®
Merchandisers
Reach-in Merchandisers
Medium and Low Temperature Cases
Installation &
Operation Manual
Shipped With Case Data Sheets
P/N 0387183_D
Impact Series
October 2007
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iii
P/N 0387183_D
Table of Contents
INSTALLATION
START UP / OPERATION
NSF Certification . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Exterior Loading . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Merchandisers Shipped With End Installed . . . . 1-2
Shipping Braces . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Remove Front Panel . . . . . . . . . . . . . . . . . . . . . . 1-2
Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installing Splashguard Brackets . . . . . . . . . . . . . 1-4
Installing Bumpers . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Load Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Load Limit Profiles . . . . . . . . . . . . . . . . . . . . . . . 4-1
Installing FDA/NSF Required Thermometer . . .4-2
MAINTENANCE
Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cleaning Honeycomb Assemblies . . . . . . . . . . . . 5-2
Cleaning Under Merchandisers . . . . . . . . . . . . . 5-2
Removing Scratches from Bumper . . . . . . . . . . . 5-2
SERVICE
REFRIGERATION / ELECTRICAL
Replacing Fan Motors and Blades . . . . . . . . . . . 6-1
Replacing Electric Defrost Heaters . . . . . . . . . . 6-3
Replacing Drain Pan Heater . . . . . . . . . . . . . . . . 6-5
RLT with Gas Defrost Only: Replacing
Slave Plate Heater . . . . . . . . . . . . . . . . . . . . . . 6-6
Removing RLT Return Air Bracket . . . . . . . . . . 6-7
Replacing Lamp Ballast (other than RLT) . . . . . 6-8
Replacing RLT Lamp Ballast . . . . . . . . . . . . . . . 6-9
Servicing Vertical Lighting . . . . . . . . . . . . . . . 6-10
Servicing Doors and Frames . . . . . . . . . . . . . . 6-10
Replacing Door or Door Frame Parts . . . . . . . 6-10
Replacing Damaged Drain Fitting . . . . . . . . . . . 6-11
Repairing Aluminum Coils . . . . . . . . . . . . . . . 6-12
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Branch Line Piping . . . . . . . . . . . . . . . . . . . . . . . 2-2
Expansion Valve Adjustment . . . . . . . . . . . . . . . 2-3
Refrigeration Thermostat . . . . . . . . . . . . . . . . . . . 2-3
Defrost Termination Thermostat . . . . . . . . . . . . . 2-5
Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Merchandiser Electrical Data . . . . . . . . . . . . . . . 2-8
Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrical Connections . . . . . . . . . . . . . . . . . . . . 2-8
Identification of Wiring . . . . . . . . . . . . . . . . . . . 2-8
Wiring Color Code . . . . . . . . . . . . . . . . . . . . . . . 2-8
WARRANTY
DRIP PIPING AND SPLASHGUARDS
Waste Outlet and Water Seal . . . . . . . . . . . . . . . . 3-1
Installing Drip Piping . . . . . . . . . . . . . . . . . . . . . 3-1
Installing Splashguards . . . . . . . . . . . . . . . . . . . . 3-2
Sealing Splashguard to Floor . . . . . . . . . . . . . . . 3-3
IMPORTANT
KEEP IN STORE FOR FUTURE REFERENCE
Quality that sets industry standards!
12999 St. Charles Rock Road • Bridgeton, MO 63044-2483
®
®
U.S. & Canada 1-800-922-1919 • Mexico 1-800-522-1900
© 2007 Hussmann Corporation
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iv
CONTENTS
REVISION D — SEPTEMBER 2007
1. Added front panel text and illustration, Page 1-2.
2. Clarified shimming directions, page 1-3.
3. Added RLT information throughout.
INSTALLATION
TOOL LIST
4. Added note to remove bumper protective film, Page 1-6.
5. Added information on Always*Clear™ glass, page 5-1.
6. Removed reference to Anthony doors, Page 6-5.
7. Added repairing aluminum coil, Page 6-12.
8. Changed warranty page.
Unloading From Trailer:
Lever Bar (also know as a Mule,
Johnson Bar, J-bar, Lever Dolly, and pry lever)
Moving Dolly
9. Added Installation Tool List, page iv.
10. Added revision history, page iv.
Setting Case Line-Up:
REVISION C — JUNE 2002
Level, 4 ft suggested
Ratchet
1. Added NSF information,pages 1-1,4-2 through 4-4.
2. Sections 2 through 6 are completely rewritten.
3. Changed warranty to March 15,2002.
1/4 in. Socket
5/16 in. Socket
1/2 in. Socket
Battery Drill/Screw Gun
Caulking Gun
10 in. Adjustable Crescent Wrench
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1-1
INSTALLATION
NSF CERTIFICATION
These merchandisers are manufactured to meet
ANSI / National Sanitation Foundation (NSF®)
Standard #7 requirements. Proper installation is
required to maintain certification. Near the serial
plate, each case carries a label identifying the
type of application for which the case was certi-
fied.
Product should always be maintained at proper
temperature. This means that from the time the
product is received, through storage, preparation
and display, the temperature of the product must
be controlled to maximize the life of the product.
SHIPPING DAMAGE
ANSI/NSF-7 Type I – Display Refrigerator / Freezer
Intended for 75°F / 55%RH Ambient Application
All equipment should be thoroughly examined
for shipping damage before and during unload-
ing.
ANSI/NSF-7 Type II – Display Refrigerator / Freezer
Intended for 80°F / 55%RH Ambient Application
This equipment has been carefully inspected at
our factory. Any claim for loss or damage must be
made to the carrier. The carrier will provide any
necessary inspection reports and/or claim forms.
ANSI/NSF-7 – Display Refrigerator
Intended for Bulk Produce
Apparent Loss Or Damage
LOCATION
If there is an obvious loss or damage, it must be
noted on the freight bill or express receipt and
signed by the carrier’s agent; otherwise, carrier
may refuse claim. The carrier will supply neces-
sary forms.
These merchandisers are designed for displaying
products in air conditioned stores where tempera-
ture is maintained at or below the ANSI/NSF-7
specified level and relative humidity is maintained
at or below 55%.
Concealed Loss Or Damage
When loss or damage is not apparent until after
equipment is uncrated, a claim for concealed
damage is made. Upon discovering damage,
make request in writing to carrier for inspection
within 15 days and retain all packing. The carrier
will supply inspection report and required claim
forms.
Placing refrigerated merchandisers in direct sun-
light, near hot tables or near other heat sources
could impair their efficiency.
Like other merchandisers, these are sensitive to air
disturbances. Air currents passing around mer-
chandisers will seriously impair their operation.
Do NOT allow air conditioning, electric fans,
open doors or windows, etc. to create air currents
around the merchandisers.
To prevent sweating on the exterior surfaces
of merchandisers, there must be A MINIMUM
CLEARANCE OF 4 INCHES (102 MM) between the
merchandisers and other fixtures or walls.
CAUTION
Do not walk or put heavy objects on case.
!
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1-2
INSTALLATION
EXTERIOR LOADING
REMOVE FRONT PANEL
(DOES NOT APPLY TO RLT)
Do NOT walk on top of merchandisers or dam-
age to the merchandisers and serious personal
injury could occur. THEY ARE NOT STRUCTURALLY
DESIGNED TO SUPPORT EXCESSIVE EXTERNAL
LOADING such as the weight of a person. Do not
place heavy objects on the merchandiser.
Before setting case, remove the front panel as
follows: remove screws from front panel tabs,
then lift the front panel. Refer to the illustration
below. Set panel and screws aside to reinstall
once all electrical work is complete.
MERCHANDISERS SHIPPED WITH END
INSTALLED
Edge Fits Over Raceway
If the case was shipped with the end installed,
two long bolts were used to hold the shipping
brace to the end. If the shipping bolts are
reinserted after removing the brace, they will
extend into the product area and may damage
the coil. THEREFORE, BE SURE TO REPLACE
THESE BOLTS WITH THE SHORTER BOLTS
PROVIDED.
Tabs Fit in
Retainer Slots
Front Panel
Remove Screws
Be careful not to damage the factory-installed
end while moving the merchandiser. Make sure
that tools are positioned past the end and beneath
the merchandiser’s support bar.
At completion of all electrical work, installation
contractor shall re-install the panels using care to
ensure all panels are centered and properly
fastened.
SHIPPING BRACES
Move the merchandiser as close as possible to its
permanent location and then remove all packag-
ing. Check for damage before discarding packag-
ing. Remove all separately packed accessories
such as kits and shelves.
Locate the shipping block in the
center of the heat exchanger (see
illustration), and remove it before
piping the merchandiser. This
block was installed to minimize
shipping vibration.
Heat Exchanger
Shipping
Block
Top View of Merchandiser
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1-3
LEVELING
Approximately
Centered
Merchandisers must be installed level
to ensure proper operation of the
refrigeration system and to ensure
proper drainage of defrost water.
When leveling merchandisers, use a
carpenter’s level as shown.
Rear of Reach-in
Base
Component
Metal leveling shims or wedges are
provided with each merchandiser for
use if needed.
NOTE: BEGIN LINEUP LEVELING
FROM THE HIGHEST POINT OF THE
STORE FLOOR.
Place shims under the rail and make
sure that they are positioned at a base
component (crossbar). This transfers
the weight directly from the loaded
case through to the floor. Placing shims
at other locations will cause uneven
distribution of weight leading to piping
leaks, as well as sagging or wracked
doors.
Base Component
Shim Here
Shim Here
Shim
Here
NO SHIM
HERE
5-Door Island Shown
Electrical Wireway
Skid/External Base
Bottom Front
Support
Electrical Wireway
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1-4
INSTALLATION
DOOR ADJUSTMENT
INSTALLING SPLASHGUARD BRACKETS
After leveling and joining the merchandisers,
adjust and level doors according to manufacturer’s
instructions shipped with each product. Factory
settings are lost due to vibration during shipment.
1. Attach splashguard retainer and splashguard
retainer support to splashguard support brack-
et using two screws per bracket.
Splashguard
Retainer Support
JOINING
Sectional construction means that two or more
merchandisers may be joined in line yielding one
long continuous display requiring only one pair
of ends. Joining kits and instructions are
shipped with each merchandiser.
Splashguard
Support Bracket
To join like fixtures, a joining kit is required.
To join unlike fixtures, or like fixtures operating
at different temperatures, a 11/2 inch (38 mm)
partition kit is required. To join same
Screw
Splashguard Retainer
temperature fixtures on different defrost cycles,
a plexiglass partition kit is required.
2. INSTALL SPLASHGUARD SUPPORT BRACKETS
BEFORE PIPING CASE. The leveling brackets
have a maximum extension of one (1) inch
(25 mm) for uneven floors.
ALL JOINTS MUST BE AIR-TIGHT TO PREVENT
FORMATION OF ICE OR CONDENSATION.
Bumper Retainer
Refer to separate joining instruction shipped
with each case
Screw
Base Rail
DO NOT PLACE SHIMS UNDER SPLASHGUARD
BRACKETS.
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1-5
INSTALLING BUMPERS
Offsetting the bumpers and top rails helps to
disguise the joint locations, giving the lineup a
smoother look.
Do NOT install the last bumper sections at this
time. These sections will be installed in the last
step.
Begin at the left end of the line-up. A starter
bumper is factory-installed with end kits. Insert
the internal joint trim, then add the full-length
bumper.
Once all except the last section of bumper have
been installed, refrigerate the case line-up for
at least six (6) hours. The last sections of
bumper should be kept inside a refrigerated
case or cooler during this time to allow the
bumpers to contract.
Align each bumper section with its retainer and
push into place, working from the end of the line-
up. Install full length bumpers and internal joint
trims offset across joints. Make sure that no gaps
exist between sections. Continue installing
bumpers the length of the line up.
Before installing the last full-length section,
measure the remaining space. Use a miter box
and fine-tooth saw to cut last bumper to length.
Install the last section.
Merchandiser
Joint
Merchandiser
Joint
Internal Joint
Trims
Bumper
Full Length
Bumpers
Starter
Bumper
Miter Box
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1-6
INSTALLATION
Remove protective film from bumpers once
installation is complete.
Optional end bumpers are factory-installed.
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2-1
REFRIGERATION / ELECTRICAL
REFRIGERANT
The correct type of refrigerant will be stamped on
each merchandiser’s serial plate which is located
on the left-hand end of the interior top liner.
NOTE: If Gas defrost is used, the liquid line
will need to be increased two sizes larger inside
the merchandiser area. This is necessary to ensure
even liquid drainage from all evaporators during
defrost.
!
WARNING
Line Sizing
Refrigerant lines should be sized as shown on the
refrigeration legend that is furnished for the store
or according to ASHRAE guidelines.
Refrigeration lines are under pressure and
should be depressurized before attempting
to make any connections.
Oil Traps
P-traps (oil traps) must be installed at the base of
REFRIGERANT PIPING
all suction line vertical risers.
Connection Location
Pressure Drop
The refrigerant line connections are at the right-
hand end of the merchandiser (as viewed from
the front) beneath the display pans.
Pressure drop can rob the system of capacity. To
keep the pressure drop to a minimum, keep the
refrigerant line run as short as possible using a
minimum number of elbows. Where elbows are
required, USE LONG RADIUS ELBOWS ONLY.
After connections have been made, seal this out-
let thoroughly. Seal both the inside and the out-
side. We recommend using an expanding
polyurethane foam insulation.
INSULATION
With GAS Defrost
The suction and liquid lines should NOT contact
each other and should be insulated separately
for a minimum of 30 ft (9144 mm) from the
merchandiser.
CAUTION
When brazing pipes be sure to use the
insulation blanket shipped with the
merchandiser to prevent damage to
the plastic case bottom.
!
With OTHER Than Gas Defrost
The suction and liquid lines should be clamped or
taped together and insulated for a minimum of
30 ft (9144 mm) from the merchandiser.
Multiplexing
Piping of merchandisers operating on the same
refrigeration system may be run from merchan-
diser to merchandiser through the end frame
saddles provided for this purpose. DO NOT RUN
REFRIGERANT LINES THROUGH MERCHANDISERS
THAT ARE NOT ON THE SAME REFRIGERATION
SYSTEM as this may result in poor refrigeration
control and compressor failure.
With All Defrost
Additional insulation for the balance of the liquid
and suction lines is recommended wherever
condensation drippage is objectionable or the
lines are exposed to ambient conditions.
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2-2
REFRIGERATION / ELECTRICAL
Liquid Line – Off-time and Electric Defrost
• May be reduced by one size after one half the
case load run. Do not reduce below evaporator
connection size.
• Take-offs to evaporators exit the bottom of the
liquid line. Provide an expansion loop for each
evaporator take-off (minimum 3 in. (76 mm)
diameter).
CAUTION
!
The following information is applicable only
for piping Hussmann merchandisers to
Hussmann refrigeration equipment.
BRANCH LINE PIPING
Liquid Line – Koolgas Defrost
Suction Line – All Defrosts
• Pitch in direction of flow.
• Maximum of 6 evaporators per Branch System.
• Increase the liquid line size inside the case by
two sizes over the branch size.
• May be reduced by one size at one third of case
run load and again after the second third. Do
NOT reduce below evaporator connection size.
• Suction returns from evaporators enter at the
top of the branch line.
Branch Size
In Case Size
1/2
5/8
7/8
1 1/8
1 3/8
1 /8
2 1/8
7/8
1 1/8
1 3/8
5
• Take-offs to evaporators exit the bottom of the
liquid line. Provide an expansion loop for each
evaporator take-off (minimum 3 in. (76 mm)
diameter).
Suction Line Return
3-In. Loop (76 mm)
Liquid Line Take Off
Koolgas Defrost Liquid Line Two Sizes Larger in Merchandiser
From
Liquid
Manifold
Electric or Offtime Defrost Liquid Line
To
Suction
Manifold
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2-3
EXPANSION VALVE ADJUSTMENT
REFRIGERATION THERMOSTAT
The thermostat body is located in the electrical
raceway near the right-hand end of the merchan-
diser. Its sensing bulb is located behind the right
end interior back panel.
Expansion valves must be adjusted to fully feed
the evaporator. Before attempting to adjust
valves, make sure the evaporator is either clear or
only lightly covered with frost, and that the
merchandiser is within 10 deg F (6.5 deg C) of
its expected operating temperature. Adjust valves
as follows:
Attach two sensing probes
(either thermocouple or
thermistor) to the evaporator.
Position one under the clamp
holding the expansion valve
bulb; securely tape the other
to the coil inlet line.
Some “hunting of the
”
expansion valve is normal.
The valve should be adjusted
so that during the hunting
THE GREATEST DIFFERENCE
BETWEEN THE TWO PROBES IS
3–5 deg F (1.7–2.8 deg C).
With this adjustment, during
a portion of the hunting the
temperature difference
Check Valve
Optional
Heat
Gas Bypass
Exchanger
body
Expansion
Valve
between the probes will be
less than 3 deg F (1.7 deg C)
and at times 0.
Expansion Valve
Bulb
Make adjustments of no more
than 1/4 turn for Balanced
Port TEV and 1/2 turn at a
time for other valve models.
Wait at least 15 minutes
before rechecking the probe
temperature or making further
adjustments.
Component Location in
RL / RM / RLN / RLNI Models
Thermostat
Manifold
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2-4
REFRIGERATION / ELECTRICAL
Distributor
Assembly
RLT Coil
TEV Bulb
Mounted
on Side of
Suction Tube
TEV
Optional
Gas Bypass
Check Valve
Heat Exchanger
Assembly
Component Location in RLT Models
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2-5
DEFROST TERMINATION THERMOSTAT
The standard disc type defrost termination ther-
mostat is not adjustable.
ELECTRIC
ELECTRIC DEFROST ONLY
5 Door
&
4 Door
RL
RLN
RLNI
RLNIE
On low-temperature merchandisers, the defrost
termination thermostat or optional termination
sensor is located on the right end of the coil at
the bottom center return bend. If an optional
adjustable thermostat is used, the bulb will be
clamped to the suction line on the left end of the
case.
2 Door
RL
RLN
RLNI
RLNIE
3 Door
RL
RLN
RLNI
RLNIE
Defrost Termination
Thermostat Location
.
RLT
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2-6
REFRIGERATION / ELECTRICAL
CONTROL SETTINGS
MEDIUM TEMPERATURE
CONTROL SETTINGS
LOW TEMPERATURE
Conventional Single Compressor
Measure Discharge Air Temperature
at the center of the case
Conventional Single Compressor
Measure Discharge Air Temperature
at the center of the case
at the discharge honeycomb.
at the discharge honeycomb.
Merchandiser temperature must be controlled by
a thermostat or other device with a 3–6 deg F
(1.7–3.3 deg C) differential. It will be wired to
control the compressor motor contactor.
Merchandiser temperature must be controlled by
a thermostat or other device with a 3–6 deg F
(1.7–3.3 deg C) differential. It will be wired to
control the compressor motor contactor.
Standard Off Time defrost is temperature termi-
nated. The defrost termination thermostats for all
the merchandisers on one compressor are wired
in series. On outdoor units the defrost timer will
control a liquid line solenoid beginning a defrost
pumpdown 4 minutes before defrost.
Standard Electric defrost is temperature terminat-
ed. The defrost termination thermostats for all
the merchandisers on one compressor are wired
in series. Failsafe must not control defrost cycle
length, especially when less than 208V power
supply is used for defrost heaters, or if frost
build up is heavy from shopping demands.
The defrost frequency and lengths listed may
require adjustment for specific store conditions.
Factors include:
On outdoor units the defrost timer will control a
liquid line solenoid beginning a defrost pump-
down 4 minutes before defrost.
Store temperature and humidity
Low head pressure
Long refrigerant line runs
Seasonal changes
Merchandiser temperature lower than
recommended
Optional Gas defrost is time terminated and has
fan cycling thermostat. The defrost frequency and
lengths listed may require adjustment for specific
store conditions. Factors include:
Store temperature and humidity
Low head pressure
When practical, defrost when store is closed.
Long refrigerant line runs
Low pressure control settings are applicable to
outdoor condensing units where ambient does not
fall below 0 deg F.
Seasonal changes
Merchandiser temperature lower than
recommended
When practical, defrost when store is closed.
Low pressure control settings are applicable to
outdoor condensing units where ambient does not
fall below 0 deg F.
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2-7
CONTROL SETTINGS
MEDIUM TEMPERATURE
CONTROL SETTINGS
LOW TEMPERATURE
Parallel Compressor Rack
Measure Discharge Air Temperature
at the center of the case
Parallel Compressor Rack
Measure Discharge Air Temperature
at the center of the case
at the discharge honeycomb.
at the discharge honeycomb.
Merchandiser temperature must be controlled by
a mechanical or electronic pressure regulator or
thermostat that will be mounted on the rack.
Merchandiser temperature must be controlled by
a mechanical or electronic pressure regulator or
thermostat that will be mounted on the rack.
Standard Off Time defrost is temperature termi-
nated. The defrost frequency and lengths listed
may require adjustment for specific store condi-
tions. Factors include:
Standard Electric defrost is temperature terminat-
ed. Failsafe must not control defrost cycle length,
especially when less than 208V power supply is
used for defrost heaters, or if frost build up is
heavy from shopping demands.
Store temperature and humidity
Low head pressure
Long refrigerant line runs
Seasonal changes
Merchandiser temperature lower than
recommended
Optional Gas defrost is time terminated and has
fan cycling thermostat. The defrost frequency and
lengths listed may require adjustment for specific
store conditions. Factors include:
Store temperature and humidity
Low head pressure
Stagger defrosts to maintain stable compressor
loading and sufficient defrost gas. When practi-
cal, defrost when store is closed.
Long refrigerant line runs
Seasonal changes
Merchandiser temperature lower
than recommended
Stagger defrosts to maintain stable compressor
loading and sufficient defrost gas. When practi-
cal, defrost when store is closed.
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2-8
REFRIGERATION / ELECTRICAL
MERCHANDISER ELECTRICAL DATA
Merchandiser data sheets for specific models are
shipped with this manual. The data sheets provide
merchandiser electrical data, standard electrical
schematics, parts lists and performance data.
Refer to the merchandiser data sheets and case
serial plate for electrical information. Refer to
the separate wiring diagrams shipped with the
case for specific information about the case and
any optional wiring kits that may have been
applied.
When two or more merchandisers with full length
raceways are installed in line, remove the splash-
guards, end caps and raceway covers, and install
the nipple and nuts (supplied) providing electrical
passage from one merchandiser to the next.
Following NEC and local codes is the
responsibility of the electrical contractor.
ELECTRICAL CONNECTIONS
All wiring must be in compliance with NEC and
local codes. All electrical connections are to be
made to the terminal blocks in the electrical race-
way behind the lower front panel at the right-
hand end of the merchandiser (facing front).
FIELD WIRING
Field wiring must be sized for component amperes
stamped on the serial plate. Actual ampere draw
may be less than specified. Field wiring from the
refrigeration control panel to the merchandisers is
required for defrost termination thermostats and for
optional refrigeration thermostats. When multiple
merchandisers are on the same defrost circuit, the
defrost termination thermostats are wired in series.
ALWAYS CHECK THE SERIAL PLATE FOR
COMPONENT AMPERES.
!
WARNING
Terminal block NOT for case-to-case wire
connection.
IDENTIFICATION OF WIRING
Electric Defrost is standard for low temperature
merchandisers and requires temperature termina-
tion. Gas defrost is optional
Leads for all electrical circuits are identified by
colored plastic bands. These bands correspond to
the color code sticker (shown below) located
inside the merchandiser raceway.
Off Time Defrost is standard for medium temper-
ature merchandisers and is time terminated.
WIRING COLOR CODE
Leads for all electrical circuits are identified by a colored plastic band: neutral wire for each
circuit has either White insulation or a White plastic sleeve in addition to the color band.
PINK............REFRIG. THERMOSTAT LOW TEMP.
LIGHT BLUE .REFRIG. THERMOSTAT NORM TEMP.
DARK BLUE..DEFROST TERM. THERMOSTAT
PURPLE .......ANTI-SWEAT HEATERS
BROWN ........FAN MOTORS
ORANGE OR
TAN..........LIGHTS
MAROON ..RECEPTACLES
YELLOW* ..DEFROST HEATERS, 120V
RED*........DEFROST HEATERS, 208V
GREEN* .......GROUND
*EITHER COLORED SLEEVE OR COLORED INSULATION
ELECTRICIAN NOTE: Use copper conductor wire only.
CASE MUST BE GROUNDED
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3-1
DRIP PIPING AND SPLASHGUARDS
WASTE OUTLET AND WATER SEAL
CAUTION
!
The waste outlet location varies for each of the 1,
2, 3, 4, and 5 door merchandisers. Drip piping is
located between the front case base and the
splashguard fixture and runs parallel to the case
(see Data Sheet for exact locations).
Splashguard brackets MUST be installed
before piping case.
(See Page 1-3)
4. Avoid long runs of drip piping. Long runs
make it impossible to provide the pitch neces-
sary for good drainage.
INSTALLING DRIP PIPING
Poorly or improperly installed drip pipes can
seriously interfere with the merchandiser's opera-
tion and result in costly maintenance and product
losses. Please follow the recommendations listed
below when installing drip pipes to ensure proper
installation.
5. Provide a suitable air break between
flood rim of the floor drain and outlet
of drip pipe. To meet code on low base
merchandisers, it may be necessary
to install a field-supplied drip pipe
reducer. An alternative is to cut the
last section of drip pipe at an angle.
1. Never use drip piping smaller than the nomi-
nal diameter of the pipe or water seal sup-
plied with the merchandiser.
6. Prevent drip pipes from freezing:
A. Do NOT install drip pipes in contact with
uninsulated suction lines. Suction lines should
be insulated with a non-absorbent insulation
material.
2. When connecting drip piping, the water seal
must be used as part of the drip piping to pre-
vent air leakage or insect entrance. Never use
two water seals in series in any one drip pipe.
DOUBLE WATER SEALS IN SERIES WILL CAUSE
AN AIR LOCK AND PREVENT DRAINING.
B. Where drip pipes are located in dead air
spaces, such as between merchandisers or
between a merchandiser and a store wall,
provide means to prevent freezing.
3. Pitch the drip piping in the direction of flow.
There should be a minimum pitch of 1/8 inch
per foot (1 mm per 100 mm).
Field Installed
Case Bottom
Drip Piping
Waste Outlet
This End MUST Be
Above Tee Fitting
TEE-SIDE
Plug
Field-Installed
Water Seal
Field-Installed
Coupling
Tee
Adapter
Fitting
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3-2
DRIP PIPING AND SPLASHGUARDS
INSTALLING SPLASHGUARDS
The splashguard is shipped inside each mer-
chandiser. AFTER merchandisers have been lev-
eled and joined, and all drip piping, electrical
and refrigeration work has been completed,
re-install the front color panel, then install the
splashguards.
First, position top of splashguard over the top
edge of the bracket; second, push the lower edge
of the splashguard toward the bottom of the
bracket until it snaps into place.
1
2
Splashguard
Retaining
Bracket
Splashguard
Joint
Splashguards are joined with a galvanized
metal splice connector that comes with the
joint kit. Join the splashguards before
installing on case.
Side
Detail
Splashguard
Splice Connector
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3-3
SEALING SPLASHGUARD TO FLOOR
OPTIONAL Stainless steel splashguards may be
sealed to the floor using a vinyl cove base trim.
The size of trim needed will depend on how
much the floor is out of level.
IF REQUIRED by local sanitation codes, or if
desired by the customer, plastic splashguards may
be sealed to the floor using silicone type sealer.
The amount needed will depend on how much
the floor is out of level.
To install the trim to the splashguard:
• Remove all dirt, wax and grease from the area
of the splashguard where adhesion will be neces-
sary. This is to ensure a good and secure installa-
tion.
• Remove all dirt, wax and grease from the area of
the splashguard where adhesion will be necessary.
This is to ensure a good and secure installation.
• Apply a good silicone type sealer along the
bottom of the splashguard. Sealant must be
removed and replaced when servicing.
• Apply a good contact cement to the cove trim
and allow proper drying time according to the
directions supplied with the cement.
• Install the trim to the splashguard so that it is
lying flush with the floor. DO NOT SEAL THE TRIM
TO THE FLOOR.
• If required by local health codes Cove Trim
may be sealed to the floor using a silicone type
sealer. Sealant must be removed and replaced
when servicing.
Splashguard
Silicone-type
Sealer
Splashguard
Cement
Cove Trim
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3-4
DRIP PIPING AND SPLASHGUARDS
NOTES
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4-1
START UP / OPERATION
STARTUP
LOAD LIMITS
See the merchandiser's Data Sheet Set for
refrigerant settings and defrost requirements.
Bring merchandisers down to the operating
temperatures listed on the data sheet.
Shelf life of perishables will be short if load limit
is violated. AT NO TIME SHOULD MERCHANDISERS
BE STOCKED BEYOND THE LOAD LIMITS INDICATED.
DO NOT BLOCK HONEYCOMB.
STOCKING
Product should NOT be placed in merchandisers
until all refrigeration controls have been adjusted
and merchandisers are at proper operating
temperature.
LOAD LIMIT PROFILES
All shelves and the lower deck are intended to
display product. Shelf height is adjustable in one
inch increments. Spacing of 12 inches is
recommended for most applications. Maximum
load per shelf is 170 pounds. Merchandisers may
be ordered with optional “L” shaped wire
shelves.
RL / RM / RMF
Proper rotation of product during stocking is
necessary to prevent product loss. Always bring
the oldest product to the front and set the newest
to the back.
AIR DISCHARGE AND RETURN FLUES MUST REMAIN
OPEN AND FREE OF OBSTRUCTION AT ALL TIMES to
provide proper refrigeration and air curtain
performance. Do not allow product, packages,
signs, etc. to block these grilles. Do not use non-
approved shelving, baskets, display racks, or any
accessory that could hamper air curtain
performance.
COIL
FAN
Do not prop doors open while stocking. And keep
the doors closed as much as possible to prevent
coil frosting and high merchandiser temperature.
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4-2
START UP / OPERATION
RLN
or
RLNI
Load
RLNI
Load
RMN
Load
Limits
Limits
Limits
COIL
COIL
COIL
FAN
FAN
FAN
INSTALLING FDA/NSF REQUIRED
THERMOMETER
The following pages provide the same
information that ships with the thermometer.
This requirement does not apply to display
refrigerators intended for bulk produce (refer
to page 1-1).
RLT
Load
Limits
Please note that the tape cannot be exposed after
installation.
C
O
I
L
FAN
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4-3
Suggested Mounting Locations
in Single Deck Glass Front
Impact Merchandisers
This is an NSF-7 &
US FDA Food Code
Required
Package Guard,
Facing Out
Thermometer
Thermometer — Hussmann Part TM.4911251
Hussmann Corporation • 12999 St. Charles Rock Road • Bridgeton, MO 63044-2483
© 2007 Hussmann Corporation
Double Stick Tape
End Panel
Price Tag
Molding
Flexible Plastic
Fits in Price Tag
Moldings
Suggested Mounting Locations
in Multi-deck Merchandisers
Hussmann P/N 0429971_C
10/2007
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A.
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START UP / OPERATION
Important – Please read!
This thermometer is provided in response to United States
and
Each installation will be different
depending on how the unit is
The thermometer may need to be
moved several times to find the
warmest location. Mounting options
include flexible plastic for price tag
molding application, magnet
stocked, shopping patterns in the
department and ambient conditions
of the store. The suggested loca-
tions provided herein are possible
locations. It is the responsibility of
the purchaser / user to determine
the location within the food storage
area of the unit that best meets the
code requirements above.
applied to back of flexible plastic for
steel end wall, and double stick
tape. Tape must not be exposed
after installation.
Questions about either code should
be addressed to local agencies or
other appropriate officials.
Keep with merchandiser
or give to store manager.
DO NOT DESTROY.
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5-1
MAINTENANCE
CARE AND CLEANING
!
WARNING
Long life and satisfactory performance of any
equipment is dependent upon the care it receives.
To ensure long life, proper sanitation and mini-
mum maintenance costs, these merchandisers
should be thoroughly cleaned, all debris removed
and the interiors washed down, weekly.
SHUT FANS OFF DURING CLEANING
PROCESS.
DO NOT USE:
• Abrasive cleansers and scouring pads, as
these will mar the finish.
Fan Plenum
• Solvent, oil or acidic based cleaners on any
interior surfaces.
• Ammonia based cleaners on acrylic surfaces.
To facilitate cleaning, the fan plenum is hinged
and also fastened with screws at each end. After
cleaning be sure the plenum is properly lowered
into position and that screws are reinstalled
OR PRODUCT LOSS WILL RESULT due to improper
refrigeration.
DO:
• Remove the product and all loose debris to
avoid clogging the waste outlet.
Exterior Surfaces
• Store product in a refrigerated area such as a
freezer. Remove only as much product as can
be taken to the freezer in a timely manner.
• First turn off refrigeration, then disconnect
electrical power.
The exterior surfaces should be cleaned with a
mild detergent and warm water to protect and
maintain their attractive finish. NEVER USE
ABRASIVE CLEANSERS OR SCOURING PADS.
• Thoroughly clean all surfaces with soap and
hot water. DO NOT USE STEAM OR HIGH
WATER
Always*Clear™ Glass
Wipe inside of glass with isopropyl alcohol and
a soft cloth. Allow surface to dry before closing
door. Use of other cleaners or abrasives may
damage the Always*Clear surface, and/or void
the warranty. Refer to manual that ships with
doors.
PRESSURE HOSES TO WASH THE INTERIOR.
THESE WILL DESTROY THE MERCHANDISERS’
SEALING CAUSING LEAKS AND POOR PERFOR-
MANCE.
• Remove screws and lift hinged fan plenum
for cleaning. BE SURE TO REPOSITION THE FAN
PLENUM AFTER CLEANING MERCHANDISER.
• Take care to minimize direct contact between
fan motors and cleaning or rinse water.
• Rinse with hot water, but do NOT flood.
NEVER INTRODUCE WATER FASTER THAN THE
WASTE OUTLET CAN REMOVE IT.
• Allow merchandisers to dry before resuming
operation.
• After cleaning is completed, turn on power
and refrigerant to the merchandiser.
• Verify that merchandiser is working properly.
Interior Surfaces
The interior surfaces may be cleaned with most
domestic detergents, ammonia based cleaners and
sanitizing solutions with no harm to the surface.
!
WARNING
Do NOT use HOT water on COLD glass surfaces.
This can cause the glass to shatter and could
result in personal injury. Allow glass fronts,
ends and service doors to warm
before applying hot water.
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5-2
MAINTENANCE
CLEANING HONEYCOMB ASSEMBLIES
CLEANING UNDER MERCHANDISERS
Honeycombs should be cleaned every six months.
Dirty honeycombs will cause merchandisers to
perform poorly. The honeycombs may be cleaned
with a vacuum cleaner. Soap and water may be
used if all water is removed from the honeycomb
cells before reassembling. Be careful not to
damage the honeycombs.
Remove splashguards not sealed to floor. Use a
vacuum with a long wand attachment to remove
accumulated dust and debris from under the
merchandiser.
REMOVING SCRATCHES FROM BUMPER
1. Remove the sheet metal screws located in the
front metal retainer which holds the honey-
comb assembly in place.
Most scratches and dings can be removed using
the following procedure.
1. Use steel wool to smooth out the surface area
of the bumper or top rail.
2. Lift the honeycomb assembly out of the
L-bracket to remove it.
2. Clean area.
3. Clean and dry the honeycomb.
3. Apply vinyl or car wax and polish surface for
a smooth glossy finish.
4. After cleaning, reassemble in reverse order of
removal.
Honeycomb
Internal
Top Panel
Frame
Screw
Adhesive
Interior
Top Panel
SIDE VIEW
Honeycomb
Retainer
!
WARNING
Do NOT allow product to sit in a
non-refrigerated area.
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6-1
SERVICE
REPLACING FAN MOTORS AND BLADES
See cross section for location of evaporator
fans. Should it ever be necessary to service or
replace the fan motors or blades be certain that
the fan blades are re-installed correctly.
!
WARNING
Always disconnect the electrical power at
the main disconnect when servicing or
replacing any electrical component. This
includes, but is not limited to, such items
as fans, heaters, thermostats and lights.
For access to RL / RM / RLN / RMN / RLNI /
RLNIE fans:
1. Turn off power.
Fan Assembly
2. Remove bottom display pans.
3. Disconnect fan from wiring harness.
4. Remove fan blade.
S
e
vi
r
c
e
M#O.XXX
XX
X
X
Speed-Nut
5. Remove screws holding fan motor/bracket
assembly to plenum and remove assembly.
XXXXXXX
Screws
Fan Blade
6. Replace fan motor/bracket assembly and
reinstall screws.
Airflow
Direction
7. Reinstall fan blade.
8. Reconnect fan to wiring harness.
9. Turn on power.
Bracket
Plenum
Motor
10. Verify that motor is working and blade is
turning in the correct direction.
11. Close air gaps under fan plenum. Warmer air
moving into refrigerated air reduces effective
cooling. If the plenum does not rest against
the case bottom without gaps, apply foam
tape to the bottom of the fan plenum to
reduce improper air movement. Use silicone
sealant to close other gaps.
12. Replace display pans. Bring merchandiser to
operating temperature before restocking.
Hussmann recommends against frame heater
cycling with Innovator doors to prevent door
seals from freezing to the frames and tearing.
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6-2
SERVICE
RLT ONLY
For access to these fans:
Motor
Lock Nut
Tool
1. Turn off power.
2. Remove bottom display pans.
3. Disconnect fan from wiring harness.
4. Remove fan blade.
Nut
Fan Blade
5. Lift fan plenum and remove screws holding
bottom of motor to fan basket.
Gasket
6. Replace fan motor and blade.
7. Lower fan plenum.
8. Reconnect fan to wiring harness.
9. Turn on power.
Screws
Tape
10. Verify that motor is working and blade is
turning in the correct direction.
11. Close air gaps under fan plenum. Warmer air
moving into refrigerated air reduces effective
cooling. If the plenum does not rest against
the case bottom without gaps, apply foam
tape to the bottom of the fan plenum to
reduce improper air movement. Use silicone
sealant to close other gaps.
Motor
Bracket
12. Replace display pans. Bring merchandiser to
operating temperature before restocking.
!
WARNING
Always disconnect the electrical power at
the main disconnect when servicing or
replacing any electrical component. This
includes, but is not limited to, such items
as fans, heaters, thermostats and lights.
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6-3
REPLACING ELECTRIC DEFROST
HEATERS (RL / RLN / RLNI / RLNIE
Only)
Electric defrost requires a heater on the front
and rear of the coil as shown. The heaters are
held in place by tabs in the coil brackets.
9. Verify that heater is working correctly.
10. Close air gaps under fan plenum. Warmer air
moving into refrigerated air reduces effective
cooling. If the plenum does not rest against
the case bottom without gaps, apply foam
tape to the bottom of the fan plenum to
reduce improper air movement. Use silicone
sealant to close other gaps.
Electric Defrost
Bend Tabs
on Each
Bracket
to Release
or Secure
Heaters
11. Replace display pans. Bring merchandiser to
operating temperature before restocking.
Rear Defrost Heater
1. Disconnect Power.
2. Remove coil cover.
3. Remove clips holding heater to coil tube.
4. Remove heater from slots in coil bracket.
5. Position new heater in slots.
6. Replace clips.
Front Defrost Heater
1. Disconnect Power.
2. Lift fan plenum up and back to access the
heater.
7. Replace the coil cover.
3. Bend tabs holding heater to horizontal.
4. Remove heater from coil bracket.
5. Position new heater in bracket.
8. Turn on power.
9. Verify that heater is working correctly.
10. Replace display pans. Bring merchandiser to
operating temperature before restocking.
6. Bend tabs back to vertical to hold heater in
bracket.
7. Replace the coil cover and lower fan plenum.
8. Turn on power.
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6-4
SERVICE
REPLACING ELECTRIC DEFROST
HEATERS (RLT Only)
RLT electric defrost heaters are located under
the coil as shown in the photo below. Mounting
brackets and supports are attached to plenum
brackets.
1. Disconnect Power.
2. Remove lower back panels to access the
heater.
3. Lift fan plenum up and back to access the
heater.
4. Remove heater from bracket.
5. Position new heater in bracket.
6. Close the bracket with the element support
7. Turn on power.
RLT Defrost Heater Location
8. Verify that heater is working correctly.
Defrost Heater
RLT Defrost Heater
Heating Element Support
LH Plenum Mounting Bracket
RH Plenum Mounting Bracket
Heating Element Support
This view shows one bracket assembly, typical on 2-door case;
two assemblies are used on 3-door case,
three on 4-door, four on 5-door case.
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6-5
REPLACING DRAIN PAN HEATER —
ELECTRIC AND GAS DEFROST
(Low Temperature Only )
!
WARNING
The drain pan heater is located as shown
below.
Always disconnect the electrical power at
the main disconnect when servicing or
replacing any electrical component. This
includes, but is not limited to, such items
as fans, heaters, thermostats and lights.
Remove Drain Pan Heater
1. Disconnect power.
2. Pull heater out from under jiffy clips.
3. Position new heater under jiffy clips. Be
sure offset is properly positioned around
the drain. If jiffy clips are removed, make
certain sealer is replaced.
4. Reconnect power.
5. Verify that heater is working correctly.
Detail
Screw
Jiffy Clip
Sealer
Drain Heater
Side View
Screw
Sealer
Drain Heater Offset
Jiffy Clip
Drain
Heater
Jiffy Clip
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SERVICE
RLT with GAS DEFROST ONLY:
REPLACING SECONDARY PLATE
HEATER
The secondary plate heater is located as
shown below.
Remove Secondary Plate Heater
1. Disconnect power.
Slide Rod Heater
Under Tabs.
Lightly Press
2. Pull heater out from under jiffy clips.
Down on Tabs.
3. Position new heater under jiffy clips. Be sure
offset is properly positioned around the
drain. If jiffy clips are removed, make cer-
tain sealer is replaced.
4. Reconnect power.
5. Verify that heater is working correctly.
Rear Secondary
Plate and Heater
Front
Secondary
Plate and
Heater
Interlock
Plates
Together
Strap together
and Attach to
Harness
!
WARNING
Always disconnect the electrical power at
the main disconnect when servicing or
replacing any electrical component. This
includes, but is not limited to, such items
as fans, heaters, thermostats and lights.
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6-7
REPLACING LAMP BALLAST
(OTHER THAN RLT MODELS)
The lamp ballasts are located in the electrical
C. Lift the front panel up and out from the
raceway, in the left-hand end of the merchandiser.
front of the case. Tabs on front panel must
clear slots on bumper retainer.
To gain access:
1. Disconnect the electrical power to the light
fixture.
3. Service or replace ballasts as required.
4. Reinstall front panel by sliding it into bumper
retainer slots, then reinstall screws.
2. Remove the front panel.
A. Pull off the bumper.
B. Remove screws from bumper retainer.
NOTE: The front panel is attached by
(2) screws (two-door),
5. Install bumper.
6. Restore power to merchandiser.
(3) screws (three -door),
(4) screws (four-door),
(5) screws (five door), to the front panel
Ballas
Lift-up on
Raceway
Front
Panel
Area
Screws
Bumper
Ballasts
Bumper
Retainer
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SERVICE
REPLACING RLT LAMP BALLAST
The lamp ballasts are located in the electrical
raceway, in the left-hand end of the merchandiser.
To gain access:
1. Disconnect the electrical power to the light
fixture.
2. Remove the front panel. Lift the front panel
up and out from the front of the case.
3. Service or replace ballasts as required.
4. Reinstall front panel
5. Restore power to merchandiser.
RLT Wiring Routed Up Through Top Panel to
Wireway on Top
Door Frame and Door Heater
Wiring Routed Through
Wireway Cover
Wireway
Field
Ballast Tray into Wireway
Connection
Knock-outs
Top Foam
Assembly
Ballast
Tray
Fan and Heater Wiring
Routed Through Top Foam Assembly
Door Frame
Assembly
!
WARNING
Always disconnect the electrical power at
the main disconnect when servicing or
replacing any electrical component. This
includes, but is not limited to, such items
as fans, heaters, thermostats and lights.
Hussmann recommends against frame heater
cycling with Innovator doors to prevent door
seals from freezing to the frames and tearing.
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6-9
REPLACING DAMAGED DRAIN FITTING
SERVICING VERTICAL LIGHTING
Refer to door manufacturer’s manual for servic-
ing of vertical lamps.
The following procedure is for the field repair of
a broken drain fitting.
1. Use a drill with a 17/8-inch (48 mm) hole saw
to drill out the bottom of the drain fitting. Be sure
to drill completely through fitting and bottom
liner.
SERVICING DOORS AND FRAMES
See door manufacturer’s service manual for
servicing information. One manual is shipped
with each merchandiser.
REPLACING DOOR OR DOOR FRAME PARTS
Parts for Reach-in doors and door frame
assemblies must be ordered direct from the door
manufacturer This includes the glass doors, door
frame assemblies, lamps, ballasts, door handles,
hold open slides, and power cords.
Drain Fitting Viewed from Inside Case
Refer to specific warranty supplied with the
door. The manufacturers have a warranty
against moisture penetration, a warranty against
tempered glass breakage, and a warranty on
ballasts. Lamps are not covered by Hussmann
or the door manufacturer.
2. Apply teflon tape to threaded end of adapter
and screw into threaded end of tee.
3. Apply an ABS and PVC compatible primer
and sealer to adapter and inside of drain. Insert
adapter into drain fitting.
Foam Bottom
Assembly
Modified
Drain Fitting
PVC Adapter
1 /2 x 1 /4 in.
1
1
(38 x 32 mm)
(obtained at local
building supply store)
Tee
1
1 /4 in. TxSxS
(32 mm)
End Section View
Reach-In
HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A.
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6-10
SERVICE
REPAIRING ALUMINUM COIL
The aluminum coils used in Hussmann merchan-
disers may be easily repaired in the field.
Materials are available from local refrigeration
wholesalers.
Technique:
1. Locate Leak.
2. REMOVE ALL PRESSURE.
3. Brush area UNDER HEAT.
Hussmann recommends the following solders and
technique:
Solders
4. Use PRESTOLITE TORCH ONLY.
Number 6 tip.
Aladdin Welding Products Inc.
P.O. Box 7188
5. Maintain separate set of stainless steel
brushes and USE ONLY ON ALUMINUM.
1300 Burton St.
Grand Rapids, MI 49507
Phone: 1-800-645-3413
6. Tin surface around area.
Fax:
1-800-645-3414
7. Brush tinned surface UNDER HEAT,
X-Ergon
thoroughly filling the open pores around leak.
1570 E. Northgate
P.O. Box 2102
Irving, TX 75062
8. Repair leak. Let aluminum melt solder, NOT
the torch.
Phone: 1-800-527-9916
9. Don't repair for looks. Go for thickness.
10. Perform a leak check.
NOTE:
Hussmann Aluminum melts at 1125°F (607°C)
11. Wash with water.
Aladdin 3-in-1 rod at
X-Ergon Acid core at
732°F (389°C)
455°F (235°C)
12. Cover with a good flexible sealant.
P/N 0387183_D
WWW.HUSSMANN.COM
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®
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.A. 63044-2483
01 July 2005
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