Zero Zone HYBRID Instruction manual

ZERO ZONE
HYBRID™MEDIUM & LOW TEMP
DISPLAY CASE
Installation, Operation & Maintenance Manual
Compliant with 2012 DOE Regulations
MN-01-H • MAR 2015

II
This manual is specic to the Zero Zone Hybrid™ display case.
For standard Zero Zone display case installation and operation, please refer
to the Zero Zone Medium & Low Temp Display Case Installation & Operation Manual.

III
Table of Contents
ZERO ZONE WARRANTY ............................................................................................................... IV
Limited Warranty .......................................................................................................................IV
Extended Warranties .................................................................................................................IV
Length of Extended Warranty ...................................................................................................IV
Product Not Manufactured By The Seller .................................................................................IV
Limitation and Exclusion of Warranties .....................................................................................IV
PLANNING ........................................................................................................................................ 1
DELIVERY ......................................................................................................................................... 2
Case Delivery Through 80" Door ................................................................................................ 2
SETTING THE CASE ........................................................................................................................ 3
Contents Shipped Inside of Case ............................................................................................... 3
Positioning Hat Channels............................................................................................................ 4
Dividers Between Cases............................................................................................................. 5
MECHANICAL .................................................................................................................................. 6
Once in Final Location ................................................................................................................ 6
Setting the Condensing Unit ....................................................................................................... 7
Quick Connect Fittings................................................................................................................ 8
Coupling Insulation ..................................................................................................................... 9
ELECTRICAL/CONTROL ............................................................................................................... 10
Electrical Connections .............................................................................................................. 10
Carel Controller Sensor Wires ...................................................................................................11
PLUMBING ..................................................................................................................................... 12
Case Drain Line to Floor Drain ................................................................................................ 12
TRIM OUT ....................................................................................................................................... 13
Installing Drain, Pump & Pan.................................................................................................... 13
ENCLOSED PUMP ......................................................................................................................... 15
CB121LSUL Pump with Brackets ............................................................................................. 15
TRIM OUT ....................................................................................................................................... 19
Setting the Condensate Evaporation Pan................................................................................. 19
Bumper & Kickplate .................................................................................................................. 20
Shroud Assembly...................................................................................................................... 21
OPERATION ................................................................................................................................... 22
Start-Up..................................................................................................................................... 22
Carel Controller Standard Features.......................................................................................... 22
Instructions for Setting the Time ............................................................................................... 22
Turning the Lights On & Off ...................................................................................................... 23
Automatic Hold-Open Doors..................................................................................................... 24
MAINTENANCE .............................................................................................................................. 25
Solid Shelf Installation & Removal............................................................................................ 25
Wire Shelf Installation & Removal............................................................................................. 26
Bottom Electrical Box Wire Colors (VZCH/VCCH Only) ........................................................... 27
Instructions for Condensate Removal Systems with Condensate Evaporation Pan................. 28
Refrigeration Cleaning & Maintenance ..................................................................................... 29
Preventative Maintenance - Condensing Units & Evaporator Coils.......................................... 29
Carel Controller Programming Instructions............................................................................... 30
Carel Controller Low Temp Codes ............................................................................................ 31
Carel Controller Medium Temp Codes...................................................................................... 32
Carel Controller Basic Operations ............................................................................................ 33
Silencing the Carel Temperature Alarm .................................................................................... 34
Conditions that Trigger the Carel Alarm.................................................................................... 35
Condensing Unit Pressure Switch Settings .............................................................................. 36
OPTIONS ........................................................................................................................................ 37
Sound Attenuation Kit & Balloon Guard.................................................................................... 37
End Close-Off ........................................................................................................................... 38
Fan Kit....................................................................................................................................... 38
Shroud Frame Assembly........................................................................................................... 39
Special Louvered Shroud Design ............................................................................................. 41
Optional Disconnect Installation................................................................................................ 46
MANAGER’S EMERGENCY GUIDE .............................................................................................. 47

IV • Zero Zone Warranty
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). The obligation under this warranty shall be limited to repairing or exchanging any part,
or parts, without charge, FOB Factory, and which is proven to the satisfaction of Zero Zone’s 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
such 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 Company will extend to the original purchaser, 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 it’s “Service and Installation” 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. In those instances on manufactured systems where factory installed “Zero Zone Oil Management Systems” are purchased the original
limited warranty shall be extended automatically to two (2) years total and purchased extended warranties shall be extended automatically for
a total of six (6) years from the date of factory shipment. 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 HEREIN ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND REMEDIES WHATSOEVER,
INCLUDING, BUT NOT LIMITED TO, IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE.
ZERO ZONE WARRANTY

Planning • 1
ENTRANCE & UNLOADING
What is the height of the entryway that the case(s) will need to go through?
Where will the case(s) be unloaded from the truck? Is there room for the case(s) to be unloaded from the truck?
CASE INSTALLATION & MOBILIZATION
Are you able to move the case(s) inside store to nal location?
The condensing unit will produce some noise. Has this been taken into account when identifying the nal location for these case(s)?
Have you considered the door opening/swing and aisle width?
HEAT REJECTION
Has the rejected heat from condensing unit(s) into store been considered?
Do you have adequate room around the case(s) for the condensing unit to be able to reject heat? There should be a 30" minimum
clearance between the top of shroud and the store ceiling.
Options/considerations if the clearance is less than the 30" minimum:
Add egg crates to the store ceiling panels
Add auxiliary fans to dissipate heat
Use louvered case shrouds
Use an alternate shroud height; Zero Zone Engineering must be contacted
ELECTRICAL
Is there suitable voltage?
Is the appropriate circuit breaker installed and available in the store power panel?
Do you want/need an electrical disconnect at the case(s)?
PLUMBING
Will you be using a oor drain? Can the proper slope to the drain be provided?
Will you be using a pump with the Condensate Evaporation Pan system? This setup will add humidity to the store.
SEISMIC RESTRAINTS
Does your permitting require there to be seismic restraints?
HIGH HUMIDITY
Do you need an auxiliary fan system to provide air movement along the back and underneath the case(s)?
Do you need louvered kickplates for air to be able to move underneath the case(s)?
PERMITTING
The case(s) should be permitted as remote equipment.
Always check with the local inspector to make sure your install follows all code requirements.
REMOTE MONITORING
Remote monitoring is an option that is available for the case(s).
PLANNING

2 • Delivery - Case Delivery Through 80" Door
DELIVERY
2 to 5-door cases are fork-liftable from either end of the case.
1-door cases are not fork-liftable through a standard doorway.
ATTENTION FORK TRUCK OPERATOR!
2-Door 24" Cases:
Forks must extend from 20" to no more than 24" under
the case from ends through bases.
2-Door 30" Or 3-Door 24" Standard Or Deep Cases:
Forks must extend from 26" to no more than 30" under
the case from ends through bases.
3-Door 30" Or 4-Door 24" Cases
Use 48" long forks!
Forks must extend from 39" to no more than 43" under
the case from ends through bases.
4 & 5-Door 30" Or 6-Door 24" Cases
Use 48" long forks!
Forks must extend from 44" to no more than 47" under
the case from ends through bases.
Note: Do not damage end of case with fork truck.
1. Remove bracket from back of case. 2. Pull quick connect lines away and down from case.
3. Reposition quick connect lines and reinstall bracket,
once through doorway.
Temperature
Probe Wires
Case Delivery Through 80" Door
Do not place (“leave, store, or hold”) case outdoors in direct sunlight or high ambient temperature.
OVERALL CASE DEPTH IS 40 1/8"

Setting the Case - Contents Shipped Inside of Case • 3
Pump and Pan Assembly
Condensate Evaporation Pan
Hat Channels with 1", 1.75" or 2.5" Bases
Contents Shipped Inside of Case
SETTING THE CASE

4 • Setting the Case - Positioning Hat Channels
SETTING THE CASE
Position hat channels with tape up.
For 3 and 4-door cases, (as shown above left), the center hat channel needs to be angled
to rest on front and back base. Do not locate under drain hub!
For 5-door cases (as shown above right) there are 4 hat channels - position as shown.
In most instances, cases will require leveling by the use of shims. Refer to Display Case
Installation & Operation Manual (Leveling Section).
Positioning Hat Channels

Setting the Case - Dividers Between Cases • 5
SETTING THE CASE
Dividers Between Cases
Clear plexi dividers separate refrigeration
circuits between same-temp cases.
Insulated dividers are provided between medium temp and low
temp cases in lineups. Both types of dividers are factory-installed
prior to shipping.

6 • Mechanical - Once in Final Location
MECHANICAL
If electrical box was removed for entry, put back into position.
2 to 5-Door Shown
Once in Final Location