Hussmann Innovator Handbuch

P/N 0425683F

September 2006

INNOVATOR

AND

INNOVATOR II

REACH-IN

GLASS DOOR

INSTALLATION

& SERVICE

MANUAL

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

www.hussmann.com

HUSSMANN CORPORATION, BRIDGETON, MO 63044-2483 U.S.A.

Table of Contents

General . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Always*Clear™Glass . . . . . . . . . . . . . . . . 1

Shipping Damage . . . . . . . . . . . . . . . . . . . 1

New Installations . . . . . . . . . . . . . . . . . . . 1

Adjusting Closing Torque . . . . . . . . . . . . . 1

Adjusting Door Sag . . . . . . . . . . . . . . . . . 2

Conditioning Gasket . . . . . . . . . . . . . . . . . 2

Replacing Doors . . . . . . . . . . . . . . . . . . . . 3

Replacing Door Hinge Spring . . . . . . . . . 5

Replacing Magnetic Gasket . . . . . . . . . . . 5

Restoring Gasket Seal . . . . . . . . . . . . . . . .6

Door Handle Replacement . . . . . . . . . . . . 8

Frame Heater Replacement . . . . . . . . . . . 9

Lamp Replacement (Center Mullion) . . . 11

Lamp Replacement (End Mullion) . . . . . 13

Ballast Replacement . . . . . . . . . . . . . . . . 13

Heater Harnesses . . . . . . . . . . . . . . . . . . 14

Wiring Diagrams . . . . . . . . . . . . . . . . . . 15

Replacement Parts Chart . . . . . . . . . . . . 17

Replacement Parts List . . . . . . . . . . . . . . 18

WARRANTY

Revision E

1. Added Always*Clear cleaning information, page 1.

2. Revised text for diffuser removal, pages 11 & 12.

3. Revised wiring diagrams, pages 15 & 16.

4. Added ballast change-out direction, page 24.

REVISION F

1. Added instruction for conditioning gaskets during

initial case installation, page 2.

2. Revised wiring diagrams, pages 15 & 16.

3. Added Aftermarket part numbers, pages 18 through 23.

Innovator Door Installation and

Service Instruction

P/N 0425683F

iii

GENERAL

Be sure merchandisers have been leveled accord-

ing to the installation instructions shipped with

the merchandiser.

The door nameplate is attached to the top of the

door, handle side, behind the magnetic gasket.

The frame nameplate is located on the top left

near the switch.

ALWAYS*CLEAR™GLASS

Hussmann recommends using a soft cloth with

isopropyl (rubbing) alcohol to clean the inside

(coated) glass surface. Isopropyl alcohol does not

freeze and evaporates without leaving residue.

Always allow the surface to dry before closing

the door. Use of abrasives may damage the

coated surface and void the warranty. Labels

(stickers) applied to the coated surface will cause

damage and void the warranty.

SHIPPING DAMAGE

All equipment should be thoroughly examined for

shipping damage before and during unloading.

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.

NEW INSTALLATIONS

Untape the doors and remove the shipping braces

located at top and bottom of the doors.

Doors are not fine adjusted at the factory since

they will go out of adjustment during shipment.

This is normal.

ADJUSTING CLOSING TORQUE

Adjust closing torque by turning the bottom

hinge pin in the direction the door closes. Use a

1/2in. (13 mm) wrench. Turn the hinge pin until

the door closes on its own, usually 3 to 4 clicks or

3/4turn. See Figure 1.

DO NOT over-torque the hinge spring assembly.

Excessive torque (over 1 full turn) will result in

damage to the spring assembly and/or door. If

door does not close on its own after one full turn

(5 clicks), look for obstructions causing the door

to hang up.

Figure 1. Adjusting Closing Torque

Innovator Door Installation and

Service Instruction

P/N 0425683F

HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM

ADJUSTING DOOR SAG

To adjust door sag (saw-tooth effect from door to

door), loosen the two hinge plate mounting

screws using a Torx Plus no. 27 bit. Adjust hinge

plate as needed, then tighten the screws. See

Figure 2.

CONDITIONING GASKETS

The manufacturer cannot control the environment

surrounding cases during shipment. Temperature

and humidity fluctuations during shipment, as

well as excessive vibration, may promote gaps

between gasket and frame. These gaps prevent

gaskets from sealing even when correctly fitted at

the factory. This is not a warranty issue or defect.

Follow this procedure to ensure gaps close and

gaskets seal properly:

1. Remove all shipping retainers and packing

material.

2. Close each door. Use a flashlight to identify

any gaps between frame and gasket.

3. Energize all anti-sweat, fan and light circuits

for at least two hours, but not more than four

hours, prior to initiating the refrigeration cycle.

4. Monitor all gaps. If gaps remain at the end of

four hours, follow the procedure for Restoring

Gasket Seal, beginning on page 6 of this manual.

5. Initiate cooling sequence once gaps disappear.

Do not exceed 8 hours of energized circuits

without refrigeration. Doing so may cause

damage to the case and will void the warranty.

P/N 0425683F

2HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM

Figure 2. Adjusting Door Sag

Loosen both

hinge plate

mounting

screws.

ATTENTION

TO ENSURE PROPER DOOR GASKET SEAL – REMOVE ALL SHIPPING

RETAINERS AND ENERGIZE ALL ANTI-SWEAT, FAN & LIGHT CIRCUITS 2

TO 4 HOURS PRIOR TO INITITATING REFRIGERATION CYCLE.

DO NOT EXCEED 8 HOURS OF ENERGIZED CIRCUITS WITHOUT

REFRIGERATION. DAMAGE OR PRODUCT FAILURE MAY OCCUR AND VOID

THE WARRANTY. DO NOT REMOVE THIS LABEL UNTIL REFRIGERATION IS

INITIATED.

Before and After Gasket Conditioning

REPLACING DOORS

1. Loosen torque on door before removing the

door. Wedge a screwdriver between the bottom of

the door and the hinge socket, then lift the door

up. This will lift the bottom hinge pin up and out

of the bottom hinge socket. Hold the hinge pin

with a 1/2 in. (13 mm) open end wrench to keep

it from spinning out and stripping the socket. See

Figure 3.

Innovator Door Installation and

Service Instruction

P/N 0425683F

HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM

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 doors, lights,

fans, heaters, and thermostats.

WARNING

Lift up

Screwdriver

Figure 3. Loosening Torque on the Door

2. Unscrew the two #6 Phillips screws that hold

the black plug into the side of the door as shown

in Figure 4. Remove the plug from the door.

3. Grasp the strain relief just below the cord and

pull until the heater terminal plug comes out. See

Figure 5. Note that the left end door must be

opened more than 90 degrees to access the

screws.

4. Use a flat blade screwdriver as shown in

Figure 6 to lift the door retainer over the shoulder

screw.

5. Push down the top hinge pin until it clears the

top socket using a flat blade screwdriver as

shown in Figure 7. With finger, hold the hinge

pin in the door to keep it from popping out. Tape

may be used to temporarily hold the hinge pin

once door is removed.

P/N 0425683F

4HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM

Figure 4. Removing Screws to Plug

Figure 5.

Removing the Heater Terminal Plug

Remove Screws

Figure 6. Removing the Door Retainer

Door Retainer

Figure 7.

Removing the Door from the Top Hinge Pin

Top

Hinge

6. Rock the door out and pull the bottom hinge

pin out from the bottom socket.

7. Install the new door in reverse order.

8. Adjust the torque on the new door. If needed,

adjust sag.

REPLACING DOOR HINGE SPRING

The door must be removed before replacing the

door hinge spring.

Pull the hinge spring assembly out of the bottom

of the door and replace with a new assembly. See

Figure 8. Note that there are right-hand and left-

hand hinge spring assemblies.

REPLACING MAGNETIC GASKET

Carefully remove the old gasket from the groove

in the back of the door, Figure 9.

The new gasket will be easier to work with if it is

at ambient temperature. Begin by lubricating the

new gasket with a mild soap and water solution.

Innovator Door Installation and

Service Instruction

P/N 0425683F

HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM

Figure 8. Replacing Door Hinge

Spring Assembly

Figure 9. Removing Door Gasket

Gasket

Work from the corners to the centers of each side,

top and bottom. Carefully push the new gasket

into the groove at each corner, refer to Figure

10(A). Then, push the gasket into the channel at the

center of the top, bottom and each side, Figure

10(B). Avoid stretching the gasket.

Sub-divide remaining areas and push the gasket

in at those points, Figure 10(C).

Sub-divide once again and repeat pushing the

gasket in until all of the gasket is evenly seated in

the groove, Figure 10(D).

Use a soft cloth or paper towels to dry the gasket

before closing door on clean door frame.

RESTORING GASKET SEAL

Occasionally, a crimped or damaged gasket can

cause gaps in the seal (Figure 11), leading to frost

formation on the doors. Use this procedure to

close gaps and end frost formation on doors.

Locate Gaps

Normally, interior case lighting will provide

enough light to see gaps. In some cases, the only

way to see gaps is to provide a backlight as

shown in Figure 12(A). Backlight the door

mullion and look for places the light shines

between the door and gasket, Figure 12(B).

P/N 0425683F

6HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM

Corners first Middle of Door

Sub-divide Middle Locations Sub-divide again

Figure 10.

Sequence for Installing New Gasket

(A) (B)

Figure 11.

Improperly Installed or Damaged Gasket

Figure 12. Back-Lighting Gaps in Gasket

Back-Light

Gap

(A)

(B)

Gap

Heat the Gasket

Make sure the door is closed.

Beginning at the top of the gap,

use a heat gun or electric hair

dryer (1500-1600 watt) to heat

the gasket with a constant up

and down motion.

IMPORTANT: If a gap runs

the entire length of the door,

heat the area 4 in. (100 mm)

above and 8 in. (200 mm)

below the top-most point where

the gap starts and work in

12 in. (300 mm) increments.

If the gasket becomes shiny,

remove heat immediately as

this is an indication that the

gasket is near the melting

point.

If possible, direct the hot air

onto the gasket and also

through the gap between the

gasket and mullion. This will

help to heat both sides of the

gasket. Refer to Figure 13(A)

and (B).

As the gasket softens and

becomes pliable, the magnet in

the gasket should pull it across

the gap. As the gap closes,

move heat down to create a

zippering effect as shown in

Figure14.

If the gasket is not pulled

across the gap by the magnet,

reach around the mullion (from

the inside) and pull the gasket

skirt toward the mullion.

Innovator Door Installation and

Service Instruction

P/N 0425683F

HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM

Gap

Back-Light

Direct the hot air through the gap

between the gasket and mullion.

Back-Light

Remember to use a constant

up and down motion when

applying heat.

Figure 13. Applying Heat to Gasket

(A)

(B)

Figure 14. Zipper Effect

(A)

(B)

As shown in Figure 15, this can also be accom-

plished by pushing the magnet across the gap from

the outside with a pencil or other non-heat conduct-

ing material.

On doors where the gap is against an end, top, or

bottom mullion, this process can still be done;

however, the heat will need to be directed

between the lip of the mullion and the edge of the

door. It will work in the same fashion but the

back-light shining through and showing on the

mullion will have to be a guide as to the position

of the gasket.

Cool the Gasket

Once the gap is closed, remove the heat and

allow the gasket to cool, undisturbed, for 3 to

5 minutes. As the gasket cools, it will set

permanently in this new shape.

Once the gasket is cool to the touch, open the and

close the door. Verify that the gasket seals. If not,

repeat the process. If the gasket rolls it must be

replaced.

Use a soft cloth or paper towels, and a mild soap

and water solution to thoroughly clean the gasket.

Dry the gasket completely with a fresh cloth or

paper towels before closing the door on a clean

door frame.

DOOR HANDLE REPLACEMENT

Carefully pull the

magnetic gasket out

of the groove nearest

the handle to expose

the mounting screws

as shown in

Figure 16. Remove

the screws and

replace the handle.

After reinstalling

screws, carefully

push gasket back

into groove. If need-

ed, use a mild soap

and water solution to

lubricate the gasket.

Clean and dry the

gasket to complete

the door handle

replacement.

P/N 0425683F

8HUSSMANN CORPORATION • BRIDGETON, MO 63044-2483 U.S.A. • WWW.HUSSMANN.COM

Figure 16. Replacing Door Handle

Mounting Screws

Figure 15. Pulling Gasket Into Place

With a Pencil

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