EcoVision EZ Door Upgrade for D6 Kysor Warren Multi-deck Merchandisers

Transcription

1 EcoVision EZ Door Upgrade for D6 Kysor Warren Multi-deck Merchandisers Installation & Operation Manual IMPORTNT Keep in store for future reference! MNUL- I/O ECOVISION EZ D6 KYSOR WRREN P/N _D May 2018 Spanish French

2 P/N _D BEFORE YOU BEGIN Read these instructions completely and carefully. PERSONL PROTECTION EQUIPMENT (PPE) Personal Protection Equipment (PPE) is required whenever servicing this equipment. lways wear safety glasses, gloves, protective boots or shoes, long pants, and a long-sleeve shirt when handling glass. IMPORTNT KEEP IN STORE FOR FUTURE REFERENCE Quality that sets industry standards! St. Charles Rock Road Bridgeton, MO U.S. & Canada Mexico Hussmann Corporation 2 U.S. & Canada Mexico

3 EcoVision EZ Door Upgrade P/N _D REVISION HISTORY REVISION D 1. dded Caution, Page 3; Updated Drawings on Pages 8, 13-18, 23, 25 REVISION C 1. Updated Page 13 REVISION B 1. Original issue ECOVISION EZ Door Installation Tool List Level, (minimum of 2 ft long) Ratchet 1/4 in. Socket 7/16 in. Socket 3/8 in. Socket 1/2 in. Open End Wrench Battery Drill/Screw Gun Rubber Mallet Hammer Putty Knife 4ft Ladder * * * * * * * * * * * * * * * * * * * * * * * * * * NSI Z535.5 DEFINITIONS DNGER Indicate[s] a hazardous situation which, if not avoided, will result in death or serious injury. WRNING Indicate[s] a hazardous situation which, if not avoided, could result in death or serious injury. CUTION Indicate[s] a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Not related to personal injury Indicates[s] situations, which if not avoided, could result in damage to equipment. Caution: Tipping Hazard Case tipping may occur if cases are not properly leveled and secured, or if cases are not properly loaded. Excessive ambient conditions may cause condensation and therefore sweating of doors. Facility operators should monitor doors and floor conditions to ensure safety of persons. HUSSMNN CORPORTION BRIDGETON, MO U.S.. 3

4 P/N _D SHIPPING DMGE ll equipment should be thoroughly examined for shipping damage before and during unloading. This equipment has been carefully inspected at our factory. ny claim for loss or damage must be made to the carrier. The carrier will provide any necessary inspection reports and/or claim forms. GENERL Verify the merchandiser model(s) to be outfitted with the EcoVision EZ door kit(s) by locating the merchandiser s serial plate. This instruction details the installation of EcoVision EZ doors for Kysor Warren D6 Multi-deck Merchandisers. Doors may be installed without the need to remove product from the merchandisers. Check with the store manager, and let them know how long a door lineup will take to complete. The average time to install each door is about 20 minutes. Water Misters and Light Rails may not be used with glass doors. Remove any mist equipment from case before installing doors. Note Read these instructions carefully and completely before attempting to install doors. Do NOT stand or walk on top of merchandiser. Do not store items or flammable materials atop the unit. Use caution handling glass parts. lways wear safety glasses, long pants, gloves and arm guards when handling glass doors. Do not lean doors against case. Doors should remain in packing crate until it is time to install on to case. Do NOT lean glass doors against the merchandiser lineup. Leave them packed in their protective packaging until they are ready to be directly installed in the lineup. ccidental glass breakage can be dangerous. lways wear protective glasses and gloves when handling glass. 1 Installing Doors requires at least two installers!. Carefully unpack Door upgrade kit(s), and examine parts. Do not carry doors by the handle. 4 U.S. & Canada Mexico

5 EcoVision EZ Door Upgrade P/N _D 2 Remove existing Top Rail Extrusion and Front Color Panel Parts will be discarded. Top Rail Extrusion Front Color Pane 3 Remove entire canopy assembly. Discard canopy assembly. HUSSMNN CORPORTION BRIDGETON, MO U.S.. 5

6 P/N _D 4 Case without Canopy and Light Channel Disassembly is complete. Doors are ready to be installed. 6 U.S. & Canada Mexico

7 EcoVision EZ Door Upgrade P/N _D BRCKET- CNOPY CNOPY TO FSCI BRCKET CNOPY FSCI F C MULLION-END (Needed for all door kits) B Gravity Hinge Clip Tag RETINER-DOOR (No center mullion kits use full length retainer) B B E EXT RIL SUPPORT HINGE PLTE LOWER FRONT PNEL BOSTON BUMPER RETINER BUSHING MULLION-CTR Remove tag after door is installed on case B B C C F B B B D E OVERVIEW OF DOOR INSTLLTION Use small bracket in place of center mullion on "No Center Mullion" Kits D C HONEYCOMB RETINER D C C LIGHT CHNNEL GUSSET-CNOPY SUPPORT-CNOPY TRIM-FSCI F Discrete Handle doors shown dhesive Bumper 1 per 2 doors LOCKWSHER, BOLT, NUT see page XX DETIL B B B B LOWER FRONT PNEL TRIM PIECE B C D SCREW X 0.5" TEK HEX SCREW-SM X 1 1/4 TEK2 W SCREW 8-18 X 1-1/4 HEX WSHER HED SS BLCK #2 BSD SCREW-HEX WSHER HED 10X24X1/2 THRED CUTTING E F COVER-HINGE PLTE JOINT BUSHING-GRVITY TOP PIN CP-BSE 1.26"X.669" BLK PLSTIC ( ) BSE-CP 1.26"X.669"X.551" BLK PLSTIC ( ) WSHER-1/4 YELLOW ZINC FINISH FLT ( ) SCREW-CP 1/4-20 X 3 HEX HD STEEL ZINC PLT GRDE-5 ( ) FOM PNEL CORNER REINFORCING BRCKET WSHER-1/4 YELLOW ZINC FINISH FLT ( ) LOCKWSHER-1/4 SPLIT 300 SS ( ) NUT-HEX 1/ SS ( ) HUSSMNN CORPORTION BRIDGETON, MO U.S.. 7

8 P/N _D 5 Place shim onto foam bottom. The slots are not centered in the part. The smaller gap goes toward the inside of the case. Shim Side View of Case DETIL 6 Place riser assembly onto foam bottom. Rail Side View of Case Outside of Case DETIL 8 U.S. & Canada Mexico

9 EcoVision EZ Door Upgrade P/N _D 7 Install front color panel into channel at bottom. There are no screws used to install panel. Panel is held in place by bottom extrusion. Front Color Panel Bottom Channel 8 Place bottom plastic extrusion assembly over the riser assembly. Capture the front panel under the extrusion. Bottom Plastic Extrucion SCREW 8-18 X 1-1/4 HEX WSHER HED SS BLCK #2 BSD Gravity Hinge Plate Rail Capture the Front Panel under Extrusion Outside of Case HUSSMNN CORPORTION BRIDGETON, MO U.S.. 9

10 P/N _D 9 Insert reinforcing bracket between foam panel and honeycomb retainer on each end of the case. Bracket sits flush with foam panel. If screw from honeycomb retainer is in the way, temporarily remove it. lign the brackets with the foam panel end. Reinforcing Bracket Spacing of Brackets in (1019mm) in (1019mm) in (936mm) in (3670mm) 12FT CSE TOP SUPPORTS in (1222mm) 4FT CSE TOP SUPPORTS in (1008mm) in (1008mm) in (703mm) in (703mm) in 2445mm 8FT CSE TOP SUPPORTS in (1835mm) 6FT CSE TOP SUPPORTS Repeat for remainder of brackets. Space brackets at the distances shown. 10 U.S. & Canada Mexico

11 EcoVision EZ Door Upgrade P/N _D 10 Drill two ¼ inch holes through center slots of reinforcing plate, through the foam top panel using bracket as template. Drill (2) ¼ inch holes in each plate Place a canopy support over each 11 foam panel reinforcing bracket. Place canopy support approximately 4 inches past the foam panel. Canopy Support Foam Panel Reinforcing Bracket HUSSMNN CORPORTION BRIDGETON, MO U.S.. 11

12 P/N _D 12 Position Canopy Support so that it is approximately 4 inches past Foam Canopy. 4in 13 Connect each Canopy Support to the foam panel bracket with the hardware shown above. The canopy support should stick out approximately 4 inches past the foam panel. Hand-tighten hardware. (Do not tighten completely) This allows for adjustment in the canopy to install future parts, and to make sure doors are vertically straight. BSE-CP 1.26"X.669"X.551" BLK PLSTIC SUPPORT- CNOPY KYSOR DOOR CP-BSE 1.26"X.669" BLK PLSTIC SCREW-CP 1/4-20 X 3 HEX HD STEEL ZINC PLT GRDE-5 SCREW-SM 8-18 X 3/8 HW B WSHER-1/4 YELLOW ZINC FINISH FLT BRCKET-FOM PNEL CORNER REINFORCING WSHER-1/4 YELLOW ZINC FINISH FLT NUT-HEX 1/ SS LOCKWSHER- 1/4 SPLIT 300 SS 12 U.S. & Canada Mexico

13 EcoVision EZ Door Upgrade P/N _D 14 Take Canopy ssembly and slide the assist brackets over the canopy supports. Push Canopy assembly until it is tight against the assist bracket. The assist brackets are to assist in holding the canopy assembly in place until screws are fastened. Caution: Do not leave the canopy unsupported until screws have been fastened in next Step. Canopy Support Push Canopy as far back as possible Tight against assist bracket Canopy ssembly 15 The canopy assembly to each canopy support. Once screw on the left side of the bracket, and one screw on the right side. Canopy ssembly Canopy Support 2 Screws per Canopy Support HUSSMNN CORPORTION BRIDGETON, MO U.S.. 13

14 P/N _D 16 Loosen all the nuts on canopy support. This allows for adjustment. Do not remove completely. Pull canopy assembly toward outside of case. This provides room to install the light channel. Loosen Screws Do not Remove Pull Canopy ssembly Gussets on Canopy ssembly Light Channel ssembly Pull canopy assembly toward outside of case. This provides room to install the light channel. 14 U.S. & Canada Mexico

15 EcoVision EZ Door Upgrade P/N _D 17 Install Internal Canopy Panel Mullion (Installed in next Steps) Internal Canopy Panel 18 Install Mullion ngle mullion toward inside of case, and engage the flange in the extrusion. (Step #1) STEP 1 STEP 2 HUSSMNN CORPORTION BRIDGETON, MO U.S.. 15

16 P/N _D 19 Engage mullion into slot in canopy support, and fasten with #10 screws. Repeat for all other mullions. Canopy Support #10 Screw Mullion 20 Place level on each mullion, and move the canopy assembly in or out until the mullion is level. 21 Once the mullions are level, tighten all the ¼ inch nuts (20). 16 U.S. & Canada Mexico

17 EcoVision EZ Door Upgrade P/N _D 22 Re-Install Honeycombs 23 Insert wiper retainer into bottom extrusion. Squeeze the wiper retainer, and insert into bottom extrusion. RETINER SQUEEZE BOTTOM EXTRUSION STEP 1 STEP 2 HUSSMNN CORPORTION BRIDGETON, MO U.S.. 17

18 P/N _D 24 ttach Mullions to bottom extrusion (2) screws to each mullion MULLION SCREW 8-18 X 1-1/4 HEX WSHER HED SS BLCK #2 BSD VERIFY FLNGE OF MULLION TO ENGGED IN EXTRUSION BOTTOM RIL 18 U.S. & Canada Mexico

19 EcoVision EZ Door Upgrade P/N _D 25 End Mullions must be joined together at joints between cases, and are only required at case joint, not required at partition or end. Bolts, Washers and Nuts for the end mullions are pre-installed from the factory. Bolt Location. Remove the nut and washer from the end mullion and insert bolt through end mullion and end mullion of a joining case and insert between mullions as shown in Fig End Mullion (Case 2) Nut 1/4-20 End Mullion (Case 1) DO NOT USE Lockwasher Bolt 1/4-20 x 3/4 DO NOT USE DO NOT USE Nut 1/4-20 Bolt Location Lockwasher Figure 25-1 Gasket 1/2 x 1/4 Bolt 1/4-20 x 3/4 HUSSMNN CORPORTION BRIDGETON, MO U.S.. 19

20 P/N _D 26 Install EcoVision EZ Door(s) and top bushings.. Insert top of door into bushing hole of door as shown in Fig C. Important Seating - Ensure factory door is supplied seated correctly. door The cross will align when The cross will align when the the door is is opened opened slightly. slightly. The The door will not not seat seat if not if not aligned properly. Do not aligned leave the door unseated. not leave the door unseated. Figure 26-1 B. Raise door up and position gravity hinge at the bottom of the door into bottom hinge plate cross hole as shown in Fig Downward pressure Downward pressure should should fully fully seat the seat door. the If not, door. If not, the the door door must be must opened be or closed slightly to align the opened cross or feature. closed slightly to align the cross feature. D. Install remaining doors. Remove the clip by pulling the tag, and IMPORTNT - FTER DOORS RE INSTLLED! the door will close. Remove the tag from the door, pulling the C-Clip from the gravity hinge. Remove the clip by pulling the tag, and the door will close. Figure 26-2 Bottom of Gravity Hinge L marked for LEFT door E. Remove foam block and tape. Fasten bottom door bracket. Screw lock plate to hinge plate fter fully seating the door and removing the clip, fasten the gravity fter fully hinge seating bracket the door and using removing the the 1 clip, length fasten hex the gravity head hinge screws. This bracket using the 1 length hex head screws. This will secure the door into will the secure frame. the door into the frame. Do not carry doors by handle. Personal injury and damage to the doors may result. 20 U.S. & Canada Mexico

21 EcoVision EZ Door Upgrade P/N _D 27 djusting Doors Leveling these doors is very important to ensure the door s proper operation!. Leveling Merchandisers must be installed level to ensure proper operation of the refrigeration system to ensure proper drainage of defrost water, and to ensure the gravity hinge self-closing feature operates properly. Glass alignment is also affected with improper leveling of the merchandisers. ll steps of setting joining and case leveling attention to the glass position is critical. Do not attempt to make glass adjustments prior to case leveling. B. Door djustment Loosen screws in the screw hole locations as shown on the hinge plate below. (Do not remove the screws completely). Slide the bottom plate left and right until proper alignment is achieved. Re-tighten screws. Install fasteners in locations 1 and 2 as shown below. Check that door can hold open to 90. Door lignment - Modular Bottom Hinge Plate Level each door as shown below Check for level here Door Trim x x To Correct Shift the Bottom Plate to the Right To Correct Shift the Bottom Plate to the Left HUSSMNN CORPORTION BRIDGETON, MO U.S.. 21

22 P/N _D 27a C. Open door, and place level on outside of door. Repeat and check bubble level for all doors. Level should be placed vertically as shown in the photo below. fter leveling, check that all doors close and stay closed. If not, case front needs to be shimmed up. cceptable Level Bubble Range cceptable Level Bubble Range x Level Bubble 2ft Level shown OUTSIDE of Door IMPORTNT! If bubble is here, case front needs to be shimmed up until bubble is in center. Proper leveling will ensure gravity close will function throughout case life. Door must be opened 90 with level placed on door to check for gravity door closing and hold open function. Do not place level on top of door. Check level with case filled with product. Do not put level on top of case. 22 U.S. & Canada Mexico

23 EcoVision EZ Door Upgrade P/N _D 28 Install Canopy Fascia Screws at top end Fasten two screws at the top of each end. Fasten screws at bottom of canopy fascia. Screws at top end Failure to reinstall canopy nuts could cause case parts to become loose and fall, causing serious personal injury. Canopy Fascia Install 1-inch bumper retainer and bumper. 1-INCH BUMPER HUSSMNN CORPORTION BRIDGETON, MO U.S.. 23

24 P/N _D 29 Start up / Stocking Locate the merchandiser s refrigerant settings and defrost requirements. Bring merchandisers down to the operating temperatures listed on the data sheet. Product should NOT be placed in merchandisers until merchandiser is at proper operating temperature. Proper rotation of product during stocking is necessary to prevent product loss. lways bring the oldest product to the front, and set the newest product to the back. ir Discharge and return flues must remain open and free of obstruction at all times to provide proper refrigeration and air curtain performance. Figure 29-1 Product Stocking Limits 24 U.S. & Canada Mexico

25 EcoVision EZ Door Upgrade P/N _D TECHNICL GUIDELINE FOR CSE ND REFRIGERTION SYSTEM DJUSTMENTS Upgrading your existing store with doors is an excellent way to reduce energy costs. However, adjustments to your equipment may be required as a result of adding doors, because the original equipment was designed for higher refrigeration loads. Below is a list of recommended changes that need consideration for cases, line-ups and the refrigeration system after upgrading to doors in order to maintain optimal performance of the refrigeration equipment. For a detailed analysis and quote of the specific adjustments needed at your store, please contact your Hussmann sales representative. The Hussmann Team will help ensure that your existing equipment remains at optimal performance after the door upgrade. Without proper evaluation by a Hussmann pplication Engineer or qualified professional, oil return, case performance, and product temperature could be negatively impacted. CSES. Thermostatic Expansion Valve (TXV)/ Orifice Each case may have multiple evaporator coils, and each evaporator coil has a TXV / orifice combination. The setting of the superheat of each coil is critical to the performance of the case. The superheat setting on the valve may require changing to achieve optimal performance of the case. The change is likely due to the large decrease in case load (the existing valve may not have enough range in its operation to accommodate the smaller load). For non-adjustable valves, add a stem kit, or replace the valve. If you have a non-adjustable Danfoss valve, it must be changed to a valve with superheat adjustment. If you have an adjustable valve, adjust the valve. Recommended superheat is 4 to 7. B. If an electronic TXV is used, no change is needed. LINE-UPS. Each line-up of cases has a solenoid valve or Evaporator Pressure Regulator (EPR) by which to control temperature. If a solenoid valve is used in either the liquid or the suction line, more than likely, these will not have to be changed. n evaluation of the sizing of these lines is required based on the reduced load. If they are oversized or undersized by more than one size, then they should be resized. The reason for this is that these valves, especially if they are in the suction line, require a pressure drop in which to operate. If valves are oversized, this pressure drop may not be strong enough to actuate the valve. This reduction in load allows the case saturated suction temperature to run 3 to 6 warmer, therefore it is recommended that a mechanical or electronic EPR, per lineup, be utilized to optimize case performance and increase energy savings. Rear-load cases must have an EPR added. HUSSMNN CORPORTION BRIDGETON, MO U.S.. 25

26 P/N _D If a mechanical EPR is used, sizing to the new load must be considered. If an electronic EPR is used, the existing valve will need to be checked for full function at the new load. B. Each line-up of cases has a liquid and suction line from a loop served by the rack, or a run from the rack to the line-up. The liquid line does not normally need to be changed. The suction line in every line up needs to be checked and changed as required. The suction riser is the most important line that must be looked at. If the new load requires a different line size, it must be changed to ensure proper lubricant volume returns back to the compressors. REFRIGERTION SYSTEM (DX SYSTEM). The DX system itself has many components that must be evaluated. They include: Compressors: fter determining the new BTU/ hr load, determine if the existing compressor selection will allow steps from 8% to 20%. If not, a compressor or more compressors may need to be removed or replaced. When the existing design uses an even number of compressors, a compressor change should be considered if the load was reduced by more than one compressor capacity. djusting the compressor output by means of un-loaders, variable frequency drives, or digital technology, may be acceptable alternate solutions. NOTE: Pay particular attention to affected circuits that are fed by a satellite compressor or conventional unit. That compressor may now be grossly oversized. Gas Defrost: If the rack is equipped with gas defrost, the main liquid line solenoid and the discharge differential valves should be evaluated. If the existing valve is oversized, a new valve should be considered. Heat Reclaim - If the rack is equipped with heat reclaim, the new value for available heat should be recalculated. It is possible that the heat reclaim coil will now be oversized. This is especially true if compressor changes have been made. Typically, whole rack BTU/hr reductions of 35 percent and greater would need to be seen. Discharge Riser: Depending on the drop of BTU/hr to the entire rack, the discharge riser (the piping that goes from the rack to the condenser), may need to be resized. Under most applications this will just need to be checked. If the drop in the total BTU/hr is greater than 35%, a resize is more than likely necessary. If this line is not resized when it is necessary to do so, lubricant return back to the compressors may be an issue. Condenser: The condenser will not typically need to be replaced. However, if winter control is provided and there is a Total Heat of Rejection (THR) load drop of greater than 40 percent, the winter control valve should be checked. Receiver Pressure Regulator: The sizing on these series of valves will probably be acceptable and a small reset on the 8/9 series may be required. 26 U.S. & Canada Mexico

27 EcoVision EZ Door Upgrade P/N _D Solenoid Valves: Depending on the manufacturer and function of the solenoid valves, the sizing may need to be looked at. Some models require a pressure drop across the valve in order to close. If the flow through the valve is too small, the pressure drop may not exist and therefore the valve may not operate as designed. Sub-Cooler: If the rack is sub-cooled and the drop in total BTU/HR is greater than 35 percent, the sub-cooler and its TXVs may need to be resized. HETING, VENTILTION, IR-CONDITIONING SYSTEM (HVC) In some instances, the HVC system is sized based on an assumption that a portion of the refrigeration capacity will be used to reduce the temperature and humidity in the store. This is called case credits. This reduction in C load is calculated based on the spillover of the chilled air from these cases by adding doors this spillover is eliminated. If these credits were taken, and doors are applied to a major part of the refrigeration load, typically 35 percent or more, the HVC system needs to be evaluated to see if it can handle the entire air-conditioning load. In addition to the adjustments above, the following tasks must also be considered: 1. Time required to isolate that portion of the system where the component(s) will be replaced 2. Removal of the refrigerant (per government guidelines) 3. Removal of the part(s) to be replaced 4. Installing the new component(s) 5. Evacuation of that part of the system that was isolated 6. Recharging of the refrigerant that was removed and 7. Setting of each valve/component installed. HUSSMNN CORPORTION BRIDGETON, MO U.S.. 27

28 P/N _D To obtain warranty information or other support, contact your Hussmann representative. Please include the model and serial number of the product. Hussmann Corporation, Corporate Headquarters: Bridgeton, Missouri, U.S October U.S. & Canada Mexico