Zero Zone CRYSTAL MERCHANDISER RVLC User manual
COMPLIANT
66-0025 REV G • JUN 2022
ZERO ZONE
CRYSTAL MERCHANDISER®FREEZERS
RVLC
With CoolView®Doors and ChillBrite®LED Lighting
INSTALLATION & OPERATION MANUAL
II
Table of Contents
ZERO ZONE WARRANTY......................................................................................1
INTRODUCTION.....................................................................................................2
INSTALLATION & OPERATION.............................................................................4
Delivery Inspection............................................................................................4
Packaging.........................................................................................................4
Location............................................................................................................4
Moving Cases...................................................................................................5
Optional Bases...........................................................................................5
Leveling.............................................................................................................6
LineupAssembly ............................................................................................11
Case Joint Caulking (Butyl*).....................................................................13
NSF Compliance Sealing (Silicone).........................................................14
Drain...............................................................................................................15
Condensate Removal System........................................................................15
Kickplates........................................................................................................15
Bumper...........................................................................................................15
Top Trim Splice ...............................................................................................16
CoolView®Doors.............................................................................................16
Anti-Sweat Reset Button..........................................................................16
Door Handles ..........................................................................................16
Hold-Open Bracket...................................................................................16
Door Gasket.............................................................................................16
Adjusting Door Sag/Sawtooth..................................................................16
TorqueAdjuster / Adjusting Door Tension.................................................16
Removing a Door.....................................................................................17
Installing a Door.......................................................................................17
Reversing Door Swing..............................................................................17
Shelves & Stocking Product............................................................................19
REFRIGERATION.................................................................................................20
Mechanical Components................................................................................20
Evaporator Coil.........................................................................................20
Evaporator Fans.......................................................................................20
Expansion Valve.......................................................................................20
Refrigerant Piping...........................................................................................20
Leak Check, Evacuation, & Charging.............................................................21
Operation Set Points.......................................................................................21
Defrost............................................................................................................22
Electric Defrost - Settings.........................................................................22
Electric Defrost - Components .................................................................23
Hot Gas Defrost - Settings.......................................................................24
Hot Gas Defrost - Components................................................................24
Air Sensors & Case Thermometers................................................................25
Anti-Sweat Heaters.........................................................................................25
ELECTRICAL........................................................................................................26
General...........................................................................................................26
Controller Sensor Wires..................................................................................26
MAINTENANCE....................................................................................................28
Air Curtain Velocity..........................................................................................28
Cleaning..........................................................................................................28
Under Case Floor Cleaning (NSF)...........................................................28
When installing a Crystal Merchandiser®in a Hybrid Merchandiser™ conguration, refer to both this manual
and the Hybrid™ Installation & Operation Manual.
Zero Zone Warranty • 1
ZERO ZONE WARRANTY
SYSTEMS DIVISION
6151 140thAve NW
Ramsey, MN 55303
Phone: 763-398-1996
Toll Free: 800-708-3735
CASE DIVISION
110 N Oakridge Drive
North Prairie, WI 53153
Phone: 262-392-6400
Toll Free: 800-247-4496
the responsive company™
DC-01-F • SEP 2019
Limited Warranty
Zero Zone, Inc. (Seller) hereby warrants that any products manufactured by it and sold are warranted to be free from defects in material and
workmanship, under normal use and service for its intended purpose, for a period of one (1) year from the date of original installation (not to
exceed 15 months from the date of factory shipment). Zero Zone ChillBrite®LED Lighting carries a 5-year parts warranty. Zero Zone CoolView®
Doors carry a 10-year glass pack parts warranty. The obligation under this warranty shall be limited to repairing or exchanging any part, or parts,
FOB Factory, which is proven to the satisfaction of the Zero Zone Service Department to be defective. Zero Zone reserves the right to inspect
the job site, installation, and reason for failure. This limited warranty does not cover labor, freight, or loss of food or product, including refrigerant
loss. This warranty does not apply to motors, switches, controls, lamps, driers, fuses, or other parts manufactured by others and purchased by
the Seller unless the manufacturer of these items warrants the same to the Seller, and then only to the extent of those manufacturer’s warranty
to the Seller.Any products sold on an “AS IS” basis shall not be covered by this warranty.
Extended Warranties
In addition to the standard limited warranty, for further consideration, the Seller will extend to the original purchaser prior to shipment, a limited
extended warranty on the compressor only, following expiration of the standard warranty. The Seller agrees to repair or exchange, at its option,
or provide reimbursement for such exchange as directed, less any credit allowed for return of the original compressor, of a compressor of
like or similar design and capacity, if it is shown to the satisfaction of Zero Zone that the compressor is inoperative due to defects in factory
workmanship or material under normal use and services as outlined by Zero Zone in its Installation & Operation Manuals and other instructions.
Length of Extended Warranty
Any compressor warranty may be extended for an additional four (4) years, but such extension must be purchased prior to shipment to be
effective.This warranty is only for the compressor and not for any other associated parts of the refrigeration system.
Product Not Manufactured by the Seller
The written warranty, if any, provided by the manufacturer of any part of the refrigeration unit sold by Seller to Buyer, but not manufactured by
Seller, is hereby assigned to the Buyer. However, Seller makes no representation or warranty regarding the existence, validity, or enforceability
of any such written warranty.
Limitation and Exclusion of Warranties
THE WARRANTIES SET FORTH HEREINARE EXCLUSIVEAND IN LIEU OFALLOTHER WARRANTIESAND REMEDIES WHATSOEVER,
INCLUDING, BUT NOTLIMITEDTO, IMPLIED WARRANTIES OF MERCHANTABILITYAND/OR FITNESS FORAPARTICULAR PURPOSE.
ZERO ZONE WARRANTY
2 • Introduction
INTRODUCTION
Important User Information
Copyright © 2022 Zero Zone, Inc.
All rights reserved. No part of the contents of this manual may be reproduced, copied, or transmitted in any form or by any means including
graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written
permission of the publisher, Zero Zone, unless it is for the purchaser’s personal use.
The information in this manual is subject to change without notice and does not represent a commitment on the part of Zero Zone. Zero Zone
does not assume any responsibility for any errors that may appear in this manual. In no event will Zero Zone be liable for technical or editorial
omissions made herein, nor for direct, indirect, special, incidental, or consequential damages resulting from the use or defect of this manual.
The information in this document is not intended to cover all possible conditions and situations that might occur. The end user must exercise
caution and common sense when installing, using, or maintaining Zero Zone products. Zero Zone products should only be installed by qualied,
professional refrigeration technicians. If any questions or problems arise, call Zero Zone at 800-247-4496.
Any change to a Zero Zone product made during the installation, start-up, or at any other time must be submitted in writing to Zero Zone for
approval and be approved by Zero Zone in writing prior to commission. The product warranty is voided when any unapproved change is made
to a Zero Zone product.
Manufacturer
Zero Zone, Inc.
110 N Oakridge Dr • North Prairie, WI 53153 • 800-247-4496 • www.zero-zone.com
Intended Use
Zero Zone products are intended to be installed and used as described in this manual and other related Zero Zone literature, specications,
drawings, and data.All Zero Zone products must be leveled after being installed.
Display Case Models
The information contained in this manual pertains to the following Zero Zone display cases:
CASE MODEL DESCRIPTION DOOR SIZE & TYPE
RVLC30 Standard Freezer 30" x 74" CoolView®Illusion™Doors
RVLC30BB Back-to-Back Freezer 30" x 74" CoolView®Illusion™Doors
RVLC30IM Ice Merchandiser 30" x 74" CoolView®Illusion™Doors
Case Features
Zero Zone produces high quality refrigerated display cases using state-of-the-art components. The cases are built with the thickest insulation in
the industry and a high efciency evaporator coil. Case features include:
Brushless DC electronic motors
Zero Zone ChillBrite®LED Lighting
Zero Zone CoolView®Illusion™Doors
Introduction • 3
INTRODUCTION
Testing Standards
These display cases were designed and tested using the following industry standards:
NSF 7 – Commercial Refrigerators and Freezers (ANSI Approved) (equipment certied by NSF)
NSF 51 – Food Equipment Materials (ANSI Approved) (equipment certied by NSF)
UL 471 – Commercial Refrigerators and Freezers (ANSI Approved) (equipment certied by ETL)
ASHRAE Standard 72 – Method of Testing Commercial Refrigerators and Freezers (ANSIApproved)
AHRI 1200 – Performance Rating of Commercial Refrigerated Display Merchandisers and Storage Cabinets (ANSIApproved)
DOE Compliant (All U.S. Sales and U.S. Territories)
ASHRAE Standard 72 species the test conditions for the equipment. It includes the ambient conditions of 75°F dry bulb and 55% RH. It also
species the door opening requirements for the performance test. Doors are opened six times in one hour for six seconds. The door opening
test period is for eight hours during one 24-hour performance test.As an example, a 5-door case will have 240 door openings during one 24-
hour test. Consult the factory if your store exceeds these test conditions.
4 • Installation & Operation
INSTALLATION & OpERATION
! CAUTION! DO NOT STAND ONTOP OFACRYSTALMERCHANDISER®. THE TOP OF THE CASE IS NOTDESIGNED TO
SUPPORTTHE WEIGHT OF APERSON.
Delivery Inspection
Zero Zone display cases are carefully factory-tested, inspected, and packed to ensure delivery in the best possible condition. The equipment
should be unwrapped and checked for damage immediately upon delivery. DAMAGE MUST BE NOTED AT TIME OF DELIVERY,AND ALL
CLAIMS FOR DAMAGES MUST BE FILED WITH THE TRANSPORTATION COMPANY, NOT WITH ZERO ZONE. The carrier will supply
necessary report and claim forms. Contact your Zero Zone sales representative or the service department to arrange for replacement parts.
Do not leave, store, or hold case outdoors in direct sunlight or high ambient temperature. With the end panels on, the case is airtight;
the inside temperature of the case will increase, and the heat will be unable to escape. This could potentially cause any plastic inside
the case to deform or warp.
Packaging
Each case in a lineup is labeled to identify the lineup and joint. The label uses a 2-digit number designation, separated by a decimal. The rst
number indicates the case lineup. The second number indicates the case joint. Case joints begin with the number “1” at the left most joint in the
lineup when looking at the front of the lineup. The rst case in the lineup will be labeled on the right end and the second case in the lineup will
be labeled on the left end. The numbers on each end to be joined will match, as indicated (See Figure 1). Back-to-Back cases have a side “A”
and a side “B”.
The rst case in a lineup (with the right side labeled “x.1”) has a packet attached to the shelving that contains touch-up paint. Every case in
a lineup has a packet attached to the shelving that contains important information about the case and/or lineup and, if applicable, special
instructions for installing ordered options.
Bumpers and kickplates are shipped on top of the case. Shelves for the case are tie-wrapped and blocked into the individual cases. Other
accessories like drain traps, drain pans, condensate evaporation pans, and hat channel rails are shipped in the case that require the parts.
Materials for joining cases—including caulk, joining bolts, splices, and end ller posts—are shipped in each case to be joined.
The door is prevented from opening during shipment with the use of a door-holding shipping bracket. The bracket is screwed to the top of the
case at each door and should be removed when the case is unpacked.
Location
These cases must not be installed in the direct rays of the sun or near a source of radiant heat. Be certain that the oor under the installation is
of sufcient strength to prevent sagging. Uneven surfaces will result in reduced performance.
Building softs must be set back at least 6" from the front of the case to allow access to electrical wiring on the top of the case.
INSTALLATION & OpERATION
Front of Back-to-Back Lineup
1.1B 1.1B 1.2B 1.2B
1.1A 1.1A 1.2A 1.2A
Front of Lineup
1.1 1.1 1.2 1.2
FIGURE 1: Case Label Information
Installation & Operation • 5
INSTALLATION & OpERATION
Cases should be set to allow a minimum 3" of space behind the back of the units. This will allow necessary air to circulate behind the
display cases and prevent condensation. Higher humidity stores with minimal air circulation require at least a 4" gap.Aminimum 2" gap is
recommended between cases on end-to-end installations.All minimum spacing requirements may increase if seismic restraints are used.
Moving Cases
Various tools and equipment may be used to move cases, including, but not limited to, a forklift, a Johnson bar, a pallet jack, furniture rollers,
casters, or a Rol-A-Lift. Be careful to avoid damaging the store ooring. Only certied forklift drivers should use forklifts to move the cases. The
case should only be lifted off the oor as high as necessary for transport. The forklift should be driven slowly; avoid abrupt motions or bumps.
Use the end frame to push/pull the case. For best results, push/pull lower on the end frame. Do not push/pull on the mullions as this
can cause the mullions to bend.
When using a Johnson bar, only contact the sheet metal of the bottom foamed panel. Do not contact the bumper support. Be careful
not to pierce the sheet metal with the corner of the Johnson bar.
When using a pallet jack or furniture rollers, only place them under the oor panels. Do not place them under the bumper support or
drain pipe as that will crush the components.
Cases have steel protective support plates under the end panels (not under insulated dividers) to protect them from Johnson bar damage.
Make sure that a forklift with the proper fork dimensions is available. Forks must be 48" long, 1 1/2" to 1 3/4" thick, and no more than 4"
wide to t the bases. Refer to the table below for instructions.
CASE MODELS INSTRUCTIONS
2RVLC30 Forks must extend 26" to 30" under the case from either end
3RVLC30 Forks must extend 39" to 43" under the case from either end
4RVLC30 Forks must extend 44" to 47" under the case from either end
5RVLC30 Forks must extend 44" to 47" under the case from either end
Back-to-Back cases are shipped with wood planks that allow the use of pipe rollers. These wood planks should be removed after the case is
moved to its nal location.
OPTIONAL BASES
For low shipping height applications, Zero Zone has optional expandable bases to accommodate up to 1 3/4" thick forks (See Figure 2). To use
a forklift on cases with expandable bases, raise the case with a Johnson bar and place wooden blocks under the case, allowing the base to
expand enough for forks to be inserted.
If a case needs to move through an 80" door opening, the case will be factory-installed with a 1" base or a 1 3/4" base and will be shipped on a
wooden pallet. Remove the case from the pallet to slide the case through the 80" doorway. The drain elbow will be shipped loose and must be
installed using extra thick PVC cement after the case is through the doorway. The base will be set into a nested base (See Figure 3).
FIGURE 2: Expandable Base FIGURE 3: Nested Base
6 • Installation & Operation
INSTALLATION & OpERATION
Spacer blocks are factory-installed in the end bases of 4 or 5-door cases that use bases taller than 3 1/2". These blocks limit the case's forward
tilt while it is being lifted by a forklift (See Figure 4).
Leveling
Cases should be set level from right to left to allow complete drainage of defrost and condensate water. Since a level oor area is seldom
available, the following steps will ensure a level installation. If your case uses seismic restraints, specic instructions for attaching seismic
restraints are included in your document package. Read and understand these instructions before assembling the lineup.
1. Measure off and mark on the oor the exact dimensions of the case lineup (See Figure 5). Refer to the xture plan or oor plan.
2. Snap a chalk line at the locations for the front and back positions of the bases.
3. Mark locations of all joints, both front and back.
4. Using a laser level or transit, nd the highest point along both base position lines. Using the high point as a reference, mark the difference
directly on the oor to each base, both front and back (See Figure 6).
5. If your case uses optional hat channel rails to raise the case height, place shims under the hat channel rails (See Figure 7 on page 7).
On 3 and 4-door cases, the center bases are not aligned, so the hat channel rails must be angled slightly to support the bases (See Figure
10 through Figure 11 starting on Page 8).
6. Place enough shims under each base or optional hat channel rail to equal the highest point. Shims should not extend beyond the front
case bases or they will interfere with installing trim. The shims should be oriented to sit under the front and rear bends of each base. Tape
all shims in place (See Figure 8 and Figure 9 on page 7).
FIGURE 4: Spacer Block
Spacer Block(s)
4 3/8" max. opening for
2 and 3-door cases.
3 3/8" max. opening for
4 and 5-door cases.
FIGURE 5: Measure and Mark Exact Case Outline FIGURE 6: Mark Floor Level Difference
Installation & Operation • 7
INSTALLATION & OpERATION
Hat Channel Rail
Hat Channel Rail
Shim
Shim
Shim
Base
Base
Base
Position hat channel rails with tape up. Place shims
perpendicularly under the hat channel rails.
2-door cases get 2 hat channel rails.
3 and 4-door cases get 3 hat channel rails.
Do not position under the drain hub.
5-door cases get 4 hat channel rails.
FIGURE 7: Hat Channel Rail Orientation
FIGURE 8: Tape Shims on the Floor Under Each Base or Hat Channel Rail
C
a
s
e
F
ro
nt
Case Fro
nt
Placement
Under Bases
Case Front
Case Front
Placement Under
Hat Channel Rails
FIGURE 9: Shims Under Bases (Without Hat Channel Rails)
Shims must be placed under the front
and rear bends of each base to prevent
the base from warping/buckling.
Case
Shims
Case
Shims
Both corners of the base
must be supported by shims
to prevent base buckling
DWG. NO. SP-6006-1 REV. A
Display Case
Shims Shims
Display Case
8 • Installation & Operation
INSTALLATION & OpERATION
FIGURE 10: RVLC30 Base Locations
2RVLC30
3RVLC30
4RVLC30
5RVLC30
Drawings are top views with bases shown under the case. The front of the case is toward the bottom of the page.
Case length does not include end panels (2 1/2" wide each).
Back of Case
Front of Case
Back of Case
Front of Case
Back of Case
Front of Case
Back of Case
Front of Case
Installation & Operation • 9
INSTALLATION & OpERATION
FIGURE 11: RVLC30BB (Back-to-Back) Base Locations
2RVLC30BB 3RVLC30BB
4RVLC30BB
5RVLC30BB
Drawings are top views with bases shown under the case.
Case length does not include end panels (2 1/2" wide each).
10 • Installation & Operation
INSTALLATION & OpERATION
7. To maintain even, consistent gaps and proper door operation, the case must be leveled front-to-back and side-to-side. Ensure that the
case is set square to within 1/8" (See Figure 12).After the case is set, use at least a 48" level to ensure the case is level.Add additional
shims as needed under specic bases.
8. Cases should be set with a slight backward tilt to offset the forward lean of a fully loaded case. We recommend an additional 3/8" of shims
be installed under the front bases after the case is leveled (See Figure 13).
FIGURE 13: Tilt Back
Add 3/8" of shims under front bases
for proper tilt back.
Approximate tilt back of empty case:
1" on standard depth case
7/8" on Deep case
FIGURE 12: Case Squareness
1. Measure squareness from top right corner of the case to the bottom left
corner of the case.
2. Measure again from the top left corner of the case to the bottom right
corner of the case.
3. Measurements should be equal. Difference should be no more than 1/8".
DR-271-A
Installation & Operation • 11
INSTALLATION & OpERATION
9. When joining a Crystal™freezer to a Crystal™cooler, both cases should be tilted back with an additional 3/16" of shims under the front
bases after the case is leveled. When joining multiple freezers and coolers in a lineup, the tilt back on the coolers should gradually increase
while working away from the cooler/freezer joint until the last case has an additional 3/8" of shims under the front base and the tilt back on
the freezers should gradually decrease to no additional shims while working away from the cooler/freezer joint (See Figure 14).
10. Place additional support shims under any bases or hat channel rails with gaps taller than one shim. Do not place shims between bases
and hat channel rails. Note: Total height of shims should be less than 3/4".
LineupAssembly
Zero Zone display cases have been designed for continuous display so that multiple cases may be joined together to create a lineup of any
desired length. The lineup will be ready for assembly after removing the packaging material.
Acase lineup must be properly aligned, which starts with properly leveling the case (See "Leveling" on page 6). It is crucial to use a laser
level to measure the high points in the oor and properly shim each base location.
FIGURE 14: Cooler to Freezer Leveling
Freezer Cooler
Multiple Freezers Multiple Coolers
Place shims under each base. Place shims under each base.
Place shims under each base. Place shims under each base.
12 • Installation & Operation
INSTALLATION & OpERATION
The bottom of the end panels are protected by steel support plates, which must be unbolted and removed before the lineup is set. There are
bolts that go up through the support plates into the underside of the foamed oor.
A1" wide trim piece seals the vertical gap between cases. It is shipped on the left end of a case with an open end. The next case in the lineup
will slide up to the trim piece so that the door seals against the trim piece. Remove the screws that held it during shipment, and use the provided
hardware to join the trim to the case using the top and bottom joining holes in the extrusion (See Figure 15).
Acase must be prepared with Butyl caulk before setting the next case in the lineup. Case caulking instructions and caulk are shipped with every
case (See Figure 16 on page 13).
Move the next case into position and bolt it to the rst case using the joining bolts that are provided. Begin tightening the bolts at the top rear,
working down the back of the case and up the front, making sure that the seams are ush. Do not pull cases together using joining bolts.
Alignment holes are located in the lower steel end frames. These are located 7" in from the joining holes.
The interior case seams must be sealed using silicone sealant for NSF compliance (See Figure 17 on page 14). Do not allow Butyl caulk
and silicone sealant to contact one another as this may affect adhesion or color of each.
An insulated divider is used to join 2 different case models or 2 different temperature cases.The divider is typically factory-installed to one of the
cases. There are 2 types of insulated dividers:
1. Between a Crystal™ freezer and a different case: The insulated divider has a panel on each side with nut inserts in the panels; each side is
bolted to the respective end frames. Do not pull cases together using joining bolts.
2. Between 2 Crystal™freezers: The insulated divider uses a thru-bolt design. The divider is attached to one of the cases using short bolts for
shipping. When the cases are installed, the short bolts are removed and longer joining bolts are installed to bolt the cases together. Do not
pull cases together using joining bolts.
Apply caulk between joints.Attach vertical joint trim using
the hex screws. Join cases using joint hardware.
SECTION F-F
ZERO ZONE WORKMANSHIP STANDARDS SHALL APPLY PER
ES-08-1007
ASME Y14.41-2012 & ASME Y14.5-2009 SHALL APPLY AS REQUIRED
ALL DIMENSIONS IN INCH UNLESS OTHERWISE SPECIFIED
SIGNIFICANT DIMENSIONS DENOTED BY
X.XX
OR
X.XXX
AND MUST MEET Cpk ≥ 1.33.
CRITICAL DIMENSIONS DENOTED BY
X.XX
OR
X.XXX
AND MUST MEET Cpk ≥ 1.66.
CAD DRAWING
NO MANUAL REVISIONS
COPYRIGHT INFORMATION
THIS DRAWING AND THE INFORMATION CONTAINED WITHIN,
IS THE SOLE PROPERTY OF ZERO ZONE, INC. ANY USE OF
THIS DOCUMENT OR DISCLOSURE OF ITS CONTENTS; BY
REPRODUCTION OR OTHER MEANS, WITHOUT THE WRITTEN
CONSENT OF ZERO ZONE, INC. IS STRICTLY PROHIBITED.
FINISH:
MATERIAL:
NOT TO SCALE
SCALE:
4/9/2020
01
1 OF 1
VLC manual assembly fig 13
SHEET:
DATE:
REVISION
ZERO ZONE, INC.
110 NORTH OAKRIDGE DRIVE
NORTH PRAIRIE, WISCONSIN
USA 53153
DRAWING No:
DESCRIPTION:
REVISION INFORMATION
01
4/15/2020
No.
REVISION DESCRIPTION
CO No.
DATE
BY
SHEET SIZE
D
TOLERANCES SHALL APPLY
UNLESS OTHERWISE SPECIFIED
.X = ± .1 .XX = ± .02
.XXX = ± .005 ANGLES = ± 1º
A A
B B
C C
D D
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
End brackets are factory installed.
Exploded for clarity.
Slotted Screw
& Washer
Washer
& Nut
Hex
Screw
Vertical Joint
Trim
SECTION F-F
ZERO ZONE WORKMANSHIP STANDARDS SHALL APPLY PER
ES-08-1007
ASME Y14.41-2012 & ASME Y14.5-2009 SHALL APPLY AS REQUIRED
ALL DIMENSIONS IN INCH UNLESS OTHERWISE SPECIFIED
SIGNIFICANT DIMENSIONS DENOTED BY
X.XX
OR
X.XXX
AND MUST MEET Cpk ≥ 1.33.
CRITICAL DIMENSIONS DENOTED BY
X.XX
OR
X.XXX
AND MUST MEET Cpk ≥ 1.66.
CAD DRAWING
NO MANUAL REVISIONS
COPYRIGHT INFORMATION
THIS DRAWING AND THE INFORMATION CONTAINED WITHIN,
IS THE SOLE PROPERTY OF ZERO ZONE, INC. ANY USE OF
THIS DOCUMENT OR DISCLOSURE OF ITS CONTENTS; BY
REPRODUCTION OR OTHER MEANS, WITHOUT THE WRITTEN
CONSENT OF ZERO ZONE, INC. IS STRICTLY PROHIBITED.
FINISH:
MATERIAL:
NOT TO SCALE
SCALE:
4/9/2020
01
1 OF 1
VLC manual assembly fig 13
SHEET:
DATE:
REVISION
ZERO ZONE, INC.
110 NORTH OAKRIDGE DRIVE
NORTH PRAIRIE, WISCONSIN
USA 53153
DRAWING No:
DESCRIPTION:
REVISION INFORMATION
01
4/15/2020
No.
REVISION DESCRIPTION
CO No.
DATE
BY
SHEET SIZE
D
TOLERANCES SHALL APPLY
UNLESS OTHERWISE SPECIFIED
.X = ± .1 .XX = ± .02
.XXX = ± .005 ANGLES = ± 1º
A A
B B
C C
D D
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
Door Door
Case Joint
End Mullion End Mullion
Vertical Joint Trim
Hex Screw
Washer & Nut Slotted Screw
& Washer
FIGURE 15: Vertical Joint Trim Installation
Installation & Operation • 13
INSTALLATION & OpERATION
Before joining the cases, remove all packaging material on the display case, including any spacer blocks inside the bases. Repeat
caulking between each case in the lineup.
Top View
Mullion
Mullion
CriticalArea:Apply caulk
to these mullion surfaces
Caulking
Back-to-Back
Cases
CriticalArea:
Caulk around
hole and opening
If present, remove
any tape or
weather stripping
from the case
45°
Apply caulk
across this
horizontal seam
FF
CriticalArea:Apply
caulk along center
of metal flanges
Apply caulk across
back panel seams
DR-296-B
*DO NOTAPPLY BUTYLCAULK ON SEAFOOD OR BAKERY CASES. Butyl caulk never cures and emits vapors that affect seafood and
bakery products. Recommended alternative caulk: Polyurethane-based (full curing, durable, moisture-activated) or silicone-based (full curing).
IT IS CRITICAL TO FOLLOW THIS PROCEDURE TO ENSURE CASESARE PROPERLY SEALED.
SURFACES TO BE CAULKED MUST BE CLEAN, DRY, FREE OF TAPE/ADHESIVE, AND FREE OF FROST (ABOVE 40ºF).
Note: Apply Butyl caulk to only one case—not both cases. The caulk will spread out when the cases are pushed together, and
excessive caulk may squeeze out of the joint. Wipe away any caulk that squeezes out. Butyl caulk will not mix with silicone sealant
(used for NSF sealing), which will affect adhesion of both.
1. Apply 3/8" thick beads of Butyl caulk* along the ceiling, rear wall, bottom of the case, and the mullion where indicated by the dashed lines
in the drawing. Caulk must be continuous with no gaps. Always apply 2 beads where specied. Caulk must be applied around a plexiglass
divider and not onto the divider itself, if applicable.
2. After cases are joined and tightened, caulk the top and back exterior seams, if accessible, to ensure a tight seal.
3. Back-to-Back (BB models) share the rear wall.Apply 2 beads of caulk along the shared rear wall as shown in DETAIL E.
4. See Figure 17 on page 14 for information about NSF compliance sealing with silicone sealant.
FIGURE 16: Case Joint Caulking (Butyl*)
14 • Installation & Operation
INSTALLATION & OpERATION
DR-297-A
THIS PROCEDURE MUST BE FOLLOWED FOR NSF COMPLIANCE.
SURFACES TO BE SEALED MUST BE CLEAN, DRY, FREE OF BUTYL CAULK, AND FREE OF FROST (ABOVE 40ºF).
Note: Cases must be properly caulked and joined before NSF sealing. Wipe away any Butyl caulk that squeezes out of the case joint.
Butyl caulk and silicone sealant will not mix, which affects the adhesion of both. See Figure 16 on page 13.
1. Apply silicone-based sealant in small, continuous beads where indicated by the dotted lines in the drawing. Do not thin or feather, as that
will affect adhesion.
2. Sealant must be added between cases at case joints, between a case and an end panel, and between all access holes and cut-outs in the
case end frame.
FIGURE 17: NSF Compliance Sealing (Silicone)
Installation & Operation • 15
INSTALLATION & OpERATION
Drain
The drain is located at the center of the case in the oor pan. The 1" PVC drain outlet
is located at the center front of the case behind the kickplate. To clean the drain, the
kickplate must be removed for access.
The drain line exits the case in the center. The lateral runs of drain pipe should be
installed through the bases (See Figure 18). There is no room in front of the base for the
drain pipe because the kickplate installs directly to the front of the bases.
Install the tee to the outlet pipe and a drain trap to the tee. Plug the open end of the tee
using the clean-out plug supplied with the drain trap kit. The drain line must be pitched
away from the case. The tee, drain trap, and plug are supplied with the case. The drain
trap must be level. The drain trap should be primed with water after installation.
The drain line must be pitched away from the case enough to ensure proper drainage. Consult your local codes for minimum requirements.
Cases with 1" bases are shipped on wooden skids or pallets. The forward drain section, tee, and “R” trap are shipped loose for eld installation.
Condensate Removal System
Zero Zone remote cases can be equipped with a condensate removal system. The system uses a drain pan with pump located behind the
kickplate and a condensate evaporation pan mounted on the top of the case.
Condensate water and any liquid spilled in the case will drain into the drain pan. The pump is equipped with a oat that turns the pump on when
there is a sufcient liquid level. Liquid is pumped through a plastic hose through a check valve and into the condensate evaporation pan. The
evaporation pan is equipped with a heater and a oat switch to turn on when the heater is
submerged in liquid. When the heater is energized, the evaporation pan will be extremely hot
and should not be touched. The pump and evaporation pan should be cleaned regularly.Any
spilled product, other than water, should be cleaned to prevent odors.
Kickplates
Each case is shipped with a front kickplate. Cases with end panels are shipped with 1 side
kickplate per end panel. Cases that join together are shipped with a kickplate splice.
1. Front and side kickplates are attached to the case bases using Tinnerman clips. Install
Tinnerman clip at each base (See Figure 19).
2. Position side kickplate.
3. Position front kickplate with ange on top and facing outward.
4. Insert screws through the front and side kickplates and into the Tinnerman clips.
There is a natural gap between the top of the kickplate and the underside of the Crystal
Merchandiser® that allows airow of 50 CFM per door. Contact the factory to order optional
louvered kickplates (provides 150 CFM per door) if additional airow is required.
Bumper
Cases are supplied with a 3" protective bumper shipped loose on top of each case. Each case
has its own bumper assembly, including end caps. The steel bumper support and snap track
are factory installed on the front of the case. The bumper may need trimming before snapping
it onto the snap track.
FIGURE 19: Kickplate Installation
Front Kickplate
Side Kickplate
Tinnerman ClipBase
FIGURE 18: Drain Installation
16 • Installation & Operation
INSTALLATION & OpERATION
Top Trim Splice
Top trim is factory installed, and it hides the door hardware located on the top exterior
of the case. Joint splices are shipped loose and must be eld installed at the upper
case joints (See Figure 20). Screw the top trim joint splice into the top trim.
CoolView®Doors
ANTI-SWEAT RESET BUTTON
The door anti-sweat circuit on CoolView®Illusion™doors is protected by a ground fault
interrupt (GFI) device. The reset button is located on the top of the display case near
the electrical box (See Figure 21).
DOOR HANDLES
CoolView®Illusion™doors use the CoolArc™door handle.The CoolArc™door handle is
attached to the glass surface of the door by an industrial-grade adhesive.
HOLD-OPEN BRACKET
CoolView®doors are self closing, and closing tension increases as the door opens
wider. The hold-open bracket keeps the door open when engaged, which is useful for
stocking shelves or case maintenance. To engage the hold-open bracket, open the
door to at least 90° until it clicks. Closing the door to about 80° will release tension on
the door, and it will self close again.
The hold-open bracket is located on the bottom of the door on Crystal™freezers
(See Figure 22).
DOOR GASKET
Each single-swing door has a full perimeter gasket mounted to the edge of the door.
ADJUSTING DOOR SAG/SAWTOOTH
Door sag/sawtooth is when the handle-side of the door is either higher or lower than the adjacent door. To x door sag on Crystal™freezers, the
torque adjuster must be moved by turning the sag adjustment screw.
1. Open the door to gain access to the sag adjustment screw on the bottom of the hinge side of the door (See Figure 22) .
2. Use a athead screwdriver to turn the sag adjustment screw. Do not use power tools; a screwdriver allows for more control.
3. To lower the handle side of the door, turn screw clockwise. The torque adjuster should move away from you as you turn the screw.
4. To raise the handle side of the door, turn screw counter-clockwise. The torque adjuster should move toward you as you turn the screw.
5. Turn the sag adjustment screw until the door is level with the adjacent door.
TORQUEADJUSTER /ADJUSTING DOOR TENSION
The torque adjuster automatically closes the door. It is located on the bottom of the hinge side of the door.The torque rod inside the door sets
into the torque adjuster, which transfers the closing tension to the torque rod. This means that the torque rod must be aligned with the torque
adjuster when installing a door.An adjustment screw on the front can be used to increase or decrease tension.
FIGURE 22: Hold-Open Bracket
SagAdjustment Screw
F
5.75
GRAIN DIRECTION
IF STAINLESS STEEL
.88
.88
FINISH SIDE REF
NOTE 1
.41
.63
4.50±.03
.188±.010
NOTES:
1. NOTED FACE AND ALL ADJACENT EDGES ARE TO BE FINISHED
PART INFORMATION
PART NUMBER
BASE METAL
FINISH
37-0437-P1
.032 ALUMINUM
BLACK
37-0437-P2
.032 ALUMINUM
WHITE COIL COAT
37-0437-P3
.032 ALUMINUM
PEARL COIL COAT
37-0437-P4
.032 ALUMINUM
SAVANNAH YELLOW COIL COAT
37-0437-P5
24 GA GALV
CHEM TREAT DRY
37-0437-P7
20 GA 204 STAINLESS STEEL
#4 BRUSHED
37-0437-P11
24 GA GALV
ANTIQUE COPPER TIGER DRYLAC
49/90620
37-0437-P16
24 GA GALV
TEXTURED WHITE
37-0437-P18
24 GA GALV
SILVER METALLIC
37-0437-P19
24 GA G60 GALV SEVILLE EMBOSSED
EMBOSSED WHITE
37-0437-P20
24 GA GALV
MATTE BLACK TIGER DRYLAC
009/80450
37-0437-P21
24 GA GALV
MEDIUM GRAY, TIGER DRY LAC
049/70785 IRON GLIMMER EFFECT
POWDER COATED
37-0437-P23
24 GA GALV
GOLDEN BROWN
37-0437-P24
24 GA GALV
SPANGLED SILVER, POWDER-COAT
37-0437-P32
24 GA GALV
TYGER DRYLAC 049/707/89 db FINE
TEXTURE GLIMMER
37-0437-P33
24 GA GALV
TYGER DRYLAC 09/60610 BEIGE
FULL HT GEN 2
ZERO ZONE WORKMANSHIP STANDARDS SHALL APPLY PER
ES-08-1007
ASME Y14.41-2012 & ASME Y14.5-2009 SHALL APPLY AS REQUIRED
ALL DIMENSIONS IN INCH UNLESS OTHERWISE SPECIFIED
RELEASED
SIGNIFICANT DIMENSIONS DENOTED BY
X.XX
OR
X.XXX
AND MUST MEET Cpk ≥ 1.33.
CRITICAL DIMENSIONS DENOTED BY
X.XX
OR
X.XXX
AND MUST MEET Cpk ≥ 1.66.
CAD DRAWING
NO MANUAL REVISIONS
COPYRIGHT INFORMATION
THIS DRAWING AND THE INFORMATION CONTAINED WITHIN,
IS THE SOLE PROPERTY OF ZERO ZONE, INC. ANY USE OF
THIS DOCUMENT OR DISCLOSURE OF ITS CONTENTS; BY
REPRODUCTION OR OTHER MEANS, WITHOUT THE WRITTEN
CONSENT OF ZERO ZONE, INC. IS STRICTLY PROHIBITED.
SEE CHART
SEE CHART
FINISH:
(PER SP-0154)
MATERIAL:
(PER SP-0404)
NOT TO SCALE
SCALE:
MODELED BY:
DRAWN BY:
9/1/2015
F
1 OF 1
37-0437
SPLICE TOP TRIM CRSTL/CRSTL
SHEET:
DATE:
REVISION
ZERO ZONE, INC.
110 NORTH OAKRIDGE DRIVE
NORTH PRAIRIE, WISCONSIN
USA 53153
DRAWING No:
DESCRIPTION:
REVISION INFORMATION
F
ADDED P32 AND P33
12552
12/29/2017
DB
No.
REVISION DESCRIPTION
ECN No.
DATE
BY
UPDATED DIMENSIONS WITH NEW TITLE BLOCK
Kurt Albrecht
SHEET SIZE
A
TOLERANCES SHALL APPLY
UNLESS OTHERWISE SPECIFIED
.X = ± .1 .XX = ± .02
.XXX = ± .005 ANGLES, ± 1º
FIGURE 20: Top Trim Splice
FIGURE 21: Anti-Sweat Reset Button
Installation & Operation • 17
INSTALLATION & OpERATION
1. Open the door to observe current door tension.Aproperly tensioned door
will close itself gently and not swing open.
2. Use a athead screwdriver to turn the door tension screw (See Figure 23).
Do not use power tools; a screwdriver allows for more control.
3. To increase tension, hold the door open 2 inches and turn the screw
counter-clockwise until the door begins to close. Once it closes, increase
tension by 2 more turns.
4. To decrease tension, turn the screw clockwise.
REMOVINGA DOOR
1. Remove the top case trim and electrical raceway cover that covers the door
hinges.
2. Turn the door tension screw clockwise until the door does not close on its
own (See Figure 23). This removes tension between the door and torque
adjuster so the door can be removed.
3. Disconnect the hold-open bracket from the bottom of the door (See Figure
22 on page 16).
4. Crack open the door and add a wedge, such as a screwdriver. Use a
needle-nose pliers to pinch the hinge pin while closing the door. This will
disconnect the door from the case (See Figure 24). Note: The door is
heavy. Be prepared to catch the weight of the door.
a. Alternative: Use a needle-nose pliers to pinch the hinge pin, and then
pull the top corner of the door away from the case. Note: The door is
heavy. Be prepared to catch the weight of the door.
5. Lift the door clear of the torque adjuster and set it down carefully. Note: For
safety, lift the door by the rails; do not lift by the handle.
INSTALLINGA DOOR
1. Lift the door and set it into the torque adjuster. Swivel the door back and forth until you can feel that the door has dropped into the torque
adjuster. Note: The door is heavy. For safety, lift the door by the rails; do not lift by the handle.
2. Carefully open the door until it is perpendicular to the case, align the hinge pin, and then push the top of the door so the hinge pin clicks
into place (See Figure 25). Note: Test whether the door is held securely by the hinge pin by pulling down on the door.
3. Attach the hold-open bracket between the bottom of the door and the bottom of the case (See Figure 22 on page 16).
4. Turn the door tension screw counter-clockwise until the door gently closes
itself (See Figure 23). Check for sag/sawtoothing.
REVERSING DOOR SWING
1. Remove the top case trim and electrical raceway cover that covers the door
hinges.
2. Remove the door from the display case. See "Removing a Door" on page
17 for a detailed description. Note: The door is heavy. For safety, lift
the door by the rails; do not lift by the handle.
3. Lift the door clear of the torque adjuster and lean it on its side, handle side
down. This makes it easier to access the wiring cover on the hinge side of
the door.
FIGURE 23: Door Tension Screw
FIGURE 24: Use a Wedge & Pinch Hinge Pin
Hinge Pin Screwdriver
as Wedge
FIGURE 25: Push Door & Hinge Pin into Place
18 • Installation & Operation
INSTALLATION & OpERATION
4. The wires to the hinge pin must be disconnected. Remove the wiring cover, disconnect the ground screw, and then pull the wires out of
the door (See Figure 26). Pry the hinge pin out from the top of the door and tug on it to identify which wires need to be disconnected (See
Figure 27). Disconnect the bullet connectors and pull the hinge pin out.
5. Pry the torque rod from the bottom of the door using a screwdriver (See Figure 28).
6. Remove the hold-open bracket from the door.
7. Reinstall the hinge pin, torque rod, and hold-open bracket on the opposite ends of the door. For the hinge pin, after feeding the wires
through the door and reconnecting them, it may be easiest to bundle the wires into 2 "ponytails" to t them inside the door (See Figure 26).
8. Move the hinge to the opposite side by swapping the hinge pin bracket and hinge cover (See Figure 29 and Figure 30).
a. Inside the electrical raceway, unplug the hinge pin from the wire harness. Use a 3/8" socket to remove the bolts that hold the hinge pin
bracket, set the bracket aside, and reinstall the bolts into the backer plates.
b. Remove the hinge pin cover and bolts on the opposite side of the door, and then install the new hinge pin bracket using those bolts.
c. Plug the wire harness into the new hinge pin. Tape the hinge pin cover on the opposite side.
9. Unlock the torque adjuster from the case by turning the locking screw that was under the torque rod by 1/16 turn (See Figure 31 on page
19). Remove the torque adjuster and save it to reuse on the opposite side.
10. Remove the torque adjuster bracket in order to remove the hold-open bolt (See Figure 31 on page 19). Reinstall the empty bracket and
add a plug into the hole left by the torque adjuster.
11. Remove the blank bracket on the opposite side of the door and replace with a new torque adjuster bracket (See Figure 32 on page 19).
Install the hold-open bolt, and then install the torque adjuster and lock it into place.
12. Install the reversed door. See "Installing a Door" on page 17 for a detailed description. Note: The door is heavy. For safety, lift the
door by the rails; do not lift by the handle.
FIGURE 27: Remove Hinge Pin FIGURE 28: Remove Torque Rod
FIGURE 29: Switch the Hinge to the Opposite Side FIGURE 30: Hinge Pin Bracket
Unplugged
from Wire
Harness
Install Hinge
Pin Bracket
Using Bolts
Hinge Pin
Cover Taped
in Place
FIGURE 26: Hinge Pin Wiring
Ground Wire
and Screw
Bundle wires into 2 "ponytails" to insert more easily.
This manual suits for next models
3
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