position brackets permitting shelves to be placed in a flat or down-tilt position (see illustration). Front product stops are recom­mended when shelves are placed in the down-tilt position.
Faceted shelves in end compartments are NOT adjustable.
NOTE: Older Lighted Shelves with
Five-Prong Connectors Only
Be sure that either
a shelf plug or the “cap”
with jumper pins is plugged
into the socket in the back panel.
Otherwise the ballast will NOT be powered
and that entire horizontal row will not light.
Load Limit
Load Limit
Shelf A lignment Stri p
5
/8 x 6 in. —16 x 152 mm)
(
Medium T emperature
P/N 428668A 4-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)
PROCEDURE FOR INSTALLING LIGHTED
SHELVES WITH SINGLE-PRONG CONNECTOR
Shelf lighting uses parallel wiring. Please follow these instructions to ensure good contact between male and female connectors.
1. SHUT OFF POWER TO CASE. REMOVE
ALL SHELVES.
2. Engage each power socket cap and ensure that each cap is fully seated before cleaning.
Ensure the proper seating of the cap at all times when the plug is not engaged.
3. Clean the merchandiser as described in the
Care and Cleaning paragraphs of Section 5 – Maintenance. Keep liquid out of sockets.
4. Verify that power is at the case and turned on. Verify that the case light switch is turned “OFF.” Switch is located in the canopy, on the left, behind first row of lamps.
5. See the illustration below. It is typical of D5, C5, and D6 models. Note that other models will have fewer rows of shelves.
Starting from the left-hand bottom section, choose the location for the first shelf, X-1.
Secure the shelf in the slotted upright. Make certain that the shelf is level and that ends are in the same slot on the left and right upright. It
is important that shelf brackets be properly seated in the slotted upright.
Canopy Light Switch Location
R
I G H T
W
R O N G
9 Sockets in
6 Sockets in
8 ft (2438 mm) Case
X-8
X-7
X-5
X-4
X-2
X-1
12 ft (3658 mm) Case
X-9 X-6 X-3
Socket with Cap Installed
Always work Left to Right, and Bottom to Top
4-4 START UP / OPERATION
P/N 428668A
6. Remove the cap from the rear wall socket and insert the shelf plug in the socket. Secure cord under clip.
7. Working from left to right, install the next shelf, X-2, to the right of the first shelf you installed.
Always work from left to right and from the bottom up in each 8 ft (2438 mm) and 12 ft (3685 mm) case. After each shelf on the bottom row is in position, be sure to remove the cap and insert the shelf plug. Push firmly.
8. Turn “ON” the case light switch after the entire bottom row has been installed in either 8 or 12 ft (2438 or 3658 mm) cases. The shelf lights should light.
If a shelf lights do not operate, A. Turn off light switch. B. Make certain the shelf lamps are properly engaged in the shelf lamp holders. C. Remove and firmly re-insert each shelf plug. D. Turn on light switch.
If lights do not operate after checking the items listed above, contact the installation contrac-
tor.
9. Using the row of shelves just installed as support, set the next shelf, X-4, in the desired location. Remove the cap and insert the shelf plug. Continue working left to right installing shelves X-5 and X-6.
Note: Since the location for the remaining shelves, X-4 to X-15, may be directly over the rear wall receptacle, the shelf should be plugged in before engaging brackets in the uprights. The lower shelf will support the weight of the next shelf until it is plugged in. After installing each shelf, verify that its plug is properly connected to its rear wall receptacle. Continue working row by row, bottom up, left to right.
Important
If a shelf is plugged in and the lamp does not work,
verify:
A. the case light switch is “ON” and B. that the shelf lamp is properly engaged in the
shelf lamp holders.
INSTALLING FDA/NSF REQUIRED
THERMOMETER
The following pages provide the same information that ships with the thermometer.
This requirement does not apply to display refrigerators intended for b ulk produce (refer to
page 1-1).
Please note that the tape cannot be exposed after installation.
Push in clip
Medium T emperature
P/N 428668A 4-5
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)
This is an NSF-7 &
1999 FDA Food Code
Required
Thermometer
Thermometer — Hussmann P/N 430108
Double Stick Tape
— Inside End Panel
— Shelf Price T ag Molding
— Return Air Grille
Suggested Mounting Locations
in Multi-deck Merchandisers
Suggested Mounting Locations
in Single Deck Glass Front
Impact Merchandisers
Flexible Plastic Fits in Price Tag Moldings
— Acrylic Package Guard, Facing Out
4-6 START UP / OPERATION
P/N 428668A
Excerpt from ANSI / NSF-7:
5.30 Temperature indicating devices
5.30.1 Each refrigerated storage compartment and cabinet
shall have at least one securely mounted temperature indicat-
ing device that clearly displays the air temperature in the
compartment. A temperature indicating device shall not be
required in beverage coolers or units intended solely for the
storage and/or display of ice cream and other frozen deserts.
5.30.2 The temperature display of a temperature indicating
device shall be visible immediately upon opening a door to
the refrigerated compartment or shall be visible from the
equipment exterior without opening a door to the compart-
ment. The sensing element of the device shall be easily
cleanable and located to reflect the temperature in the
warmest part of the food storage compartment.
Open display refrigerators shall have a temperature indicating
device that is easily cleanable and located to reflect the
warmest part of the food storage compartment. Open display
refrigerators shall include a thermometer and installation
instructions for installing the thermometer in the warmest
part of the food storage compartment, as determined by the
manufacturer.
Excerpt from 1999 FDA Food Code:
4-204.112 Temperature Measuring Devices.
(A) In a mechanically refrigerated or hot
sensor of a
measure the air temperature in the warmest part of a mechan-
ically refrigerated unit and in the coolest part of a hot
storage unit.
(B) Except as specified in ¶(C) of this section, cold or hot
holding EQUIPMENT used for POTENTIALLY HAZARDOUS FOOD shall
be designed to include and shall be equipped with at least
one integral or permanently affixed
DEVICE
temperature display.
(C) Paragraph (B) of this section does not apply to EQUIPMENT
for which the placement of a TEMPERATURE MEASURING DEVICE is
not a practical means for measuring the ambient air surround-
ing the
EQUIPMENT, such as calrod units, heat lamps, cold plates,
bainmaries, steam tables, insulated
and salad bars.
TEMPERATURE MEASURING DEVICE shall be located to
that is located to allow easy viewing of the device’s
FOOD because of the design, type, and use of the
FOOD storage unit, the
FOOD
TEMPERATURE MEASURING
FOOD transport containers,
Important – Please read!
Each installation will be different depending on how the unit is stocked, shopping patterns in the department and ambient conditions of the store. The suggested loca­tions provided herein are possible locations. It is the responsibility of the purchaser / user to determine the location within the food storage area of the unit that best meets the code requirements above.
The thermometer may need to be moved several times to find the warmest location. Mounting options include flexible plastic for price tag molding application, magnet applied to back of flexible plastic for steel end wall, and double stick tape. Tape must not be exposed after installation.
Questions about either code should be addressed to local agencies or other appropriate officials.
Keep with merchandiser
or give to store manager — do not destroy.
Hussmann P/N 429971A 11/2000
Medium T emperature
P/N 428668A 5-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

CARE AND CLEANING

Long life and satisfactory performance of any equipment is dependent upon the care it receives. To ensure long life, proper sanitation and mini­mum maintenance costs, these merchandisers should be thoroughly cleaned, all debris removed and the interiors washed down, weekly.

Fan Plenum

To facilitate cleaning, the fan plenum is hinged. After cleaning be sure the plenum is properly lowered into position or product loss will result due to improper refrigeration.
Extra care must be taken when cleaning the CW2 end compartments as the left and right fan plenums are not hinged.

Removable Front Shelf Support

The front shelf support may be removed to facilitate cleaning. Simply lift out package guard. The front shelf support can then be lifted out as shown below.
After cleaning, replace front shelf support and acrylic package guard.

MAINTENANCE

ALWAYS SHUT POWER OFF
DURING CLEANING PROCESS.
Do NOT allow product to sit in a
non-refrigerated area.
Lift
!
WARNING
!
WARNING
Package Guard
Front Shelf Support
5-2 MAINTENANCE

Exterior Surfaces

The exterior surfaces must be cleaned with a mild detergent and warm water to protect and maintain their attractive finish. NEVER USE ABRASIVE
CLEANSERS OR SCOURING PADS.

Interior Surfaces

The interior surfaces may be cleaned with most domestic detergents, ammonia based cleaners and sanitizing solutions with no harm to the surface.
Do NOT Use:
• Abrasive cleansers and scouring pads, as these
will mar the finish.
• A hose on lighted shelves or submerge the
shelves in water.
• Solvent, oil or acidic based cleaners on any
interior surfaces.
Do:
• Remove the product and all loose debris to av oid
clogging the waste outlet.
• Store product in a refrigerated area such as a
cooler. Remove only as much product as can be taken to the cooler in a timely manner.
• First turn off refrigeration, then disconnect
electrical power.
• Rinse with hot water, but do NOT flood.
NEVER INTRODUCE WATER FASTER THAN THE
WASTE OUTLET CAN REMOVE IT.
• Allow merchandisers to dry before resuming operation.
• Wipe down lighted shelves with a damp sponge or cloth so that water does not enter the light channel. DO NOT USE A HOSE OR SUBMERGE
SHELVES IN WATER.
• After cleaning is completed, turn on power to the merchandiser.

CLEANING MIRRORS

Mirrors are sheets of clear glass that have very thin reflective and protective coatings applied to one side. These coatings are susceptible to deteri­oration if certain cleaning solutions and even water are allowed to come in contact with them. Every precaution should be taken to keep all liquids away from the coated side of the mirrors. IF LIQUIDS ARE ALLOWED TO FLOW ALONG THE FACE
SIDE OF THE MIRROR TO ITS EDGE, THE LIQUID CAN
SEEP UP BETWEEN THE COATING AND THE GLASS, CAUSING SERIOUS DAMAGE.
To Help Prolong the Life of the Mirrors:
• Use only mild glass cleaning products or a weak solution of vinegar and water.
• Thoroughly clean all surfaces with soap and hot
water. DO NOT USE STEAM OR HIGH WATER
PRESSURE HOSES TO WASH THE INTERIOR. THESE WILL DESTROY THE MERCHANDISERSSEALING CAUSING LEAKS AND POOR PERFORMANCE.
• Lift hinged fan plenum for cleaning. Hook chain in rear panel to secure plenum during cleaning. BE SURE TO REPOSITION THE FAN PLENUM AFTER
CLEANING MERCHANDISER.
• T ak e care to minimize direct contact between fan motors and cleaning or rinse water.
P/N 428668A
• Do NOT spray liquids on the mirrors. Dampen the cleaning cloth, then use the cloth to wipe the mirror.
• Wipe water from the mirrors immediately to prevent difficult to remove water spots and also to prevent the water from reaching the mirror’s edge.
• Never use dirty cloths, scrapers or any other abrasive materials for cleaning.
Medium T emperature
P/N 428668A 5-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)
CLEANING HONEYCOMB ASSEMBLIES
Honeycombs should be cleaned every six months. Dirty honeycombs will cause merchandisers to perform poorly. The honeycombs may be cleaned with a vacuum cleaner. Soap and water may be used if all water is removed from the honeycomb cells before replacing. Be careful not to damage the honeycombs.
1. Compress the honeycomb and remove it from its retainer.
2. Clean and dry the honeycomb.
3. After cleaning, replace in reverse order.

REMOVING INTERIOR BACK PANELS

The interior back panels may be removed for cleaning and to gain access to the evaporator coils. Remove the rear interior back panels as follows:
1. D
ISCONNECT THE ELECTRICAL POWER TO THE
MERCHANDISER.
2. Remove shelving.
3. Remove the honeycomb.
4. Grasp the top of the rear panel. Lift the panel up, then pull forward and out.
5. Replace parts in reverse order.
6. After cleaning or servicing the merchandiser, reconnect the electrical power.
ALWAYS SHUT POWER OFF
DURING CLEANING PROCESS.
Honeycomb
Interior
Back Panel
!
WARNING
5-4 MAINTENANCE

CLEANING UNDER MERCHANDISERS

Remove splashguards not sealed to floor. Use a vacuum with a long wand attachment to remove accumulated dust and debris from under the mer­chandiser.

REMOVING SCRATCHES FROM BUMPER

Most scratches and dings can be removed using the following procedure.
1. Use steel wool to smooth out the surface area of the bumper or top rail.
2. Clean area.
3. Apply vinyl or car wax and polish surface for a smooth glossy finish.
P/N 428668A
Medium T emperature
P/N 428668A 6-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

REPLACING FAN MOTORS AND BLADES

See cross section for location of evaporator fans. Should it ever be necessary to service or replace the fan motors or blades be certain that the fan blades are re-installed correctly. THE BLADES
MUST BE INSTALLED WITH RAISED EMBOSSING
(PART NUMBER ON PLASTIC BLADES
) POSITIONED
AS INDICATED ON THE PARTS LIST. (Refer to the
case data sheet for each model.)
For access to these fans:
1. Turn off power
2. Remove bottom display pans.
3. Disconnect fan from wiring harness.
4. Remove fan blade.
5. Lift fan plenum and remove screws holding bottom of motor to fan basket.
6. Replace fan motor and blade.
7. Lower fan plenum.
8. Reconnect fan to wiring harness.
9. Turn on power
10. V erify that motor is w orking and blade is turn­ing in the correct direction.
11. Ensure the plenum rests on the case bottom with no gaps.
12. Replace display pans, Bring merchandiser to operating temperature before restocking.

CW2 Unitized End

For access to these fans:
1. Turn off power
2. Remove bottom display pans.
3.Disconnect fan from wiring harness.
4.Lift off the rear shelf support.

SERVICE

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 fans, heaters, thermostats and lights.
Do NOT allow product to sit in a
non-refrigerated area.
!
WARNING
Hook to Back Panel
Remove Screws
Left Shelf Support
!
WARNING
6-2 SERVICE
P/N 428668A
Continuing REPLACING FAN MOTORS AND BLADES CW2 Unitized End
5.Remove screws from fan cover; remove cover.
6.Remove screws that hold fan bracket to plenum. Lift fan/motor/bracket assembly out of plenum.
7.Replace fan motor and blade.
8.Reassemble in reverse order.
9. Turn on power
10. V erify that motor is w orking and blade is turn­ing in the correct direction.
11. Close air gaps under fan plenum. Warmer air moving into refrigerated air reduces effective cooling. Use silicone sealant to close gaps.
12. Replace display pans, Bring merchandiser to operating temperature before restocking.
Shelf Support removed. Two screws used on side of cover in addition to six around base of cover (as shown on left side of end case).
Medium T emperature
P/N 428668A 6-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

REPLACING FLUORESCENT LAMPS

Fluorescent lamps are furnished with moisture resistant lamp holders, shields and end caps. Whenever a fluorescent lamp is replaced, be cer­tain to reinstall the lamp shields and end caps.
The switch in the canopy operates both the canopy and the shelf lamps. The rail lamp switch is locat­ed on the rail.

REPLACING LAMP HOLDERS AND END CAPS

The Hussmann Impact lamp holder is designed to snap into the sheet metal of the case. The lamp holder has a locking ‘nub’ which fits inside the groove of specially designed end caps.
IMPORTANT!
Always replace lamp holders and end caps with Hussmann lamp holders and end caps.
Use of non-Hussmann parts may result in poor electrical contact and short lamp life.
Groove
Nub
Hussmann Impact End-Cap
Hussmann Impact Lamp Holder
Plastic Shield
End Cap
Fluorescent Lamp
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 fans, heaters, thermostats and lights.
!
WARNING
6-4 SERVICE
P/N 428668A
REPLACING ELECTRONIC BALLASTS Canopy and Shelf Lamp Ballasts
These ballasts are located at the top of the merchandiser inside the canopy. The switch in the canopy operates both the canopy and the shelf lamps.
1. DISCONNECT POWER TO THE MERCHANDISER
.
2. Remove fluorescent lamps from the canopy.
3. Remove the screws that secure the light panel.
4. Grasping the light panel at the area where the panel and the canopy meet, pull back and down until the panel swings freely.
Note: Light panels in the end compartment are hinged at the front.
5. Replace ballast and reassemble parts in reverse order.
6. Reconnect the electrical power.
Light Channel
Ballasts
Canopy
Light Channel Retainer
Hinges
at
Front
Do NOT allow product to sit in a
non-refrigerated area.
!
WARNING
Canopy and Shelf Ballasts
Ballast Locations in End Canopy
Medium T emperature
P/N 428668A 6-5
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Printed in U.S.A.)

REPLACING DAMAGED DRAIN FITTING

The following procedure is for the field repair of a broken drain fitting.
1. Use a drill with a 1
7
/8-in. (48 mm) hole saw to
drill out the bottom of the drain fitting. Be sure to drill completely through fitting and bottom liner.
2. Apply teflon tape to threaded end of adapter and screw into threaded end of tee.
3. Apply an ABS and PVC compatible primer and sealer to adapter and inside of drain. Insert adapter into drain fitting.
Drain Fitting
Viewed from Inside Merchandiser
Foam Bottom Assembly
Modified Drain Fitting
PVC Adapter 1
1
/
2 x 1
1
/
4 inch
(38 x 32 mm)
(obtained at local building supply store)
Tee 11/4 in.
(32 mm)
TxSxS
End Section View
6-6 SERVICE
P/N 428668A

REP AIRING ALUMINUM COIL

The aluminum coils used in Hussmann merchan­disers may be easily repaired in the field. Materials are available from local refrigeration wholesalers.
Hussmann recommends the following solders and technique:

Solders

Aladdin Welding Products Inc.
P.O. Box 7188 1300 Burton St.
Grand Rapids, MI 49507 Phone: 1-800-645-3413 Fax: 1-800-645-3414
X-Ergon
1570 E. Northgate
P.O. Box 2102
Irving, TX 75062 Phone: 1-800-527-9916
NOTE: Hussmann Aluminum melts at 1125°F (607°C) Aladdin 3-in-1 rod at 732°F (389°C) X-Ergon Acid core at 455°F (235°C)

Technique

1. Locate Leak.
2. REMOVE ALL PRESSURE.
3. Brush area UNDER HEAT.
4. Use PRESTOLITE TORCH ONLY. NUMBER
6
TIP.
5. Maintain separate set of stainless steel brushes and USE ONLY ON ALUMINUM.
6. Tin surface around area.
7. Brush tinned surface UNDER HEAT, thoroughly filling the open pores around leak.
8. Repair leak. Let aluminum melt solder, NOT the torch.
9. Don’t repair for looks. Go for thickness.
10. Perform a leak check.
11. Wash with water.
12. Cover with a good flexible sealant.
®
To obtain additional information or other support,
contact your Hussmann representative.
Please include the model and serial number of the product.
The full product warranty is available from our website,
www.hussmann.com
Hussmann Corporation, Corporate Headquarters: Bridgeton, Missouri, U.S.A. 63044-2483 01 July 2005
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