Zero Zone CRYSTAL MERCHANDISER User manual

ZERO ZONE
CRYSTAL MERCHANDISER®FREEZERS
With CoolView®Doors and ChillBrite®LED Lighting
INSTALLATION & OPERATION MANUAL
COMPLIANT
66-0025 REV F •APR 2020

II
Table of Contents
ZERO ZONE WARRANTY.....................................................................1
INTRODUCTION....................................................................................2
INSTALLATION & OPERATION............................................................4
Delivery Inspection...........................................................................4
Packaging........................................................................................4
Location...........................................................................................4
Installation Leveling.........................................................................4
Case Movement...............................................................................5
LineupAssembly..............................................................................6
Drain Line.........................................................................................7
Condensate Evaporation System....................................................7
Trim..................................................................................................7
Kick Plates.......................................................................................7
Cleaning...........................................................................................8
Shelf Location..................................................................................8
Shelves............................................................................................8
Loading the Case.............................................................................8
Light Switch......................................................................................9
Case Thermometer..........................................................................9
GENERAL............................................................................................10
Evaporator.....................................................................................10
Expansion Valve ............................................................................10
Evaporator Fans............................................................................10
Fan Removal..................................................................................10
SERVICE..............................................................................................11
Air Curtain Velocity.........................................................................11
LED Power Supplies......................................................................11
REFRIGERATION................................................................................12
Piping Penetrations........................................................................12
Refrigerant Piping..........................................................................12
Leak Check/Evacuation/Charging..................................................12
Temperature Settings.....................................................................12
Temperature Control......................................................................12
ELECTRICAL.......................................................................................13
General..........................................................................................13
Optional Electrical Wiring...............................................................13
DEFROSTING......................................................................................15
General..........................................................................................15
Defrost Settings and Controls........................................................15
Defrost Operation...........................................................................16
General Notes................................................................................16
Limit Thermostat............................................................................16
Defrost Heater Element.................................................................17
Heater Element Removal...............................................................17
Anti-Sweat Heaters........................................................................17
ILLUSTRATIONS.................................................................................18
Case Label Information..................................................................18
Freezer to Cooler Leveling.............................................................19
Leveling Cases Prior to Joining.....................................................20
RVLC30 Base Locations................................................................21
RVLC30BB Base Locations...........................................................22
Case Squareness..........................................................................23
Shim Placement.............................................................................24
Shim Orientation............................................................................25
RVLC30BB Wood Planks...............................................................26
Spacer Block..................................................................................27
RVLC30 Caulking Instructions.......................................................28
RVLC30BB Caulking Instructions..................................................29
T-Strip ............................................................................................30
NSF Caulking Instructions.............................................................31
Drain Line.......................................................................................32
Kick Plates - Tinnerman Clips........................................................33
30" Electric Defrost........................................................................34
30" Hot Gas Defrost.......................................................................35
Electrical Box.................................................................................36
Refrigeration Line Sizing - Frozen Foods......................................37
Refrigeration Line Sizing - Ice Cream............................................38
Electric Defrost Wiring Diagram.....................................................39
Hot Gas Defrost Wiring Diagram...................................................40
Master/Satellite Wiring Diagram....................................................41

1
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
INTRODUCTION
Important User Information
Copyright © 2020 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 qualied,
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, specications,
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 Case 30" x 74" CoolView®Ultra™Doors
RVLC30BB Back-to-Back Case 30" x 74" CoolView®Ultra™Doors
RVLC30IM Ice Merchandiser 30" x 74" CoolView®Ultra™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 efciency evaporator coil. Case features include:
Brushless DC electronic motors
Zero Zone ChillBrite®LED Lighting
Zero Zone CoolView®Ultra
™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 certied by NSF)
NSF 51 – Food Equipment Materials (ANSI Approved) (equipment certied by NSF)
UL 471 – Commercial Refrigerators and Freezers (ANSI Approved) (equipment certied 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 species the test conditions for the equipment. It includes the ambient conditions of 75°F dry bulb and 55% RH. It also
species 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
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 NOTED AT 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. 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 two 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 in the gure below. Back-to-Back cases have a
side “A” and a side “B”. See Figure 1 on page 18.
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 sufcient 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.
Installation Leveling
Alineup solely made of freezers should be level front to back and right to left.
When joining a freezer and cooler in a short lineup, both cases should be tilted back with an additional 3/16" of shims under the front bases
after the case is leveled. See Figure 2A on page 19. On long lineups, 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 2B on page 19.
Cases should be set level right to left to allow complete drainage of defrost water. Since a level oor area is seldom available, the following
steps are recommended to insure a level installation. See Figure 3 on page 20.
1. Measure off and mark on oor the exact dimensions of the case lineup. (Check blueprints).
INSTALLATION & OPERATION

Installation & Operation • 5
INSTALLATION & OPERATION
2. Snap a chalk line at the locations for the front and back positions of the base rails.
3. Mark locations of all joints (front and back).
4. Using a laser level or transit, nd the highest point along both base rail position lines. Using the high point as a reference, mark the
difference directly on the oor to each joint (front and back).
5. If you plan on using optional “hat channels” to raise the case height, place them under each pair of bases. On some cases, all bases are
not directly in line from front to back. See Figure 4 on page 21 and Figure 5 on page 22 for base locations. The 3 and 4-door hat
channels will be angled slightly to support the front and rear bases because the bases themselves are not in line.
6. Place the required number of shims under each base or optional hat channel at each joint (front and back) to equal the highest point. The
case is designed with minimal gaps between adjacent doors to provide a clean appearance. To maintain even, consistent gaps and proper
door operation, the case must be leveled front-to-back and side-to-side. Check case squareness to within 1/8". See Figure 6 on page
23. Shims should not extend beyond the front case bases or they will interfere with the installation of kick plates. Tape all shims in place.
The shims should be oriented to sit under the front and rear bends of each base.
7. The RVLC30 2-door through 5-door cases have segmented bases mounted at the ends and under the center section of the case. The
RVLC30 1-door and RVLC30BB have full bases that run front-to-back and are located at the ends and under the center sections of the
case. Place additional support shims under all other bases or hat channels, leaving no gaps taller than one shim.
8. Tape all shims in place (See Figure 7 on page 24). See Figure 8 on page 25 for the correct orientation of shims under the base or
channel.
9. If you are joining coolers to freezers, RVMC cases should be set with a slight backward tilt to offset the forward lean of a fully loaded case.
When joining a freezer and cooler in a short lineup, both cases should be tilted back with an additional 3/16" of shims under the front
bases after the case is leveled. See Figure 2A on page 19. On long lineups, 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 2B on page 19.
10. If you’ve purchased seismic restraints, specic instructions for attaching those restraints are included in your document package. These
instructions should be read and understood before the lineup is assembled.
Case Movement
! CAUTION! DO NOT PULLON THE MULLIONS WHEN MOVING THE CASE.THE END FRAME CAN BE USED TO PUSH/PULL
THE CASE. DOLLIES MAY BE PLACEDAGAINST THE CASE BOTTOM, BUTAVOID CRUSHING THE BUMPER
SUPPORTOR DRAIN PIPE.
WHEN USINGAJ-BAR, IT MUST NOT CONTACT THE SHEET METAL OF THE BUMPER SUPPORT, BUT SHOULD
CONTACTTHE SHEET METALOF THE BOTTOM FOAMED PANEL.THE BUMPER SUPPORTWILLBE DAMAGED
IF LIFTED BYA J-BAR. BE CAREFULNOTTO PIERCETHE SHEET METALWITH THE CORNER OF THE J-BAR.
The RVLC30 and RVLC30BB cases have steel protective support plates under the ends (not under insulated dividers). These are designed to
protect the end from Johnson Bar damage. Per NSF, these must be removed after cases are set.
The 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 (See Figure 9 on page 26).
MODEL FORKLIFT
FROM ENDS JOHNSON BAR FURNITURE DOLLY PIPE ROLLERS SAFE (CASE) JACKS
RVLC30 X X X X
RVLC30BB X X X X X
Care should be taken when moving the cases. The doors should be secured so they cannot open while the case is moved.

6 • Installation & Operation
INSTALLATION & OPERATION
Only experienced certied 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, avoiding any abrupt motions or bumps.
The following forklift dimensions must be maintained to avoid damaging the case when it is lifted. Fork blades wider than 4" will not t in the
bases.
2-Door Cases
Forks must extend from 26" to no more than 30" under the case.
3-Door Cases
Use 48" long forks!
Forks must extend from 39" to no more than 43" under the case.
4 & 5-Door Cases
Use 48" long forks!
Important: Fork blades wider than 4" will not t in the bases.
Spacer blocks are factory-installed in the end bases of 4 and 5-door cases that use bases taller than 3 1/2". These blocks limit the cases
forward tilt at the opposite end from the forklift while it is being lifted and must be used when lifting 4 or 5-door cases with bases taller than 3
1/2". See Figure 10 on page 27.
For low shipping height applications, Zero Zone has optional expandable bases.As shipped, the base is 1 3/4" tall. It is attached with spacers
that allow the base to slide away from the bottom of the case, creating a gap that allows the use of forklift blades thicker than 1 3/4".
When the case needs to move through an 80" door opening, the case is shipped with a 1" base on a wood pallet. Remove the case from the
pallet to slide the case through the 80" doorway. Drain elbow will need installation on a 1" base. Use extra thick PVC cement.
LineupAssembly
Zero Zone display cases have been engineered for continuous display. This means that any number of cases can be joined together to create
a display of any desired length. The bottom of the end panel is protected with a removable steel plate that must be removed after the cases are
set.
The cases will be ready for assembly after removal of the packaging material.
Case caulking instructions are shipped with every case, explaining the proper procedure for joining cases. See Figure 11 on page 28 and
See Figure 12 on page 29 for instructions.
FIELD-INSTALLED CAULK SEALANTAPPLICATION NOTES:
Butyl sealant is used to join cases and Silicone or NSF approved sealant is used for NSF compliance. Sealants should not contact one another
as this may affect adhesion or color of each.
Remove all shipping blocks applied to inside of base ends before joining cases.
Remove End protection plate located below END on outside of case.
FAILURE TO FOLLOWTHE INTENT OF CASE JOINING INSTRUCTIONS WITH SEALANTS WILLCAUSE FROST INSIDE THE CASE.
For NSF case installation compliance, the interior case seams need to be sealed using NSF approved caulk (not supplied). See Figure 14 on
page 31.

Installation & Operation • 7
INSTALLATION & OPERATION
After setting the rst case, the next case is slid into position and bolted to the rst case using four 3/8" 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 front seams are ush. Cases are not
designed to be pulled together using the joining bolts.
Alignment holes are located in the lower steel end frames. These are located 7" in from the joining holes.
Once the cases have been caulked and slid together, start the joining bolts, but do not tighten them. Slide the center extrusion (T-strip) between
the end mullions See Figure 13 on page 30. Begin tightening the bolts at the top rear, working down the back of the case and up the front,
making sure that the front seams are ush. Cases are not designed to be pulled together using the joining bolts.
Drain Line
The drain is located at the center of the case in the oor pan. The drain can be reached by removing the coil covers and then tipping the fan
plenum towards the doors. The 1" PVC drain outlet is located at the center front of the case behind the kick plate.
The drain exits the case in the center. The bases are designed for lateral runs of drain pipe to pass through and the drain pipe must be installed
in this area. See Figure 15 on page 32. There is no room in front of the base for drain pipe because the kick plate 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 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 insure proper drainage. Consult your local codes for minimum
requirements.
Condensate Evaporation System
Zero Zone remote cases can be equipped with an automatic condensate evaporation system. The system uses a pump and drain pan located
behind the kick plate and a condensate evaporator pan mounted on the top of the case.
Condensate water and any liquid spilled in the case drains out into the drain pan. The pump is equipped with a oat that turns the pump on
when there is a sufcient 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 pan will be extremely hot and should not be touched. The pump and condensate pan should be cleaned regularly.Any spilled
product should be cleaned to prevent odors.
Trim
The cases are supplied with a 3" protective bumper. Each case has its own bumper assembly including end caps. The case was shipped with
the bumper support and snap track installed on the front of the case. The bumper may need trimming before snapping it onto the snap track.
Full height (top) trim is provided to hide the door hardware located on the top exterior of the case. The top trim is factory-installed. Joint splices
are shipped loose to be installed on-site at the upper case joints.
Kick Plates
Each case is shipped with a front kick plate. Cases with end panels receive 1 side kick plate per end. Cases that join together get a kick plate
splice.
Front and side kick plates are attached to the case bases using Tinnerman clips. The ange on the front kick plate faces forward and is at the
top. The screw (supplied) goes through the kick plate and into the Tinnerman clip. See Figure 16 on page 33.
There is a natural gap between the top of the kick plate and the underside of the case that allows 50 CFM of air return per door. If more return
air is required, contact the factory to order optional louvered kick plates.

8 • Installation & Operation
INSTALLATION & OPERATION
Cleaning
Although your Zero Zone cases are thoroghly cleaned before shipping, the cases should be thoroughly cleaned again before start-up and
routinely thereafter to maintain a clean appearance. Use mild detergent and warm water (never an abrasive cleaner) to wipe out the inside of
the case before start-up. The case drain should be regularly cleared of debris and price tags.
Internal components are easily accessed by the removal of mounting screws and sheet metal component parts. The components can be
cleaned using a mild detergent and warm water or a mild sanitizer. Once the wire racks and deck pans and are removed, the coil and drain
pan can be ushed. All food products should be removed from the case when ushing with a hose. Do not use high-pressure water or steam to
clean the interior.
UNDER CASE FLOOR CLEANING (NSF)
The oor underneath your Zero Zone display case can be cleaned by following a few simple steps:
1. Remove the fasteners that hold the bottom kick plate to the display case. The fasteners are accessed from the front of the unit.
2. With the kick plates removed, remove paper and other debris (typically price tags or receipts) from the oor.
3. Vacuum under the case to remove any dust build-up that may be present.
4. Using a mild detergent and warm water, mop underneath the unit with a clean mop.
5. When nished mopping, squeegee any remaining water underneath the unit to the oor drains to speed the drying process. Replace the
kick plates when the oor has dried.
GLASS SURFACES
Cleaning interior glass reduces fogging and increases visibility. Wipe down glass or plexiglass mirrors or ends with a glass cleaner. Do not use
any products containing silicone or anti-fog.
Shelf Location
The shelves are adjustable in 1" increments and may be located in any position for best display advantage.
Be sure brackets are completely seated.
Wire shelf brackets are stamped with “R” for Right and “L” for left to aid installation.
Bottom basket is shipped in a tipped-forward position, but may be rotated 180° to obtain a at position.
Shelves
Zero Zone manufactures many different styles of shelves, baskets, and product stops. Some of the baskets may be reversed and used as a
typical shelf. Shelves are strapped to the shelf brackets for shipping. The fully assembled shelves are installed in cases prior to shipping.
Solid shelves have three parts.Asolid center section and two snap-in brackets. Solid shelves can be disassembled for cleaning. Ascrewdriver
can be used to spread the snap open to remove the brackets from the center section.
Loading the Case
The case may be loaded with merchandise after it has been operated for at least 24 hours with correct case temperature and proper control
operation. While loading the shelves, leave a minimum of 1" air space between the top of the merchandise and the shelf above it so the
customer can remove the merchandise. The air space allows an air curtain on top of the product. Product should not extend beyond the front of
the shelves or block the return air grill. The shelf loads are as follows:

Installation & Operation • 9
INSTALLATION & OPERATION
ITEM SHELF
DESCRIPTION MAXIMUM LOAD PER SHELF
1 22" and 24" deep 250 lbs.
2 Bakery or Meat Brackets
At 0° 250 lbs.
At 5° 250 lbs.
At 10° 150 lbs.
At 15° 100 lbs.
3 Ice Shelves 500 lbs.
Heavy duty shelves are available and are labeled as such.
Light Switch
The light switch is located on the ceiling on the right-hand side of the display case.
Case Thermometer
The cases are shipped with 2 thermometers. One thermometer is factory-mounted in the discharge air stream. The second thermometer is
shipped loose and should be installed in the warmest product location. Specic instructions are packaged with the shipped loose thermometer.

10 • General
See Figure 17 on page 34 and Figure 18 on page 35 for the typical component layout of the 30" door case.
The kick plate must be removed to gain access to the drain clean out. Disassemble the kick plate by removing the 2 or 3 metal screws located
in the kick rail.
Evaporator
The evaporator coil, located at the rear bottom of the case, is factory-assembled with distributor, expansion valve, and other refrigeration
components. To inspect the coil, remove the center or left of center coil cover. Asmall inspection window is located at the rear of the case. To
inspect the entire coil, remove the remaining coil covers and raise the evaporator cover.
Expansion Valve
Unless otherwise specied, a superheat adjustable externally equalized thermostatic expansion valve with a removable strainer and pressure
limiting charge is mounted to the evaporator coil. The valve is not preset.Adjust the superheat setting for maximum coil effectiveness. Typical
superheat settings are between 6°F and 10°F. Close coupled systems should use the higher superheat setting to minimize the chance of liquid
ood back. To adjust the expansion valve, remove the right end coil cover. Remove the cap from the bottom of the valve. 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 expansion valve 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 sufcient time (20 to 30 minutes) for the valve to settle before making any further
adjustments. Replace the valve stem cap after the valve superheat has been adjusted. BE CERTAIN THE VALVE STEM CAP IS WIPED DRY
FIRST.
! CAUTION! DISCONNECT POWERTOTHE CASE BEFORE SERVICING ELECTRICAL COMPONENTSTOAVOID PERSONAL
INJURYAND DAMAGE TO THE UNIT.
Evaporator Fans
Air is circulated throughout the case with 115 volt fan motors. These motors must be operating at all times except during defrost. 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.
Fan Removal
1. Unplug fan from fan power supply plug located on the front face of the fan housing.
2. Remove the fan blade nut and fan blade.
3. Remove the two mounting bolts and remove the fan assembly from the fan housing.
4. Remove the three fan motor mounting screws from the back of the fan motor.
Reverse steps 1-4 to install.
GENERAL

Service • 11
SERVICE
Air Curtain Velocity
Air curtain velocity is affected by stocking levels, coil frost loads, temperature, fan condition, and measurement method. Zero Zone recommends
using anAlnor®Velometer Jr.®, set to the 0-to-800 fpm range. Air velocity should be measured at the back edge of the discharge air honeycomb;
at the center of the middle door in the case (other doors have slightly lower velocity).Atypical RVLC30 velocity reading is 400 to 500 feet per
minute in a fully-packed case, after the case has defrosted and pulled down to operating temperature.Air curtain velocity in a partially-packed
display case is signicantly lower because more air exits the back wall duct holes.
LED Power Supplies
LED power supplies are located in the main electrical box of the RVLC30.The standard location of the electrical box is on the top of the case,
but there is an option to mount the electrical box below the case in a slide-out drawer. See Figure 19 on page 36. This option must be
specied on the original case order.

12 • Refrigeration
REFRIGERATION
Piping Penetrations
Unless otherwise specied, the liquid and suction connections are made inside the case under the evaporator fan/coil cover. Refrigerant piping
may enter the case through the left rear back panel or the left rear top panel of the case. The copper pipe should not touch or rub on the edges
of the sheet metal.After connections have been made, the refrigeration access hole in the case must be sealed completely with an aerosol-
dispensed Urethane insulation or equivalent, like Great Stuff™, for example. Penetrations made in sheet metal bafes should also be sealed.
Refrigerant Piping
Correct refrigeration line sizing and industry standard installation practices are essential for proper system operation. Zero Zone recommends
that, on a case utilizing top refrigeration exit, the riser be sized to maintain refrigerant velocity and oil return. Refrigeration risers are an available
factory-installed option. Zero Zone recommends one riser per refrigeration circuit on circuits utilizing hot gas defrost. Field piping must be 3"
away from the defrost heater element on cases utilizing electric defrost.
The end frames on the cases have cut-outs built into them to allow for case-to-case eld piping, if desired.
Zero Zone recommends a liquid line drier and moisture-indicating sight glass installed on each case prior to the expansion valve, these are also
a factory-installed option. See Figure 20 on page 37 and Figure 21 on page 38.
Leak Check/Evacuation/Charging
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 a minimum of 500 microns and nitrogen
sweep is recommended.After the system has been thoroughly evacuated of all moisture and non-condensable gas, charge the system with the
proper refrigerant, using “hi-side/low-side” charging techniques. Refer online to GreenChill Leak Check Guidelines.
Temperature Settings
R404AFROZEN FOOD R404AICE CREAM
Rack Systems
Evaporator Temp -7°F
Rack Systems
Evaporator Temp -16°F
Condensing Unit
Condensing Unit Cut-In 35 psig
Condensing Unit Cut-Out 24 psig
Condensing Unit
Condensing Unit Cut-In 27 psig
Condensing Unit Cut-Out 16 psig
Return & DischargeAir Temperature
Return Air Temp Cut-In 6°F
Return Air Temp Cut-Out 0°F
Discharge Air Temp Cut-In 3°F
Discharge Air Temp Cut-Out -3°F
Return & DischargeAir Temperature
Return Air Temp Cut-In -3°F
Return Air Temp Cut-Out -9°F
Discharge Air Temp Cut-In -6°F
Discharge Air Temp Cut-Out -12°F
Temperature Control
When purchased, factory-installed discharge air sensors are located in the center of the case behind the access panel in the ceiling panel.
There is a sticker installed on the panel that states “sensor located behind.”
If the case is ordered with defrost termination sensors, Zero Zone provides the following sensor locations unless otherwise directed by the
customers’spec.
1. On cases utilizing hot gas defrost, the sensor is strapped to the dump line.
2. On cases utilizing electric defrost, the sensor is placed in the center of the evaporator coil.

Electrical • 13
ELECTRICAL
General
! CAUTION! DISCONNECT POWERTOTHE CASE BEFORE SERVICING ELECTRICAL COMPONENTSTOAVOID PERSONAL
INJURYAND DAMAGE TO THE UNIT.
See Figure 22 on page 39 for the typical wiring diagram for a low temperature case equipped with electric defrost. See Figure 23 on page 40
for the typical wiring diagram for a low temperature case equipped with hot gas defrost. Each case is provided with a wiring diagram located in
the electric box that shows the exact wiring of the case.
There are many control options available for multiple case defrost systems. Wiring diagrams and instructions can be obtained by contacting
Zero Zone’s Service Department.
External wiring should be sized according to the amperage rating stamped on the serial plate. The serial plate is located on the ceiling inside
the left-hand door. Typical electrical values are shown on specication sheets for each of these cases in the bag attached to the case or are
available at www.zero-zone.com.All internal wiring has been done at the factory. Cases with standard wiring have their control wires terminated
in an electrical box located on top of the case. A terminal block has been used to simplify eld connections.
All wiring must comply with the National Electrical Code and all local codes.After installation of the equipment, correct operation of the electrical
circuits and controls and defrost operation and termination should be veried. All operating voltages and amperages should be measured and
recorded.
Optional Electrical Wiring
SINGLE POINT CONNECTION
The “single point” connection system is designed to reduce the time required to install and wire one display case with one condensing unit.
Figure 22 on page 39 and Figure 23 on page 40 are typical diagrams for this system.
All of the display case controls, including the disconnect switch and the electronic case controls are installed on the case and pre-wired. The
liquid line solenoid valve is installed in the liquid line and wired. The power to operate the display case is connected at the case disconnect
switch. The power to operate the condensing unit is connected in the condensing unit control panel. There are no interconnecting wires between
the condensing unit and display case.
The controls operate the system as a pump down defrost. When the display case begins defrost, the liquid line solenoid valve, fans and
anti-sweat heaters are de-energized. The defrost heaters are energized.The compressor continues to run and pumps down the coil. The
compressor cycles off on its low-pressure control. If there is any residual liquid left in the coil, the suction line pressure will rise and the
compressor may turn on and pump down the coil.
The liquid line solenoid is energized at the end of the defrost cycle and the defrost heaters are de-energized. The suction line pressure rises
and the compressor starts. When the low temperature evaporator reaches operating temperature, the fans and anti-condensate door heaters
are energized.
MASTER/SATELLITE CONNECTION
The master/satellite connection system allows one condensing unit to be connected to multiple cases. See Figure 24 on page 41 shows a
typical diagram for this system.
All of the display case controls, including the disconnect switch, time clock, temperature control, and defrost temperature control, are installed
on the case and pre-wired. The liquid line solenoid is pre-wired but is not installed in the liquid line.
The power to operate each display case is connected at each case’s disconnect switch. The power to operate condensing unit is connected
at the condensing unit. There are no interconnecting wires between the condensing unit and display case. There are interconnecting wires

14 • Electrical
ELECTRICAL
that need to be connected between the cases. The liquid line solenoid valve needs to be installed in the common liquid line before the liquid is
distributed to the cases.
The controls operate the system as a pump down defrost. When the display case begins defrost, the liquid line solenoid valve, fans and anti-
sweat heaters are de-energized. The defrost heaters are energized.The compressor continues to run and pumps down the coil.
The master case contains the time clock. Interconnecting case wiring allows the master case to control the satellite cases. When defrost is
initiated in the master case, it sends an electrical signal to each case to energize the defrost relay and initiate a defrost in all of the satellite
cases.Asecond set of interconnecting wires is connected in series between each of the cases. Each case defrost heater is de-energized when
the coil reaches the defrost termination temperature.An additional signal is relayed to the next case indicating that the termination temperature
has been reached. When all of the cases have reached termination temperature, the defrost termination circuit is complete and the defrost is
terminated.
The liquid line solenoid is energized at the end of the defrost cycle and the defrost heaters are de-energized. The suction line pressure rises
and the compressor starts. When the evaporator reaches operating temperature, the delay thermostat (Klixons) will close, energizing the fans
and anti-sweat door heaters.

Defrosting • 15
DEFROSTING
General
Periodic defrosting to keep the coil free of frost is accomplished automatically by a time clock used in conjunction with an electric or hot gas
defrost. For best results, temperature termination of defrost is strongly recommended on Zero Zone cases.
Defrost Settings and Controls
ELECTRIC DEFROST
Frequency: One defrost per day is recommended. Time of day:Avoid defrosting during periods of heavy shopping or stocking. Drip Time:
Electric defrost does not require any drip time because Zero Zone provides a built-in fan delay thermostat.
Electric Defrost Fail-safe Times:
FROZEN FOOD ICE CREAM
1/Day at 55 Minutes 1/Day at 55 Minutes
AtASHRAE test conditions and 208 volt defrost heater operation, the typical observed defrost durations are 30 minutes for frozen food and 40
minutes for ice cream.
Preferred Termination: For optimal performance, Zero Zone recommends a temperature-terminated defrost, using a defrost termination
thermostat or probe sensing the coil temperature. The case has the probe located at the center of the coil in the center of the bottom row of
tubes. If the case is so equipped, the defrost termination temperature is 50°F. Zero Zone provides a defrost termination thermostat unless a
control system defrost probe is requested.
Temperature termination based on coil temperature allows the length of defrost to vary depending on how much frost is on the coil and the
defrost heater voltage. Coil frost is a function of shopping patterns, stocking habits, general door maintenance and ambient temperature and
humidity. More frost requires a longer defrost.Alower defrost heater voltage extends the defrost duration.
Alternate Termination: If it is not possible to terminate the defrost cycle based on a defrost termination thermostat or probe sensing the
temperature at the coil, and the only available temperature probe is sensing the discharge air temperature, then the termination temperature
should be set to 65°F, zero minutes drip time.
Zero Zone electric defrost freezers are delivered with the defrost thermostat open-on-rise contacts wired in series with the defrost heaters.
Unless the installer rewires the defrost thermostat, the defrost heater is de-energized when defrosting is complete.
Electric defrost freezer is equipped with a high-limit, snap-disc thermostat that de-energizes the defrost heater if the coil temperature exceeds
85°F to provide a secondary safety termination.
HOT GAS DEFROST
Frequency: One hot gas defrost per day is recommended. Time of day: Nighttime defrosting is preferred to avoid periods of heavy shopping or
stocking. Drip time: Hot gas defrost requires a 5 minute drip time.
Hot Gas Defrost Fail-safe Times:
FROZEN FOOD ICE CREAM
Hot Gas 1/Day at 30 Minutes 5 Minute Drip 1/Day at 30 Minutes 5 Minute Drip
Reduced Temp Hot Gas 1/Day at 40 Minutes 5 Minute Drip 1/Day at 40 Minutes 5 Minute Drip

16 • Defrosting
DEFROSTING
Preferred Termination: For optimal performance, Zero Zone recommends a temperature-terminated defrost, using a defrost termination
thermostat or probe attached to the dump line.AtASHRAE test conditions, termination ranges from 12-22 minutes. If the cases are so
equipped, the defrost termination is 65°F at the dump line. Zero Zone provides a defrost termination thermostat unless a control system defrost
probe is requested.
Defrost Operation
ELECTRIC DEFROST
The compressor stops when the defrost is initiated in a non-pump-down system. On pump-down systems, the liquid line solenoid will be de-
energized when the defrost is initiated. The clock will energize the defrost contactor, which will energize the defrost heater. This de-energizes
the 115-volt fans and anti-sweat heaters.
HOT GAS DEFROST
Several types of hot gas defrost methods (using time-actuated, time-terminated or temperature-terminated defrost timers) can be used to
defrost the evaporator.
The refrigeration system designer and installer are responsible for correct line sizing for effective hot gas defrost and liquid return from the
freezers. Sizing and component selection depend on the type of defrost, size, and location of high side refrigeration system.
Zero Zone freezers equipped for hot gas defrost consist of a side port distributor and a TXV check valve for coil defrost, and a suction line check
valve to bypass hot gas to the serpentine coil. The serpentine coil is attached to the bottom of the pan to ensure pan and drain defrost.
The timer starts the hot gas defrost cycle by energizing a solenoid, reversing valve, or directional valve. The hot gas is injected from the source
into the suction line of the evaporator to be defrosted. The hot gas ows into the serpentine coil attached to the oor of the case and then into
the evaporator. Condensed liquid leaves the evaporator through the side port distributor, through a check valve into the liquid line. See Figure
18 on page 35.
General Notes
The refrigeration technician should recheck coil condition after one week of retail operations to be certain that the frequency and duration
of defrost is adequate for the particular store and locality. For example, if defrost voltage is below 200 volts, additional fail-safe time may be
required.
When using time terminated defrost, the defrost termination thermostat should be wired in series with the defrost heater.
Defrost termination thermostats may be wired in series for multiple evaporator installations.
Defrost termination thermostats may be used as a digital input for electronic controllers.
Limit Thermostat
Each freezer has factory-set limit thermostats (Klixons) attached to the coil on the right end of the freezer to regulate the operation of the
evaporator fans and defrost heater.
! CAUTION! IMPORTANT! OPERATION OF THE LIMITTHERMOSTATS CAUSES THE EVAPORATOR FANS TO REMAIN
OFF UNTILTHE COMPRESSOR IS OPERATINGAND THE COILTEMPERATURE IS BROUGHT BELOW THE
THERMOSTAT CUT-IN SETTING (10°F ). SUPERHEAT MUST BE SET CORRECTLY BY THE INSTALLING
CONTRACTOR FOR PROPERTHERMOSTAT OPERATION.

Defrosting • 17
DEFROSTING
When the freezer rst operates, the fans may cycle off and on a few times until coil temperature stabilizes below 10°F. The superheat must be
set for proper operation. Electric defrost models have a high limit thermostat installed on the coil, wired in series with the defrost heaters. This
thermostat opens if the temperature reaches 85°F. See Figure 23 on page 40.
Defrost Heater Element
One half of the U-shape heater is located on the front of the coil and the other half is located on the rear of the coil See Figure 17 on page 34.
The electric wire leads are connected in a raceway under the coil cover on the right-hand side of the case.
Heater Element Removal
The U-shape defrost heater has one leg located on the front of the coil and one leg located on the rear of the coil. The front heater is located
approximately 1" off the oor and the rear heater is approximately 2" off the oor. The heater is secured to the coil by a number of stainless steel
heater retaining clips. The heater is fastened to the oor on the right-hand side of the coil. Remove fasteners holding the heater to the oor.
The U-shape defrost heater can be removed by rst pulling the front leg of the retaining clip away from the coil and sliding the heater out from
under the clip. The rear leg of the heater can then be removed by raising the retaining clips 2" at a time, working from right to left on the coil.
Repeat this process until the retaining clips are free of the coil. The heater will slide up with the retaining clip.
Heaters are installed in the reverse order of how they were removed.
Anti-Sweat Heaters
The case has one anti-sweat heater located in each mullion, including the end mullions, and one anti-sweat heater in the case sill. The mullion
heater is located behind the front metal strike plate. Remove the front fasteners on the mullion and remove the front strike plate to access the
heater. The case sill heater is located under the front metal strike plate below the door opening. Contact Zero Zone’s Service Department for
instructions for servicing this heater.
For locations with low humidity and tightly controlled ambient conditions the lower sill heater may be disconnected for additional energy savings.

18 • Illustrations - Case Label Information
FIGURE 1
Case Label Information
ILLUSTRATIONS
Refer back to page 4
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
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