US-20260123772-A1 - FIELD-INSTALLABLE REFRIGERATED CABINET KIT WITH ON-CABINET REFRIGERATION SYSTEM

US20260123772A1US 20260123772 A1US20260123772 A1US 20260123772A1US-20260123772-A1

Abstract

In a field-installable refrigerated merchandiser kit, a prefabricated refrigeration system module releasably and operatively connects to a separate cabinet module via mutual connection fittings to form a refrigerated merchandiser. The refrigerated merchandiser can have multiple refrigeration systems cooling a common refrigerated space inside the cabinet, each with an independent temperature controller. A refrigeration system can be disconnected from the cabinet only by separating releasable fasteners and disconnecting electrical plug-in connections. Each refrigeration system is prefabricated with integrated condensate removal. The refrigeration system mounts entirely above the top wall of the cabinet enabling deployment at zero offset from a backing structure. The refrigerated merchandiser can be deployed to occupy a footprint and have a ratio of shelf space volume to foot print greater than 3.25 ft 3 /ft 2 .

Inventors

Joseph Fontecchio
John Friend
Christian Pizzi
Daniel Pestka

Assignees

TRUE MANUFACTURING CO., INC.

Dates

Publication Date: 20260507
Application Date: 20251107

Claims (20)

1 . A field-installable refrigerated merchandiser kit comprising: a reach-in cabinet having an interior, a top wall above the interior, and one or more cabinet systems integrated into the reach-in cabinet; a refrigeration system including a base, a sealed refrigeration circuit supported by the base; a temperature controller including a user interface; a main electrical distribution assembly including an enclosure and a main power cable configured to extend from the enclosure, the main power cable terminated by a plug-in connector for making a plug-in connection to a main power source; a power distribution cable terminated by a plug-in connector; wherein in kit form, (a) the refrigeration system, the main electrical distribution assembly, and the temperature controller are detached from the top wall of the reach-in cabinet and (b) the refrigeration system is electrically disconnected from the main power cable; wherein the field-installable refrigerated merchandiser kit is configured to be installed as a refrigerated merchandiser via a field installation process comprising: mounting the refrigeration system, the main electrical distribution assembly, and the temperature controller all to the top wall of the reach-in cabinet; making a plug-in connection of the plug-in connector of the power distribution cable; wherein when the field-installable refrigerated merchandiser kit is installed as the refrigerated merchandiser via the field installation process: the main electrical distribution assembly is configured to distribute power from the main power cable to the refrigeration system, the one or more cabinet systems integrated into the reach-in cabinet, and the temperature controller; the main electrical distribution assembly is configured to connect the temperature controller to the one or more cabinet systems; the temperature controller is configured to thermostatically control the sealed refrigeration circuit; and the temperature controller is configured to control the one or more cabinet systems.
2 . The field-installable refrigerated merchandiser kit of claim 1 , wherein the top wall of the reach-in cabinet has prefabricated attachment points for mounting the refrigeration system, the temperature controller, and the main electrical distribution assembly to the top wall of the reach-in cabinet at predefined locations.
3 . The field-installable refrigerated merchandiser kit of claim 2 , wherein the prefabricated attachment points are configured so that, when the field-installable refrigerated merchandiser kit is installed as the refrigerated merchandiser via the field installation process, the user interface is in front of the base and the main electrical distribution assembly is spaced apart from the base.
4 . The field-installable refrigerated merchandiser kit of claim 3 , wherein the base comprises first screw holes, the main electrical distribution assembly comprises a bottom portion having second screw holes, and the prefabricated attachment points comprise first pre-formed screw openings and second pre-formed screw openings, the first screw holes arranged to align with the first pre-formed screw openings and the second screw holes arranged to align with the second pre-formed screw openings.
5 . The field-installable refrigerated merchandiser kit of claim 4 , wherein the temperature controller comprises a housing and brackets on the housing, the brackets configured to meet the top wall of the reach-in cabinet forward of the base.
6 . The field-installable refrigerated merchandiser kit of claim 4 , further comprising a field-installable shroud, wherein when the field-installable refrigerated merchandiser kit is in kit form, the field-installable shroud is detached from the top wall of the reach-in cabinet, wherein the field installation process by which the field-installable refrigerated merchandiser kit is configured to be installed as a refrigerated merchandiser further comprises mounting the field-installable shroud on the top wall of the reach-in cabinet to conceal the refrigeration system, wherein when the field-installable refrigerated merchandiser kit is installed as the refrigerated merchandiser via the field installation process, the user interface is exposed through the field-installable shroud.
7 . The field-installable refrigerated merchandiser kit of claim 4 , wherein the reach-in cabinet comprises a return air plenum in the interior along the top wall, wherein the top wall of the reach-in cabinet comprises a port providing fluid communication between an exterior of the reach-in cabinet and the return air plenum, the first pre-formed screw openings including a first subset of first pre-formed screw openings and a second subset of first pre-formed screw openings spaced apart widthwise from the first subset, wherein the port is in between the first subset of first pre-formed screw openings and the second subset of first pre-formed screw openings, wherein the refrigeration system comprises a gasket on the base, wherein when the refrigeration system is mounted to the top wall of the reach-in cabinet at the respective predefined location, the gasket circumscribes the port in between the first subset of first pre-formed screw openings and the second subset of first pre-formed screw openings and is compressed between the base and the top wall for sealing an interface therebetween.
8 . The field-installable refrigerated merchandiser kit of claim 7 , wherein the field installation process by which the field-installable refrigerated merchandiser kit is configured to be installed as a refrigerated merchandiser further comprises temporarily placing the refrigeration system on the top wall of the reach-in cabinet with the base and subsequently lowering the base at the mounting location to compress the gasket between the base and the top wall.
9 . The field-installable refrigerated merchandiser kit of claim 1 , wherein the one or more cabinet systems comprise a cabinet lighting system and one or more door heaters and the temperature controller is configured to control the cabinet lighting system and the one or more door heaters.
10 . The field-installable refrigerated merchandiser kit of claim 1 , wherein the sealed refrigeration circuit is charged with r290 refrigerant at a charge of 150 grams or less and the reach-in cabinet defines a free refrigerated space cross-sectional area of at least 1350 square inches.
11 . The field-installable refrigerated merchandiser kit of claim 10 , wherein when the field-installable refrigerated merchandiser kit is in kit form, the reach-in cabinet is configured to fit upright through a man door doorway of no more than seven feet; wherein when the field-installable refrigerated merchandiser kit is installed as the refrigerated merchandiser, the refrigerated merchandiser is too tall to fit upright through the man door doorway.
12 . The field-installable refrigerated merchandiser kit of claim 11 , wherein the interior of the reach-in cabinet has a free refrigerated space height of at least 63 inches.
13 . The field-installable refrigerated merchandiser kit of claim 12 , wherein the reach-in cabinet is configured to accommodate 24-inch-deep shelves.
14 . The field-installable refrigerated merchandiser kit of claim 1 , further comprising a signal and load cable terminated by a plug-in connector, wherein the field installation process further comprises making a plug-in connection of the plug-in connector of the signal and load cable.
15 . The field-installable refrigerated merchandiser kit of claim 1 , wherein the refrigeration system is a first refrigeration system, the temperature controller is a first independent temperature controller, and the power distribution cable is a first power distribution cable, wherein the field-installable refrigerated merchandiser kit further comprises a second refrigeration system, a second independent temperature controller for the second refrigeration system, and a second power distribution cable terminated by a plug-in connector; wherein in kit form, the second refrigeration system and the second independent temperature controller are detached from the top wall of the reach-in cabinet and the second refrigeration system is electrically disconnected from the main power cable; wherein the field installation process by which the field-installable refrigerated merchandiser kit is configured to be installed as a refrigerated merchandiser further comprises: mounting the second refrigeration system and the second independent temperature controller to the top wall of the reach-in cabinet with the first refrigeration system, the first independent temperature controller, and the main electrical distribution assembly; making a plug-in connection of the plug-in connector of the second power distribution cable; wherein when the field-installable refrigerated merchandiser kit is installed as the refrigerated merchandiser via the field installation process: the main electrical distribution assembly is further configured to distribute power from the main power cable to the second refrigeration system and the second independent temperature controller; and the second independent temperature controller is configured to thermostatically control the second refrigeration system.
16 . The field-installable refrigerated merchandiser kit of claim 15 , further comprising a first signal and load cable terminated by a plug-in connector and a second signal and load cable terminated by a plug-in connector, wherein the field installation process further comprises making a plug-in connection of the plug-in connector of the first signal and load cable and making a plug-in connection of the plug-in connector of the second signal and load cable.
17 . The field-installable refrigerated merchandiser kit of claim 15 , wherein the sealed refrigeration circuit of the first refrigeration system is a first sealed refrigeration circuit comprising a first variable speed compressor; wherein the second refrigeration system comprises a second sealed refrigeration circuit comprising a second variable speed compressor.
18 . The field-installable refrigerated merchandiser kit of claim 17 , wherein the base of the first refrigeration system is a first base and wherein the first refrigeration system comprises a first inverter supported by the first base such that, during the field installation process, (i) the first inverter is configured to move with the first base to an installed position above the top wall of the reach-in cabinet and (ii) the first inverter is configured to be electrically connected to the main power cable when the plug-in connection of the plug-in connector of the first power distribution cable is made; and wherein the second refrigeration system comprises a second inverter and a second base supporting the second sealed refrigeration circuit and the second inverter such that, during the field installation process, (i) the second inverter is configured to move with the second refrigeration system to an installed position above the top wall of the reach-in cabinet and (ii) the second inverter of the second refrigeration system is configured to be electrically connected to the main power cable when the plug-in connection of the plug-in connector of the second power distribution cable is made.
19 . The field-installable refrigerated merchandiser kit of claim 18 , wherein when the field-installable refrigerated merchandiser kit is installed as the refrigerated merchandiser via the field installation process: the first independent temperature controller is configured to adjust the first inverter to control a speed of the first variable speed compressor; and the second independent temperature controller is configured to adjust the second inverter to control a speed of the second variable speed compressor.
20 . The field-installable refrigerated merchandiser kit of claim 19 , wherein when the field-installable refrigerated merchandiser kit is installed as the refrigerated merchandiser via the field installation process both the first independent temperature controller and the second independent temperature controller are configured to moderate inrush of current on the main power cable by independently controlling the first inverter and the second inverter to gradually increase compressor speed at startup.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims priority to U.S. Provisional Patent Application No. 63/082,805, filed Sep. 24, 2020, which is hereby incorporated by reference in its entirety for all purposes. FIELD The present disclosure pertains generally to a refrigerated merchandiser, as well as to a refrigerated cabinet kit comprising one or more field-installable refrigeration system modules configured to be releasably and operably mounted and installed on a cabinet module to form a refrigerated merchandiser. BACKGROUND Reach-in refrigerated cabinets have access doors and are used to store and/or display refrigerated goods. One well-known type of refrigerated reach-in cabinet is a display refrigerated merchandiser. Conventionally, there are two types of refrigerated merchandisers: (1) the self-contained type and (2) the remote refrigeration type. The United States Department of Energy's regulations differentiate between self-contained and remote refrigeration systems. For example, energy consumption regulations for self-contained refrigeration systems are based on the measured energy consumption of the machinery, whereas energy consumption regulations for remote refrigeration systems are based on refrigerant mass flow and calculated assumptions of electrical loads. Self-contained merchandisers are prefabricated assemblies comprising a cabinet with an integrated refrigeration system. In many self-contained merchandisers, the refrigeration systems are hermetically sealed so that there is no loss of refrigerant through access valves or mechanical connections. The refrigeration system in a self-contained merchandiser is precisely engineered for the application and applicable regulations, accounting for the size of the cabinet, the loads, and the temperature requirements. Compliance with these constraints enables self-contained merchandisers to operate very efficiently in comparison with remote refrigeration merchandisers (discussed below). Self-contained merchandisers can employ onboard systems for removing condensate that forms on the refrigeration system without separate drain connections. Air-cooled self-contained merchandisers only require a single cord and plug electrical connection to operate. Water-cooled self-contained merchandisers require only a single cord and plug electrical connection and a water connection for removing heat from the condenser. This makes self-contained merchandisers a preferred option for retailers that lease their buildings or otherwise require the refrigeration cabinet to occasionally be moved from place to place within the building. Remote refrigeration merchandisers, by contrast, are commonly built into a retail building at the time of deployment. Most typically, a refrigeration system for a plurality of remote merchandiser cabinets is installed on the roof of a building and the merchandiser cabinets are installed as fixtures inside the building such that they are physically separated from the remote refrigeration system components by the building's roof. HVAC contractors must make refrigeration connections between evaporators mounted inside the cabinet and the piping chases that connect the merchandiser to the remote condenser, which is typically located on the building roof. (Not all remote refrigeration systems are on the rooftop. There are mechanical rooms that house these at times.) In addition, to address the condensate that forms on the evaporator during use, a plumber must make a drain connection between a condensate removal line of the cabinet and the building's drain line, which usually runs in a trench under the floor of the cabinet. Occasionally, hoses and pumps can be used to send the condensate to a heated drain pan. Lastly, electrical connections are provided by an electrician as remote refrigeration is a fixed installation. Thus, remote refrigeration merchandisers are most suitable for retailers that own or have very long-term leases on retail buildings due to the trenching in the flooring to run refrigerant lines, drain water, and electrical cables. In addition to the inherent permanence of a remote refrigeration merchandiser, another disadvantage of remote refrigeration systems in relation to self-contained merchandisers is operating efficiency. To ensure that the necessary refrigeration capacity is always available, refrigeration systems mounted on the roof or remote locations of the building are typically oversized in relation to the actual refrigeration requirements of the cabinets deployed inside the building. In other words, remote refrigeration systems lack the application-specific engineering of their self-contained counterparts. This is due to the approach to sizing the refrigeration systems. Remote systems must consider seasonal fluctuations of outdoor temperatures and running multiple different products (freezers, refrigerators, floral, etc.) cabinets off of the same refrigeration system sized for worst case conditions. In this w