frost-trol GREGAL Manual

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Versión: 2
D008270
INSTALLATION AND MAINTENANCE MANUAL
GREGAL
SOLID LINES

INSTALLATION AND MAINTENANCE MANUAL
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GREGAL
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D008270 Versión: 2 -1-
Index
EEC DECLARATION OF CONFORMIT ................................................................ 3
SAFET ADVICE ............................................................................................. 4
1. GENERAL INFORMATION ................................................................... 7
1.1. DESCRIPTION OF REFRIGERATED DISPLA CABINET ............................ 8
1.2. GENERAL CHARACTERISTICS ............................................................. 8
1.3. SHOP CONDITIONS .......................................................................... 9
1.4. OPERATING THE COOLING S STEM .................................................... 9
1.5. RECEIPT OF REFRIGERATED CABINET ................................................. 9
1.6. DAMAGE SUSTAINED IN TRANSIT ...................................................... 9
1.7. TECHNICAL ASSISTANCE................................................................... 9
1.8. STORAGE .......................................................................................10
2. INTALLATION OF REFRIGERATED DISPLA CABINET ............................10
2.1. CABINET LOCATION .........................................................................10
2.2. UPACKING ......................................................................................11
2.3. LEVELLING .....................................................................................11
2.4. INSTALLATING THE DRAINAGE SISTEM ..............................................11
2.5. ASSEMBL ......................................................................................13
2.6. REFRIGERATING S STEM CONNECTION .............................................18
2.7. INSTALLATION’S DR ING .................................................................18
2.8. THERMOSTATIC VALVE CONTROL ......................................................18
2.9. ELECTRICAL CONNECTION ...............................................................19
2.10. DOORS INTALLATION ......................................................................20
2.11. CLEANING ......................................................................................20
3. OPERATION ....................................................................................21
3.1. INITIAL START-UP ...........................................................................21
3.2. PRODUCT LOADING .........................................................................21
4. MAINTENANCE AND CLEANING .........................................................22
4.1. GENERIC CLEANING ROUTINE ...........................................................23
4.2. INTERNAL CLEANING PROCEDURE .....................................................23
4.3. DOORS MAINTENANCE .....................................................................24
4.4. REPLACING LAMPS ..........................................................................24
5. SPARE PARTS REQUEST ...................................................................25
6. FAULTS AND REPAIRS ......................................................................26
6.1. MALFUNCTIONS ..............................................................................26
6.1.1. THE UNIT DOESN’T START UP OR IT STOPS: ......................................26
6.1.2. THE UNIT DOES NOT GET COLD ENOUGH: .........................................26

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D008270 Versión: 2 -2-
6.2. FINAL SHUTDOWN ...........................................................................28
6.3. DISMANTLING THE CABINET .............................................................28
6.4. DECLARTION OF ROHS CONFORMIT .................................................29

INSTALLATION AND MAINTENANCE MANUAL
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D008270 Versión: 2 -3-
EEC DECLARATION OF CONFORMITY

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SAFETY ADVICE
The maximum load for each shelf is 160kg/m2.
The refrigerated display cabinet must not be installed in places where
explosive gases are present. Do not expose the equipment to
atmospheric agents.
Packaging materials (plastic bags, nails, screws, polystyrene, etc.)
should not be left within reach of children as they pose potential
sources of danger.
Poor levelling could result in problems with the drainage of water
resulting from defrosting, which could cause the unit to break down.
It’s mandatory to leave 8cm between the cabinet rear wall and the
supermarket wall to ensure the airflow.
Keep clear of obstructions all ventilation openings of the cabinet
enclosure.
Don’t use metallic or cutting objects to accelerate the defrost process.
It may scratch or damage inner surfaces.
Gloves should be worn to protect hands when cleaning inside the
evaporator and the condenser. This will protect hands against possible
cuts or scratches from the unit’s internal elements.
Make sure that the drainage holes are not obstructed by any
remaining merchandise, as this could impede the drainage of excess
water resulting from defrosting.
Do not use any electrical appliances inside the storage compartments
for the food frozen by the equipment, unless recommended by the
manufacturer.
Do no damage the refrigerating circuit.

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Do not expose the equipment to atmospheric agents.
Do not store explosive substances such as aerosol cans with a
flammable propellant in the refrigerated cabinet.
Keeping pharmaceuticals, glass bottles or flasks in the cabinet is
strictly forbidden.
Only qualified personnel can remove panels or guards, and
specially the electric board cover, when this requires the use of
tools.
Before obtaining access to terminals, all supply circuits must be
disconnected.
Unplug the cabinet before performing any form on internal servicing of
the unit.
For the electrical connection it is mandatory to incorporate a switch
disconnector in accordance with installation regulation. This switch has
to be directly connected to supply terminals and has to be able to
provide full disconnection in all poles under overvoltage Category III
conditions.
The power cords must be properly spread out, safe from shocks and
far from liquids, water and heat sources, and in perfect condition. The
use of adaptor plugs is forbidden.
If the power cord is damaged, it must be replaced by the
manufacturer in order to avoid a hazard.
Earthing is mandatory according to current legislation, as is providing
protection against power surges, short circuits and indirect contacts.
Ensure that the power supply voltage meets the details on the rating
plate of the cabinet. The cabinet must be properly connected to the
earthing system.

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Do not use direct or indirect water jets on the cabinet. Do not touch
the equipment with damp or wet hands or feet; do not use it while
barefoot.
Parts that form the refrigeration circuit must not be cut or separated
until the refrigerant has been removed for recovery at a specialized
centre.
The components of the refrigerating circuit must not be cut or
separated.
WARNING: In appliances employin transcritical R744
refri eration system is under high pressure. Do not tamper with the
system. It must be serviced by qualified persons only. Contact
qualified service personal before disposal.
It is completely forbidden to perforate the cabinet. If this occur, it
could create irreparable damages.
If you wish to stick adhesive signs onto the cabinet, only use thin foil.
Do not lay thick insulating layers on the external walls of the
equipment as this could compromise cabinet performance.
In order to reduce flammability-related risks, this cabinet may only be
installed by suitably qualified personnel.
Product that you load into the cabinet must always be cooled to at
least the cabinet's conservation temperature. The cabinet is not able
to reduce the temperature of products, only conserve them.
Gloves should be worn during product loading operations.
Any other use not explicitly mentioned in this handbook must be
considered as hazardous. The manufacturer disclaims all liability for
damage resulting from improper, incorrect or unreasonable use.

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1. GENERAL INFORMATION
Welcome to the new series of remote refrigerated display cabinet modules from
Frost-Trol for the sale of perishable food products. We are delighted by your
decision to choose us.
This assembly and maintenance manual has been especially designed with a view
to assist maintenance staff by facilitating the installation of these cabinets, thus
making their task more pleasant, as well as to gain optimal productivity from these
units and also so that the Marketing Director is able to gain the maximum
commercial return possible.
Read this manual carefully and store it with the refri eration unit. Pay
particular attention to the sections that emphasize your safety. Follow these
instructions to ensure that the unit will run smoothly and its life span may be long
and productive.
We are open to any suggestions that you might have concerning the design of this
manual. Please write to the following address or call us on the telephone number
given below:
The A-weighted emission sound pressure level is below 70dB(A).
Frost-trol, S.A.
Technical Department
Avda. del Castell Vell, 176
12004 Castellón (Spain).
Tel.: [phone]
Fax: [phone]
e-mail: [e-mail]
www.frost-trol.com

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1.1. DESCRIPTION OF REFRIGERATED DISPLAY
CABINET
The refrigerated cabinets referred to in this manual belong to the Gregal Solid-
Lines 2020 product series from Frost-trol. They are vertical self-service multideck
refrigeration display cabinets with low front that have been designed specifically for
the sale of refrigerated products.
The new range of Solid Lines vertical multideck display cabinets is launched in the
market with a redesigned look and performance of all models. The star of the
range, the Gregal model, comes in the traditional heights of 2000 and 2200 mm.
The cabinet has a wide range of optional accessories. If you need details about its
assemblage, please contact with Frost-trol, S.A.
1.2. GENERAL CHARACTERISTICS
1662 [65 1/2"]
950 [37 3/8"]
2014 [79 1/4"]
2069 [81 1/2"]
992 [39 1/8"]
950 [37 3/8"]
225 kg/m²
605 [23 7/8"]
450 [17 3/4"]
450 [17 3/4"]
500 [19 5/8"]
160 kg/m²
1530 [60 1/4"]
HxL=1675 [66"]x614 [24 1/8"]
235 [9 1/4"]
205 [8"]
77 [3"]
MÓDULOS
1250 1875 2500 3750
HM0000206120BD20
1662 [65 1/2"]
950 [37 3/8"]
2014 [79 1/4"]
2069 [81 1/2"]
1688 [66 1/2"]
992 [39 1/8"]
950 [37 3/8"]
450 [17 3/4"]
450 [17 3/4"]
500 [19 5/8"]
160 kg/m²
225 kg/m²
192 [7 1/2"]
605 [23 7/8"]
80 [3 1/8"]
235 [9 1/4"]
HM0000206120ND20
MÓDULOS
1250 1875 2500 3750
INCREASE FOR EACH GA LE END +30
INCREASE FOR EACH INTERMEDIATE GA LE END +30
INCREASE FOR EACH INOX UMPER +42

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1.3. SHOP CONDITIONS
Frost-trol refrigerated display cabinets are designed to operate in air-conditioned
areas that maintain an air temperature of 25º C and a maximum relative humidity
of 60 % (climate class 3, in accordance with ISO EN 23953-2). The performance of
the refrigerated display cabinet is adversely affected when operated under air
temperatures and humidity conditions that are higher than those for which they
have been designed.
1.4. OPERATING THE COOLING SYSTEM
The condensing unit requires an air temperature of at least 20ºC and a maximum
of 30ºC for efficient ventilation of the condenser. The minimum temperature of the
condenser should never fall below 20ºC.
1.5. RECEIPT OF REFRIGERATED CABINET
Check the unit carefully to make sure that it is not damaged and no part or
accessory is missing. For information about missing parts or accessories please
contact the Frost-Trol Commercial Department or our official representative for
your country.
This refrigerated display cabinet has been thoroughly inspected to ensure the
highest level of quality. Any order for components should be made to Frost-Trol or
our official representative for your country within 48 hours of receipt of the
cabinet.
1.6. DAMAGE SUSTAINED IN TRANSIT
If the cabinet has sustained any damage in transit, then you must make a claim
with the Shipping Company immediately, by stating the damage on the delivery
note and having this signed by the carrier.
1.7. TECHNICAL ASSISTANCE
Should you have any technical queries concerning the installation of the
refrigerated display cabinet or cooling system, please contact our Technical
Department.
If you need to get in contact with Frost-Trol with regard to a specific element,
please make sure that you are able to quote the model and serial number. This
information can be found on the nameplate, which is located inside the refrigerated
display cabinet.

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1.8. STORAGE
Do not storage the cabinet outdoors; do not expose to climatic conditions or to
direct sunlight.
The cabinet with plastic cover may reach temperatures above 80° C in the sun,
which might result in the deformation of plastic parts.
Check the good condition of the packaging before storing the cabinet.
2. INTALLATION OF REFRIGERATED DISPLAY CABINET
The installation of the appliance and the refri erant unit must only be
made by the manufacturer’s service personnel or similarly skilled person.
2.1. CABINET LOCATION
Consult the Construction Manager or the person responsible for the installation of
unit. Ask them to inform you of its installation location or if there are any changes
to where it is to be installed.
Check that the installation location chosen is suitable. To do this, make sure that
there is no air flow present, as this could affect the units by blowing hot air into
them. The unit must not be installed near air conditioning air discharge openings,
ventilators, doors or other machines that, due to their location, could expel warm
air from their condensing units into the cabinet or onto its condensing unit.
The refrigerated display cabinet must not be installed in places where
explosive gases are present. Do not expose the equipment to
atmospheric agents.
If the chosen location is not suitable for the installation of the cabinet, inform the
Construction Manager or the person responsible for the supermarket accordingly,
so that they can either specify another location or make the necessary
modifications that would make the original location suitable (closure of air vents,
removal of ventilators, closure of doors, etc.).
During the installation (or while carrying out maintenance) you must always wear
proper safety equipment to preserve your security.

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It’s mandatory to leave 8cm between the cabinet rear wall and the
supermarket wall to ensure the airflow.
2.2. UPACKING
Unpackin is reserved for skilled personnel.
The refrigerated cabinet is protected by plastic wrapping. Remove this and take out
the accessories which can be found inside the cabinet:
Using a fork-lift truck or pallet-lift, lift the cabinet, remove the wooden or plastic
supports and replace them with the plastics bases that can be found inside the
cabinet with the other accessories.
Packaging materials (plastic bags, nails, screws, polystyrene, etc.)
should not be left within reach of children as they pose potential
sources of danger.
2.3. LEVELLING
Use the adjustable bases to level the unit. Poor levelling could result in problems
with the defrost-water drainage, which could then freeze and thus cause the unit to
break down.
Poor levelling could result in problems with the drainage of water
resulting from defrosting, which could cause the unit to break down.
IMPORTANT!
The surfaces that the lines are to be placed on may not be perfectly horizontal.
Therefore it would be best to first take the section of line that is to be placed onto
the highest part of the surface and screw its adjustable bases to their smallest
possible heights whilst allowing the section to remain horizontal. This will ensure
that the bases on the end sections do not need to be excessively extended.
2.4. INSTALLATING THE DRAINAGE SISTEM
An incorrect installation of the wastepipes system can interfere negatively in the
regular activities of the storekeeper and produces unnecessary costs of
maintenance and product damages.
The siphons should be installed as near to the unit's opening as possible. The tubes
should be secured so that the siphons do not have to support their entire weight.

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When doing so try to tilt them slightly and fit them with an appropriately sized
collecting tray as this will allow the water to be removed effectively.
REMEMBER!
-The siphons should be installed as near to the unit's opening as possible.
-Do not use drip piping with nominal diameter less than the pipe provided in
the cabinet.
-Place siphons to prevent bad smells.
-Place the drip piping in the flow direction.
-The tubes should be secured so that the siphons do not have to support
their entire weight.
-Connect the drip pipes to an adequate manifold to allow a correct dripping.
-Protect the drip piping system against freezing as needed.
-Do not install drip piping in contact with not insulated suction lines.
-Avoid installing excessive pipe length.

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2.5. ASSEMBLY
When assembling lines that consist of more than one unit, the units should be
assembled in the correct order, i.e. their positions correspond with the numbers
indicated on the side of each unit (e.g. 4 in position 4, 3 in position 3.).
When the units' final positions have been determined, you may proceed to fit them
together, either manually or mechanically be careful to ensure that no pressure is
exerted on fragile components, such as glass, insulation glass or other weak
components.
When welding the refrigeration tubes, take particular care to protect the parts of
the unit that could be damaged by the heat produced from the welding.
All tube and cable fittings should be sealed from the outside to ensure that they
remain completely waterproof.
Tools and materials needed:

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CODE
COMPONENT
QTY
APLICATION
UARA000701
WASHER M
-
8
DIN.9021 GALV.
12
_
UARA000710
WASHER M
-
10 DIN.9021 GALV.
6
_
UEXT000103
UMPER ALIGNER REF.3000387000
1
_
UHER000223
RI ED CLIP
. REF495218
2
UPPER FRINGE
UTAL000835
ALLEN SCREW DIN 912 8x35 GALV.
2
TOP
UTAL000880
ALLEN SCREW DIN 912 8x80
GALV.
2
ASE
UTAL008101
ALLEN SCREW DIN 912 8x100 GALV..
2
REAR
UTUE000800
NUT M
-
8 GALV. DIN.934 S
6
_
UVAR000200
ASSEM LY STEEL DIPSTICK 4x70
3
PRICE HOLDER &
HONEY COM
XAUX170184
PROFILE H
UTAU014998
SCREW TAE 4,2x13 NEGRO
On the following pages are instructions for joining two units together, with pictures
to help.
1Place the cabinets in its correct location in the supermarket. Pick up the
cabinet as showed in Fig.1 Lift the unit and remove the covers or wooden
bases on the adjustable bases of the cabinet (Fig.1). Before putting down
the cabinet on the ground, screw on the adjustable bases. Screw them on
fully so as to allow better adjustment later.
Figura 1
2Level the two cases length and wide sides. If necessary, use a wooden
wedge to facilitate the adjustable bases regulation.

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3Level the second module against the first. If necessary, use a wooden
wedge to facilitate the adjustable bases regulation.
Figura 2
4Remove base decks and assembly covers nearest to the cabinet end
(Fig.5).
5For cabinets without doors (ND): Insert steel dipstick inside the
priceholder. Make sure that all the striated surface has been introduced
inside the bumper. If the cabinet has inox bumper, fit them using the
bumper aligner.
6Joint cabinets together nesting the cabinet aligner from one in the holders
placed on the framework of other one.
7Bring the cases close to each other by using a tightening clamp.
Tightening clamps are to be placed on the cabinet framework.
8Put and screw the assembly screw and joining one framework with the
other.Use 2 washes and 1 nut for each assembly screw.
9Remove tightening clamps.
10 Verify correct alignment of the upper fringes. If necessary, loosen the
adjusting screw and realign.
11 Put back covers, base decks and plinth panels back on the cabinet.
12 Mount front and side plinth panels. Screw them on the cabinet legs.

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2
1
3
4
5
6
ND BD
5
7
1
3
2
4
5
6

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PLINTH
PANNELS
UPPER FRINGE
ADJUSTMENT

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2.6. REFRIGERATING SYSTEM CONNECTION
The refrigerated display cabinet described in this manual does not include a
condensing unit, but is provided with the necessary connections to be connected to
the existing cooling circuit.
It is the responsibility of the installer to establish a cooling system that is capable
of providing the cooling capacity demanded by the cabinet taking into account both
the size of the case and the distance to the cooling system.
2.7. INSTALLATION’S DRYING
The evaporators are pressurised with N
2
at 20±0,5 bar. Check this
value before depressurising.
If this is not the case then do not actuate the cabinet and contact the
Frost-Trol technical department within 72 hours.
The refrigerated cabinet must be dehydrated in avacuum and at the unit's normal
operating pressure.
Poor dehydration causes breakages of the evaporator's
solder joints at the bends, because the humidity at different
points in the refrigeration cycle condenses into micro drops
of H
2
O which then get deposited and accumulate in the
solder joint cracks on the low pressure side. When the H
2
O
changes state into a solid, this causes a protuberance on
the outside of the copper piping that will eventually break,
causing a leak.
Before turning on the installation, check meticulously the circuit’s sealing verifying
the screw’s tighten of the thermostatic expansion’s valve and the Schrader valve.
2.8. THERMOSTATIC VALVE CONTROL
In order to obtain maximum evaporator efficiency, the expansion valves should be
adjusted to have a reheating value of 3 to 6 degrees.
When viewed from the front, the expansion valve is situated on the far left of the
unit.To ascertain the reheating value measure the evaporation pressure on the
Schrader valve, which is located on the unit. Read the pressure on the pressure
gauge, which also displays the temperature, Te, that corresponds to the
evaporation pressure.
Measure the exact aspiration line temperature using the thermocouple in front of
the thermostatic expansion valve bulb. This will ensure that you obtain the
temperature of the evaporator's exit, Tse. The difference between the two
temperatures is the reheating value, Tr, in the evaporator:
Tse-Te=Tr
To adjust the reheating remove the cap from the thermostatic expansion valve
reheating screw and turn it anti-clockwise to lower the reheating, or clockwise to
increase the reheating.