Hussmann CW2U-138GE User manual

Shop Around
Medium Temperature
Dairy, Delicatessen and Produce
Merchandisers
Installation &
Operation Manual
Shipped With Case Data Sheets
P/N 428668A.
Impact Series
August, 2001
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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. • [phone] • FAX [phone]
TABLE OF CONTENTS
P/N 428668A
®

Medium Temperature
P/N 428668A 1-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Print d 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 tempera-
ture 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 sun-
light, 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 merchan-
disers 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 merchan-
disers at the same time using one shim.
NOTES:
•BEGIN 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.
WARNING
!
Rear
Levels
Front of Merchandiser
Serial Plate
NOTE: Do not place levels
on Display Pans or
on Shelves.

Medium Temperature
P/N 428668A 1-3
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Print d 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 1/2in. (13 mm) gasket around the
perimeter of case and across the top as shown.
Be sure to overlap gaskets as shown. 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 mer-
chandisers 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.
1/2 x1/2in. Gasket
Donut Gasket
CW2G and
CW2XG
AA
D
C
B
B
C
D
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.

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)
Front of CW2U-138
Two
screws
per
bracket Bracket
at 4 ft
interval

Medium Temperature
P/N 428668A 1-5
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Print d in U.S.A.)
Optional flat end: The flat end splashguard retain-
er 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 lift-
ing the top edge with the other hand. A flat
screwdriver 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 posi-
tion 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 over
the edge as shown.
Optional Flat End
Splash-guard Attachment
Attach retainer
before attaching end

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 11/2in. (38 mm) parti-
tion kit is required. Instructions for installing the
partitions are included with the kit.
Miter Box
Bumper
Joint Base Plate
End Case

Medium Temperature
P/N 428668A 2-1
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 (Print d 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 refrigera-
tion 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 right-
hand 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 merchandis-
er 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 pip-
ing 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
!
Pan
Piping Locations
Fan
Plenum
Fan
Plenum
Pan
Front Rear
Pod
Piping Locations
Piping Locations

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 insula-
tion 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 evapo-
rator take-off.
(Minimum 3 in.
(76 mm) loop.)
Suction Line Return
Minimum Loop
3-in. (76 mm)
Liquid Line Take Off
Offtime Defrost
Liquid Line
Suction Line
8 Ft Case
(2438 mm) 12 Ft Case (3658 mm) 8 Ft Case (2438 mm) 12 Ft Case (3658 mm)