Zero Zone Reveal Merchandiser ORMC82 User manual
ZERO ZONE
REVEAL MERCHANDISER®
OPEN MULTI-DECKS
With ChillBrite®LED Lighting
INSTALLATION & OPERATION MANUAL
COMPLIANT
66-0057 REV E •AUG 2021
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 ..............................................................................................8
Canopy Splice.................................................................................................10
Hand Rail Splice.............................................................................................10
Alternate Bumper Splice & Glass Front Splice...............................................11
Drain...............................................................................................................11
Kickplates........................................................................................................12
Bumper...........................................................................................................12
Mirrors.............................................................................................................13
Night Curtains.................................................................................................14
Under Shelf Lights..........................................................................................14
Canopy Lights.................................................................................................15
Shelves & Stocking Product............................................................................15
REFRIGERATION.................................................................................................16
Mechanical Components................................................................................16
Evaporator Coil & Expansion Valve..........................................................16
Evaporator Fans.......................................................................................16
Refrigerant Piping...........................................................................................16
Operation Set Points.......................................................................................18
Off-Cycle Defrost............................................................................................18
Case Thermometer.........................................................................................18
ELECTRICAL........................................................................................................19
General...........................................................................................................19
MAINTENANCE....................................................................................................20
Cleaning..........................................................................................................20
Under Case Floor Cleaning (NSF)...........................................................20
When installing a Reveal Merchandiser®in a Hybrid Merchandiser™ conguration, refer to both
this manual and the Hybrid Merchandiser™ 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 OFALL OTHER WARRANTIESAND REMEDIES WHATSOEVER,
INCLUDING, BUT NOTLIMITED TO, IMPLIED WARRANTIES OF MERCHANTABILITYAND/OR FITNESS FORAPARTICULAR PURPOSE.
ZERO ZONE WARRANTY
2 • Introduction
Important User Information
Copyright © 2021 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.
Display Case Division
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 SILL HEIGHTS
ORMC82 82" Standard Multi-Deck (5-Deck) Low (L), Medium (M), or High (H) Sills
ORMC87 87" Tall Multi-Deck (6-Deck) Low (L), Medium (M), or High (H) Sills
ORMC75-MX 75" Meat Exclusive Multi-Deck (4-Deck) Low (L) or Medium (M) Sills
ORMC80-MX 80" Meat Exclusive Multi-Deck (4-Deck) Low (L) or Medium (M) Sills
ORMC80-PX 80" Produce Exclusive Multi-Deck (3-Deck) Low (L) or Medium (M) Sills
ORMC82-PX 82" Produce Exclusive Multi-Deck (3-Deck) Low (L) or Medium (M) Sills
INTRODUCTION
Reveal Merchandiser®is a registered trademark of Zero Zone, Inc. in the United States.
Introduction • 3
INTRODUCTION
Case Features
Zero Zone produces high quality refrigerated display cases using state-of-the-art components, including a high efciency evaporator coil. Case
features may include:
Electronic fan motors
Zero Zone ChillBrite®LED Lighting
Alternate Bumper with Optional Glass Front
Mirrors
Night Curtains
Quick-Connect Spray Hose
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. Consult
the factory if your store exceeds these test conditions.
4 • Installation & Operation
INSTALLATION & OPERATION
! CAUTION! DO NOT STAND ON TOP OFAREVEALMERCHANDISER®. THE TOPOF THE CASE IS NOT DESIGNED TO
SUPPORTTHE WEIGHT OFAPERSON.
Delivery Inspection
Zero Zone display cases are carefully factory-tested, inspected, and properly packed to ensure delivery in the best possible condition. The
equipment should be unwrapped and checked for damage immediately upon delivery. DAMAGE MUST BE NOTEDAT TIME OF DELIVERY,
ANDALL CLAIMS FOR DAMAGES MUST BE FILED WITH THE TRANSPORTATION COMPANY, NOT WITH ZERO ZONE. The carrier will
supply necessary report and claim forms.
Do not leave, store, or hold case outdoors in direct sunlight or high ambient temperature. This could potentially cause any plastic
inside the case to deform or warp.
Packaging
IMPORTANT: The hand rail, canopy, and honeycomb holder are shipped with protective coating. Do not remove this coating until cases
are completely installed. Wooden supports are used for shipping cases without end panels. These can be removed after moving the
case into position.
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 (See Figure 1).
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.
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.
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.
Building softs must be set back at least 6" from the front of the cases 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
Front of Lineup
Installation & Operation • 5
INSTALLATION & OPERATION
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.
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 MODEL INSTRUCTIONS
4ORMC Forks must extend 20" to 24" under the case from either end
6ORMC Forks must extend 26" to 30" under the case from either end
8ORMC Forks must extend 39" to 43" under the case from either end
12ORMC Forks must extend 44" to 47" under the case from either end
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 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 1" base will be set into an elevation kit (or "nested base") (See Figure 3).
Spacer blocks (also called ller blocks) are included in the end bases of 4 and 5-door cases that use bases taller than 4 1/2". These blocks limit
the case's forward tilt while it is being lifted by a forklift (See Figure 4).
FIGURE 2: Expandable Base FIGURE 3: Elevation Kit for 1" Base FIGURE 4: Spacer Block
4 3/8" max. opening for
4' & 6' cases.
3 3/8" max. opening for
8' & 12' cases.
Spacer Block(s)
6 • Installation & Operation
INSTALLATION & OPERATION
Leveling
Cases should be set level right to left to allow complete drainage of defrost and condensate water. Since a level oor area is seldom available,
the following steps are recommended to 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. Place enough shims under each base 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 7).
After the case is set, additional shims may need to be added at specic base locations (See Figure 8 on page 7).
6. The case must be leveled front-to-back and side-to-side. Ensure that the case is set square to within 1/8". Measure squareness from the
top right corner to the bottom left corner, and then again from the top left corner to the bottom right corner. Measurements should be equal
(See Figure 9 on page 8). Check that the case is level by setting a 4' level against the frame or intermediate standard.
7. 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.
8. Place additional support shims under any bases with gaps taller than one shim. Note: Total height of shims should be less than 3/4".
FIGURE 5: Measure and Mark Exact Case Outline FIGURE 6: Mark Floor Level Difference
FIGURE 7: Tape Shims on the Floor Under Each Base
C
a
s
e
F
ro
nt
Case Fro
nt
Placement
Under Bases
Case Front
Installation & Operation • 7
INSTALLATION & OPERATION
FIGURE 8: Reveal Merchandiser®Base Locations
4ORMC 6ORMC
8ORMC
12ORMC
Drawings are top views with bases shown under the case.
Case length does not include end panels (1 1/2" wide each).
8 • Installation & Operation
INSTALLATION & OPERATION
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 cases will be ready for assembly after removing the packaging material. However, do not remove the protective coating on
the hand rail, canopy, and honeycomb holder at this time.
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.
Before joining cases, remove all shipping blocks inside the bases and the steel support braces under the end panels. There are bolts that go up
through the support plates into the underside of the foamed oor.
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 10 on page 9).
Move the next case into position and bolt it to the rst case using the 4 joining bolts that are provided. Begin tightening the bolts at the top
rear, working down the back of the case and to the bottom front, making sure that the case seams are ush. To align cases, use a drift pin or
screwdriver on the alignment holes in the end frames, located 7" in from the joining holes. Do not pull cases together using joining bolts.
For NSF case installation compliance, the interior case seams must be sealed using NSF-approved caulk (See Figure 11 on page 9). Do
not allow Butyl sealant and NSF-approved caulk to contact one another as this may affect adhesion or color of each.
FIGURE 9: 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".
Installation & Operation • 9
INSTALLATION & OPERATION
FIGURE 10: Case Joint Caulking Instructions
IT IS CRITICAL TO FOLLOW THIS PROCEDURE TO
ENSURE CASESARE PROPERLY SEALED.
Note: Apply sealant to only one case—not both cases—as
excessive amounts of sealant may squeeze out of the case
joint. The sealant will spread out when the cases are joined.
1. Apply 1/4" to 3/8" wide beads of Butyl caulk along the ceiling,
rear wall, and base of the case where indicated by the dotted
lines in the drawing. Always apply 2 beads where specied.
2. After cases are joined and tightened, caulk the top and back
exterior seams, if possible, to ensure a tight seal.
3. Repeat this process between each case in the lineup.
SURFACES TO BE CAULKED MUST BE CLEAN,
DRY,AND FREE OF FROST (ABOVE 40ºF).
Note: NSF sealant must be applied with no gaps to seal the
case interior properly.
1. Cases must be properly caulked and joined before NSF
caulking.Avoid using excessive Butyl caulk to prevent it from
coming out of the joints because Butyl and silicone sealants
will not mix. That will affect adhesion.
2. Apply NSF-approved sealant (silicone-based) in small,
smooth beads where indicated by the dashed lines in the
drawing. 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. Do not thin
or feather excessively, as that may affect adhesion.
FIGURE 11: NSF Compliance Sealing
10 • Installation & Operation
INSTALLATION & OPERATION
Canopy Splice
A ceiling alignment bracket must be eld-installed to align the ceiling panels prior to canopy alignment. The canopy will come with factory-
installed end caps on the rst and last cases in a lineup. At each case joint, a canopy splice will need to be installed (See Figure 12).
On cases with aluminum canopies, the factory-installed splice must be aligned in the eld. Use a rubber mallet to slide the canopy splice over to
the adjacent canopy until the canopies are aligned. You may need to loosen the canopy screws if canopies are not within 3/8".
On cases with stainless steel canopies, the splice is shipped loose. Fit it over both canopies and screw into place.
Hand Rail Splice
Some cases will have the standard bumper and handrail. When joining these cases, insert the front of the hand rail trim splice into the slot at the
front bottom of the hand rail (See Figure 13). Form the trim piece over the hand rail and fasten it in the back (See Figure 14).
FIGURE 13: Hand Rail Trim (Front)
Insert Splice into Slot
FIGURE 14: Hand Rail Trim (Back)
Fasten in the Back
FIGURE 12: CeilingAlignment Bracket and Canopy Splice
(Aluminum on Left, Stainless Steel on Right)
Ceiling
Alignment
Bracket
Aluminum
Canopy Splice Stainless Steel
Canopy Splice
Installation & Operation • 11
INSTALLATION & OPERATION
Alternate Bumper Splice & Glass Front Splice
Some cases will have the alternate bumper with optional glass front. When joining two of these cases together, special splice pieces will be
provided (See Figure 15). First, hook the bumper splice over the bumper and fasten it under the bumper so it covers the seam. Next, slide the
glass front splice down over the glass fronts and fasten it to the inside of the case.
Drain
The drain can be accessed through the drain access port in the center of the oor pan in the bottom of the case (See Figure 16). The 1 1/2"
PVC drain outlet is located at the center front of the case behind the kickplate.
The drain line exits the case in the center. The lateral runs of drain pipe should be installed through the bases (See Figure 17). 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 drain 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.
The forward drain section, tee, and “R” trap are shipped loose for eld installation.
FIGURE 15: Splices for Optional Glass Front
Alternate Bumper Splice
(fasten in front)
Glass Front Splice
(fasten inside case)
FIGURE 16: DrainAccess Port FIGURE 17: Drain Installation
12 • Installation & Operation
INSTALLATION & OPERATION
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.
For a standard Reveal™case (ORMC82) or a Reveal™Tall case (ORMC87), front and side kickplates are attached to the case bases using
Tinnerman clips. Position the front kickplate so the ange is on top and facing outward. The screw (supplied) goes through the kickplate and
into the Tinnerman clip (See Figure 18).
A2-piece kickplate is used on the Reveal
™Meat Exclusive (ORMC75-MX and ORMC80-MX) and the Reveal™Produce Exclusive (ORMC80-PX
and ORMC82-PX). First, position the lower kickplate ush with the bottom of the bases and fasten it to the bases. Second, position the upper
kickplate under the case and fasten it to the bases through the lower kickplate. This will create a continuous kickplate.
There is a natural gap between the top of the kickplate and the underside of the Reveal Merchandiser® that allows airow of 20 CFM/foot. If
more airow is required, contact the factory to order optional louvered kickplates (provides 60 CFM/foot).
Bumper
Cases are supplied with a protective bumper. Most bumpers will be factory-installed to the bumper support and snap track. If a continuous
bumper is used, only the bumper support and snap track will be installed. The continuous bumper may need to be trimmed before snapping it
onto the snap track.
FIGURE 18: Kickplate Installation
1. Install Tinnerman clips at each base.
2. Install side kickplate.
3. Install front kickplate.
4. Insert fasteners to secure kickplates.
DETAIL A (ASSEMBLED)
4. INSERT FASTENERS TO SECURE KICKPLATES
3. INSTALL KICKPLATE FRONT
1. INSTALL TINNERMAN NUTS AT EACH BASE
2. INSTALL KICKPLATE END
DETAIL A (EXPLODED)
BASE
TINNERMAN NUT
KICKPLATE END
KICKPLATE INSTALLATION
KICKPLATE FRONT
REV.SP-6108 B
SPECIFIED, ALL DIMENSIONS
(PER SP-0457) REVEAL
TOLERANCES:
RELEASED
PART WEIGHT:
(IN LBS)
REVISION INFORMATION
BREMOVE EXTRA KICKPLATE COMPONENT FROM DETAIL A. 978
NO MANUAL REVISIONS
CONSENT OF ZERO ZONE, INC. IS STRICTLY PROHIBITED.
CAD DRAWING
REPRODUCTION OR OTHER MEANS, WITHOUT THE WRITTEN
FINISH:
(PER SP-0404)
(UNLESS OTHERWISE SPECIFIED)
(PER SP-0154)
MATERIAL:
SIZE
NOT TO SCALE
Ron Oman
SCALE:
MODELED BY:
A
ZERO ZONE, INC.
DOCUMENT OR DISCLOSURE OF ITS CONTENTS; BY
ARE IN DECIMAL INCH
7/27/2016
B
1 OF 1
SP-6108
KICKPLATE ASSEMBLE FIELD
SHEET:DATE:
REVISION
SHEET
DRAWN BY:
UNLESS OTHERWISE
USA 53153
DRAWING No:
DESCRIPTION:
BY
DATE
ECN No.
REVISION DESCRIPTIONNo.
BF6/9/2020
COPYRIGHT INFORMATION
THIS DRAWING AND THE INFORMATION CONTAINED WITHIN, IS
THE SOLE PROPERTY OF ZERO ZONE, INC. ANY USE OF THIS
110 NORTH OAKRIDGE DRIVE
NORTH PRAIRIE, WISCONSIN
David Giese
A
Base
Front
Kickplate
Side Kickplate
Tinnerman Clip
Fastener
Installation & Operation • 13
INSTALLATION & OPERATION
Mirrors
Mirror assemblies include the mirrors, brackets, supports, and an air deector, which are shipped together as a kit.
1. Assemble the support brackets to the mirror support. Slide the tabs on the brackets into the slots in the mirror support. Use the supplied
hex screws to fasten the brackets in place (See Figure 19). Note: There will be 3 brackets and 3 screws for 36" wide mirrors or
4 brackets and 4 screws for 48" wide mirrors.
2. Install the mirror support into the shelf standards, using both the second and third slots from the top (See Figure 20).
FIGURE 19: Support Brackets and Mirror Support
Support
Bracket
Mirror
Support
Add Hex
Screws
FIGURE 20: Install Mirror Support into the Shelf Standards
Install into second
and third slots
from the top
FIGURE 21: Shelf Standard Slots for Air Deector
MIRROR HEIGHT SLOT FORAIR DEFLECTOR
8" Tall 6th Slot from Top
12" Tall 9th Slot from Top
20" Tall 16th Slot from Top
24" Tall 19th Slot from Top
FIGURE 22: Install Air Deector Under Mirror Support
Install into shelf
standards
Air
Deector
FIGURE 23: Hang the Mirror, Insert Top First
First insert into the top of the
bracket, then into the bottom
Mirror
3. Install the air deector (also called a “mirror scoop”) into the shelf standards
under the mirror support. Refer to the table for the correct slot, counting down
from the top (See Figure 21 and Figure 22).
4. Peel the protective coating off of the mirror. Hang the mirror from the brackets.
Start by inserting it into the top and then the bottom (See Figure 23).
5. Center the mirror for optimal product display.
14 • Installation & Operation
INSTALLATION & OPERATION
Night Curtains
Cases ordered with night curtains will have factory-installed mounting brackets. A retrot kit must be ordered from Zero Zone to install onto a
case that was not ordered with night curtains.
Some night curtains pull down and lock into position like roller window blinds. Other night curtains use a magnet and attach to the metal
kickplate. If the night curtain has a magnet, orientate the night curtain so the magnet can attach to the case.
Tip the night curtain forward into the mounting bracket and twist it until you hear a click as the brackets engage (See Figure 24). Once installed,
the night curtain can be pulled down (See Figure 25).
Under Shelf Lights
1. Position the under shelf light on the bottom of the shelf with the wire connector towards the left side of the shelf (See Figure 26).
2. Attach the under shelf light to the shelf using the two magnets that are factory-installed to the light stick.
3. After installing the shelf, plug the wire into the nearest duct pocket under the shelf (See Figure 27).
4. Bundle harness wire and place into magnetic clip. Mount magnetic clip on the side of the shelf bracket.
FIGURE 24: Install Night Curtain into the Brackets FIGURE 25: Night Curtain Pulled Down
FIGURE 26: Install Light Under the Shelf FIGURE 27: Plug Into the Duct Pocket
Installation & Operation • 15
INSTALLATION & OPERATION
Canopy Lights
Canopy lights can be angled to provide the best lighting for the product. We recommend adjusting these while stocking the case.
Shelves & Stocking Product
Shelf location may be adjusted in 1" vertical increments in any position for best display advantage. Make sure the shelf brackets are securely
seated before placing any product on the shelf. The standard shelves may be tilted down at a 10° angle. Optional shelf assemblies are available
that may be tilted at 5°, 10°, or 15° angle. Bottom wire racks are available as either at with front fence or adjustable with front fence, which can
be set with a 15° angle.
The case may be stocked with product after it has operated at least 24 hours with correct case temperature and proper control operation.
Peg hooks require airow bafes above each set to maintain proper product temperatures. When stocking the shelves, leave a gap between
the product and the shelf above, which allows an air curtain on top of the product.Angled, tiered, or lightly stocked shelves will reduce the air
curtain and may require lower evaporator temps. Product should not extend beyond the front of the shelves or bottom wire rack. Note: Do not
place product on the return air grille or past the load limit line. Do not exceed shelf load capacity (See Figure 28). Do not stand on the
case when stocking or adjusting shelves.
SHELF TYPE DEPTH BRACKET TYPE LOAD CAPACITY (LBS.)
Solid Shelf,
Standard Duty
22" 2-Position (0°/10°) 250/150
4-Position (0°/5°/10°/15°) 250/250/150/100
24" 2-Position (0°/10°) 250/150
4-Position (0°/5°/10°/15°) 250/250/150/100
Solid Shelf,
Heavy Duty
10" 2-Position (0°/10°) 350/275
4-Position (0°/5°/10°/15°) 350/300/275/250
12" 2-Position (0°/10°) 350/275
4-Position (0°/5°/10°/15°) 350/300/275/250
14" 2-Position (0°/10°) 350/275
4-Position (0°/5°/10°/15°) 350/300/275/250
16" 2-Position (0°/10°) 350/275
4-Position (0°/5°/10°/15°) 350/300/275/250
18" 2-Position (0°/10°) 350/275
4-Position (0°/5°/10°/15°) 350/300/275/250
20" 2-Position (0°/10°) 350/275
4-Position (0°/5°/10°/15°) 350/300/275/250
22" 2-Position (0°/10°) 350/275
4-Position (0°/5°/10°/15°) 350/300/275/250
24" 2-Position (0°/10°) 350/275
4-Position (0°/5°/10°/15°) 350/300/275/250
FIGURE 28: Shelf Load Capacities
FIGURE 29: Acrylic Product Stops (1" Shown)
Product stop ts
into the price tag
molding.
Shelves can be ordered with 1", 2", or 3" acrylic
product stops, which t into aluminum price tag
molding. Slide the product stop into the price tag
molding and push it down to the bottom of the
channel (See Figure 29). The channel of the
price tag molding may need to be pried open with
a screwdriver, but the product stop should slide in
easily once started.
16 • Refrigeration
REfRIgERATION
Mechanical Components
EVAPORATOR COIL & EXPANSION VALVE
The evaporator coil is located in the bottom of the case under the deck pans. The
thermostatic expansion valve (TXV) is typically located at the end of the evaporator
coil. The TXV is not preset, and superheat should be adjusted to 6-8°F. Contact
Zero Zone for superheat setting if using high-glide refrigerants.
To adjust the TXV, remove the far right deck pan (See Figure 30). Remove the cap
from the bottom of the TXV. When looking at the valve stem end, turn the valve
stem counterclockwise to decrease superheat. Turn the valve stem clockwise to
increase superheat. Measure the suction line temperature at the TXV sensing bulb
and compare it to the suction temperature corresponding to the saturated pressure.
Make sure that line pressure drop is taken into account. Turn the valve stem only
1/4 turn at a time and allow sufcient time (20 to 30 minutes) for the TXV to settle
before making further adjustments.After the superheat has been adjusted, wipe the
valve stem cap dry and screw it back on.
EVAPORATOR FANS
Air is circulated through the display case by fans, which are located below the deck pans in the bottom of the case (See Figure 31).Air is drawn
through the front return air grill and discharged out of the honeycomb at the top. The fan motors must be operating at all times. Fan motors
should be replaced with motors having the same characteristics including type, physical size, lubricant temperature range, wattage, and RPM.
Fan blades should be replaced with OEM parts or have the same fan pitch as the OEM fan blade.
! CAUTION! DISCONNECT POWERTOTHE CASE BEFORE SERVICING ELECTRICAL
COMPONENTS TO AVOID PERSONAL INJURYAND DAMAGE TOTHE UNIT.
1. Disconnect power to the fan.
2. Remove the fan blade nut and fan blade.
3. Remove the mounting bolts and remove the fan assembly from the fan housing.
4. Remove the fan motor mounting screws from the back of the fan motor.
5. Replace the fan, and reverse steps 1-3 to install the cover. Restore case power.
Refrigerant Piping
Unless otherwise specied, the liquid and suction connections terminate inside the case under the coil
cover. Refrigerant piping may enter the case through the left rear back panel or the left rear top panel of
the case. Other exit options are available. The copper pipe should not touch or rub on the edges of the
sheet metal. Correct refrigeration line sizing and industry standard installation practices are essential for
proper system operation (See Figure 32 on page 17).
After connections have been made, the refrigeration access holes or penetrations in the case must be
sealed completely with an aerosol-dispensed urethane insulation or equivalent (example: Great Stuff).
After all of the refrigeration piping and system components have been assembled, the entire system must
be pressurized and checked for leaks. When the system is leak free, evacuate with a deep vacuum pump.
Triple evacuation should be done to 500 microns or less, and nitrogen sweep is recommended. After the
system has been thoroughly evacuated of all moisture and non-condensable gas, charge the system with
the specied refrigerant.
REfRIgERATION
FIGURE 30: Expansion Valve and Schrader Valve
FIGURE 31: Fans and
Case-to-Case Piping
Refrigeration • 17
REfRIgERATION
From To Liquid Line From To Liquid Line From To Liquid Line From To Liquid Line
5,280 30,720 3/8 5,280 21,010 3/8 5,280 16,790 3/8 5,280 14,310 3/8
30,730 72,750 1/2 21,020 49,900 1/2 16,800 39,960 1/2 14,320 34,110 1/2
72,760 136,380 5/8 49,910 93,740 5/8 39,970 75,160 5/8 34,120 64,210 5/8
136,390 226,300 3/4 93,750 155,790 3/4 75,170 125,030 3/4 64,220 106,890 3/4
155,800 246,590 7/8 125,040 198,070 7/8 106,900 169,440 7/8
From To Horizontal From To Horizontal From To Horizontal From To Horizontal
5,280 8,350 1/2 5,280 5,730 1/2 --- --- --- --- --- ---
8,360 15,640 5/8 5,740 10,760 5/8 5,280 8,630 5/8 5,280 7,380 5/8
15,650 25,950 3/4 10,770 17,880 3/4 8,640 14,360 3/4 7,390 12,280 3/4
25,960 41,010 7/8 17,890 28,290 7/8 14,370 22,740 7/8 12,290 19,460 7/8
41,020 82,770 1-1/8 28,300 57,220 1-1/8 22,750 46,030 1-1/8 19,470 39,430 1-1/8
82,780 143,860 1-3/8 57,230 95,580 1-3/8 46,040 80,190 1-3/8 39,440 68,720 1-3/8
143,870 226,880 1-5/8 95,590 157,230 1-5/8 80,200 126,700 1-5/8 68,730 108,640 1-5/8
157,240 325,130 2-1/8 126,710 262,250 2-1/8 108,650 225,030 2-1/8
From To Vertical
5,280 6,590 5/8
6,600 10,500 3/4
10,510 21,300 7/8
21,310 37,300 1-1/8
37,310 59,100 1-3/8
59,110 121,880 1-5/8
121,890 215,800 2-1/8
90°F Liquid, 2°F Pressure Drop‡
Up to 50 equivalent feet
‡
For 1°F pressure drop, multiply rated Btuh by 1.44 before using the Suction Horizontal Line Sizing Table.
∆For 1°F pressure drop, multiply rated Btuh by 1.45 before using the Liquid Line Sizing Table.
Suction Vertical Riser Sizing
Up to 100 equivalent feet
Up to 50 equivalent feet
90°F Liquid, 2°F Pressure Drop∆
Up to 100 equivalent feet
Up to 200 equivalent feet
90°F Liquid, 2°F Pressure Drop∆
Liquid Line Sizing
Suction Horizontal Line Sizing
90°F Liquid, 2°F Pressure Drop‡
Up to 200 equivalent feet
90°F Liquid, 2°F Pressure Drop‡
Up to 150 equivalent feet
90°F Liquid, 2°F Pressure Drop‡
Up to 150 equivalent feet
90°F Liquid, 2°F Pressure Drop∆
It may be necessary to make adjustments to compensate for special situations
which cause the actual Btuh to differ from the rated Btuh of the cases.
All liquid line and suction line sizes are inches, refrigeration O.D.
Subject to change without notice.
70°F Minimum Liquid Temperature, using 0.35 PSI Per 100 Feet (per 2006 ASHRAE Handbook - Refrigeration)
For rated Btuh:
Maximum Allowable Riser Size For Adequate Oil Return*
R-404 Line Sizing Tables for Zero Zone OVMC Multideck (+26°F Evaporator Temperature)
For rated Btuh:
For rated Btuh:
For rated Btuh:
For rated Btuh:
For rated Btuh:
For rated Btuh:
For rated Btuh:
For rated Btuh:
90°F Liquid, 2°F Pressure Drop∆
Liquid Correction Factors forSuction VerticalRiser Sizing Table -Use MinimumLiquid Temperature
Multiply rated Btuh by liquid correction factor before using the Suction Vertical Riser Sizing Table
40°F 50°F 60°F 70°F 80°F 90°F 100°F
0.85 0.89 0.94 1.00 1.07 1.15 1.24
Minimum Liquid Temperature:
Liquid Correction Factor:
40°F 50°F 60°F 70°F 80°F 90°F 100°F 120°F
0.74 0.78 0.82 0.87 0.93 1.00 1.08 1.32
1.19
Liquid Correction Factors forSuction HorizontalLineSizing Table- Use MaximumLiquid Temperature
For max imum liquid temperatures other than 90°F, multiply rated Btuh by liquid correction factor before using the Suction Horizontal Line Sizing Table
Maximum Liquid Temperature:
110°F
Liquid Correction Factor:
40°F 50°F 60°F 70°F 80°F 90°F 100°F 120°F
0.98 0.97 0.96 0.97 0.98 1.00 1.04 1.17
Liquid Correction Factors forLiquid Line Sizing Table- UseMaximumLiquid Temperature
For max imum liquid temperatures other than 90°F, multiply rated Btuh by liquid correction factor before using the Liquid Line Sizing Table
Maximum Liquid Temperature:
110°F
Liquid Correction Factor:
1.09
FIGURE 32: R-404ALine Sizing Tables for Zero Zone ORMC Multi-Deck (26°F Evaporator Temperature)
18 • Refrigeration
REfRIgERATION
Glycol cases typically have a balance valve located in the outlet line inside of the case. If a stop solenoid is provided, it will also be located in
the outlet line. Schrader valves are provided inside the case on the right-hand side of the coil for venting and draining the system.
Operation Set Points
Refer to the case spec sheet for btu/h requirements and electrical requirements. Operate the case at the proper settings to maintain product
temperature of 41°F or below, per food safety regulations (See Figure 33). Note: Set points based on at shelves. Alternate shelving—
such as angled or tiered shelving, peg hooks, or produce inserts—may require lower operating temperatures.
Off-Cycle Defrost
See Figure 34 for off-cycle defrost settings. During off-cycle defrost, refrigerant is stopped either by stopping the compressor or by closing the
liquid line solenoid valve and allowing the compressor to pump down. The fans and lights remain on during off-cycle defrost.
If temperature termination is selected, set the termination temperature at 45°F for discharge air and coil temperature. Note: Stocking or
shopping during off-cycle defrost may cause premature defrost termination.
Case Thermometer
The cases are shipped with two thermometers. One thermometer is factory-mounted in the center ceiling pocket cover to sense the discharge
air stream. The second thermometer is shipped loose and should be installed in the warmest product location as required by NSF. Specic eld
installation instructions are packaged with the thermometer that is shipped loose.
FIGURE 34: Defrost Settings
SETTING MEAT DAIRY/DELI/PRODUCE BEVERAGE
Defrost Type Off-Cycle Off-Cycle Off-Cycle
Frequency 4 Per Day 4 Per Day 4 Per Day
Duration 36 Minutes 30 Minutes 30 Minutes
FIGURE 33: Case Temperature Internal Control Options (R-404A)
SETTING MEAT DAIRY/DELI/PRODUCE BEVERAGE
Evaporator Temperature 22°F 26°F 28°F
Condensing Unit Cut-In 62 psig 67 psig 71 psig
Condensing Unit Cut-Out 54 psig 59 psig 62 psig
ReturnAir Temperature Cut-In 44°F 48°F 50°F
ReturnAir Temperature Cut-Out 40°F 44°F 46°F
DischargeAir Temperature Cut-In 31°F 35°F 37°F
DischargeAir Temperature Cut-Out 27°F 31°F 33°F
Superheat Setting 6-8°F 6-8°F 6-8°F
Note: For high-glide refrigerants, use dew point for unit sizing. Adjust evaporator pressure as needed to maintain
discharge air temperatures. To receive the full benet of high-glide refrigerant properties, the superheat may need to
be lowered to 4-6°F. Contact Zero Zone with questions.
This manual suits for next models
5
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