Structural Concepts CDR5745A, GP236DRLB, GP340DRLB.5580, GP440RRLB.5571, GP440RRLB.5572 Installation And Operating Manual
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READ AND SAVE THESE INSTRUCTIONS
INSTALLATION
AND OPERATING
G-SERIES
> REFRIGERATED SALAD/SANDWICH CASE / SELF-SERVICE GRAB-N-GO AT FRONT SECTION
> REFRIGERATED PAN SYSTEM AT TOP SURFACE (BEHIND SNEEZE GUARD)
> REFRIGERATED DRAWERS & STORAGE DOOR AT CASE REAR FOR DELI MEAT & CHEESES
> REFRIGERATED SELF-SERVICE GRAB-N-GO FRONT SECTION / HEATED SERVICE PIZZA DISPLAY
> REFRIGERATED SELF-SERVICE GRAB-N-GO FRONT / HEATED SERVICE PIZZA STONE DISPLAY
> REFRIGERATED SELF-SERVICE/SERVICE PREP CASE WITH REAR STORAGE, Etc.
Model GP837R
Model GP340DRLB.5580
MANUAL P/N 20-00045
Model GP841RR
Model GP641RRLB
Model GP441RR
I:\Oper Manuals\G-Series_Grab-N-Go_GPXXXR_RR_DRLB_RHLB_RRLB_20-00 045.pub
Model GP236DRLB (Front Panel
To Be Attached As Part of Lineup)
Model GP841R.5184
Model CDR5745A
Note: See MODEL APPLICABILITY section in this manual for a
complete list of models represented by this operating manual.
888 E. Porter Road · Muskegon, MI 49441 Phone: 231.798.8888 Fax: 231.798.4960 www.structuralconcepts.com
Model GP440RRLB.5571
Model GP440RHLB.5574
Rev Q Date: 5.14.2014
TABLE OF CONTENTS / MODELS INCLUDED IN MANUAL
TABLE OF CONTENTS / MODELS INCLUDED IN MANUAL …………………………………..…………...
MODEL APPLICABILITY …………………………………………………………………………………………
OVERVIEW / TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS ….…......…..
INSTALLATION: SKID REMOVAL / ALIGNING CASE / FRAME SUPPORT RAILS ………………….….
INSTALLATION, CONT’D: SNEEZE GUARD ASSEMBLY SELF-INSTALLATION (RETROFITTING) ...
CASE START-UP / THERMOMETER FUNCTION & LOCATIONS .……………...………………………..
LED LIGHT REMOVAL/REPLACEMENT, PLUG/CORD POSITIONING, PROPER PLUG INSERTION.
FLUORESCENT LIGHT REMOVAL/REPLACEMENT (MODEL GP841R.5184 ONLY) ...…………….….
DECKING, EVAPORATOR COIL FAN DISCHARGE, TXV LOCATION (MODEL GP837R ONLY) .…....
DECKING, EVAPORATOR COIL FAN DISCHARGE, TXV LOCATION (MODEL GP841R.5184 ONLY
DECKING, EVAPORATOR COIL FAN DISCHARGE, TXV LOCATION - SNEEZE GUARD AREA ….....
DECKING, EVAPORATOR COIL FAN DISCHARGE, TXV LOCATION - REAR SECTION ………….….
THERMOMETER PROBE / DEFROST PROBE LOCATIONS - FRONT SECTION …….….....................
THERMOMETER PROBE / DEFROST PROBE LOCATIONS - REAR SECTION .....………………..…...
THERMOMETER PROBE / DEFROST PROBE LOCATIONS - TOP SECTION ….....…………….….…..
MODEL GP236DRLB (DRY TOP UNIT) - REAR PANEL / FIELD ACCESS / TEMP. CONTROLLER .....
MODEL GP236DRLB (DRY TOP UNIT) - LED LIGHTS / THERMOM. / HONEYCOMB / EVAP. COIL ...
MODEL GP540RRLB.5571B (SIMILAR TO GP440RRLB.5571) - OVERVIEW OF CASE FRONT …......
MODEL GP540RRLB.5571B (SIMILAR TO GP440RRLB.5571) - OVERVIEW OF CASE REAR ….…...
MODEL GP540RRLB.5571B (SIMILAR TO GP440RRLB.5571) - SHELVING / CRUMB TRAY /
DECKING AIR RETURN / HONEYCOMB ……………………………………………………………..
MODEL GP540RRLB.5571B (SIMILAR TO GP440RRLB.5571) - LED LIGHTING LAYOUT / FRONT
GLASS / EVAPORATOR COIL / TXV / FANS ……………………………………………………… …
MODEL CDR5745A (SVC. CASE ONLY) - OVERVIEW OF CASE FRONT ……………………………….
MODEL CDR5745A (SVC. CASE ONLY) - OVERVIEW OF CASE REAR ………………………………...
MODEL CDR5745A (SVC. CASE ONLY) - OVERVIEW OF LED LIGHTS / AIRFLOW / SHELVING …..
MODEL CDR5745A (SVC. CASE ONLY) - OVERVIEW OF EVAPORATOR COIL, FAN, DRAIN, ETC..
MODEL CDR5745A (SVC. CASE ONLY) - OVERVIEW OF UNDERSIDE OF UNIT ………….………….
REFRIGERATED SELF-SERVICE GRAB-N-GO FRONT SECTION / HEATED SERVICE PIZZ A
DISPLAY (MODEL GP440RHLB.5574 ONLY) …………………..……………………………….…...
OPTIONAL NIGHT AIR CURTAIN INSTALLATION & OPERATING INSTRUCTIONS (GP541RR
SHOWN / APPLICABLE TO GP441RR, GP641RR & GP841RR) ...………………………………..
CLEANING SCHEDULE (TO BE PERFORMED BY STORE PERSONNEL) ………….………………......
CLEANING SCHEDULE (TO BE PERFORMED BY STORE PERSONNEL): STAINLESS STEEL .........
PREVENTIVE MAINTENANCE (TO BE PERFORMED BY TRAINED SERVICE PROVIDER) ………….
MAINTENANCE FUNDAMENTALS - HONEYCOMB AIR DIFFUSERS (SERVICE TECHS ONLY) …....
TROUBLESHOOTING (TO BE PERFORMED BY STORE PERSONNEL) ………………………….….….
TROUBLESHOOTING (TO BE PERFORMED BY TRAINED SERVICE PROVIDERS) ………………….
TROUBLESHOOTING - CONDENSING SYSTEM (TRAINED SERVICE PROVIDERS ONLY) ………...
TROUBLESHOOTING - EVAPORATOR SYSTEM (TRAINED SERVICE PROVIDERS ONLY) ...….…..
SERIAL LABEL LOCATION & INFORMATION LISTED / TECH INFO & SERVICE ……………….…......
TECHNICAL SERVICE CONTACT INFORMATION & WARRANTY INFORMATION ……......................
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11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28-30
31
32-35
36
37
38
39
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41
42
43
44
45
2
MODEL APPLICABILITY
THIS OPERATING MANUAL IS APPLICABLE TO THE FOLLOWING MANUALS
CDR5745A
GP236DRLB (D = Dry Top)
GP340DRLB.5580 (D = Dry Top)
GP440RRLB.5571
GP440RRLB.5572
GP440RHLB.5574
GP441RR
GP441RR.5386
GP441RRG.5825
GP441RRLB
GP540RRLB.5571B
GP541RR
GP541RRLB
GP541RR.5692
GP640DRLB.5580A (LB = Lower Base Units)
GP640RRLB.5571A
GP640RRLB.5572A
GP640RRLB.5578A
GP641RR
GP641RR.5798B
GP641RRLB
GP737R
GP737RG
GP836RRLB
GP837R
GP840RRLB.5571C
GP840RRLB.5572B
GP841R.5184
GP841RR
GP841RRLB
GP1041RR.5798D
3
OVERVIEW / TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS - PAGE 1 of 2
OVERVIEW
Front Case Main Display Area: These cases are
designed to merchandise pre-chilled packaged food
and beverage products at 38 °Fahrenheit /
3 °Celsius or less product temperatures.
Rear Drawers and Condiment Pans
designed to merchandise pre-chilled packaged
also
: These areas are
food and beverage products at 38 °Fahrenheit /
3 °Celsius or less product temperatures.
Product must be pre-chilled to 38 °F / 3 °C or less
prior to being placed in refrigerated area of case.
Product must be pre-heated to at least 150 °F / 66 °C
or higher prior to being placed in heated service pizza
display area.
This remote refrigerated unit is a barista serve
unpackaged food and customer self serve packaged
food and drink case.
Cases should be installed and operated according to
this operating manual’s instructions to ensure proper
performance.
Improper use will void warranty.
This multi-functional unit is designed to perform
quietly with easy operation.
Merchandising capabilities meet the required
standards for maintaining proper refrigerated food
temperatures and sanitation.
TYPE 1 Units
This unit is designed for the display of products in ambient
store conditions where temperatures and humidity are
maintained within a specific range.
As this unit is manufactured for Type 1 conditions, ambient
conditions are to be at 55% maximum humidity and
maximum temperatures of 75 °F (24 °C).
COMPLIANCE
Performance issues when in violation of applicable
NEC, federal, state and local electrical and plumbing
codes are not covered by warranty.
See below compliance guideline.
WARNINGS
This page contains important warnings to prevent
injury or death.
Please read carefully!
PRECAUTIONS and WIRING DIAGRAMS
See next page for PRECAUTIONS and WIRING
DIAGRAM information.
WARNING
ELECTRICAL
HAZARD
WARNING
KEEP
HANDS
CLEAR
WARNING
HOT
SURFACE
COMPLIANCE
This equipment MUST be installed in compliance with
all applicable NEC, federal, state and local
electrical and plumbing codes.
WARNING
Risk of electric shock. Disconnect power before servicing unit.
CAUTION! More than one source of electrical supply is
employed with units that have separate circuits.
Disconnect ALL ELECTRICAL SOURCES before servicing.
WARNING
Hazardous moving parts. Do not operate unit with covers removed.
Fan blades may be exposed when deck panel is removed.
Disconnect power before removing deck panel.
WARNING
Heated Surface (Stone) Pizza Display Area is Hot!
Allow to cool before cleaning.
4
OVERVIEW / TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS - PAGE 2 of 2
PRECAUTIONS
Following are important precautions to prevent
damage to unit or merchandise.
Please read carefully!
See previous page for specifics on OVERVIEW,
TYPE, COMPLIANCE and WARNINGS.
WIRING DIAGRAM
Each case has its own wiring diagram folded and in its
own packet.
CAUTION! LAMP REPLACEMENT GUIDELINES
LED lamps reflect specific size, shape and overall design.
CAUTION
Any replacements must meet factory specifications.
Fluorescent lamps have been treated to resist breakage and
must be replaced with similarly treated lamps.
CAUTION! GFCI BREAKER USE REQUIREMENT
If N.E.C. (National Electric Code) or your local code
requires GFCI (Ground Fault Circuit Interrupter) protection,
you MUST use a GFCI breaker in lieu of a GFCI receptacle
Wiring diagram placement may vary; it may be placed
near ballast box, field wiring box, raceway cover, or
other related location.
POWER CORD AND PLUG MAINTENANCE
Caution! Risk of electric shock.
If cord or plug becomes damaged, replace only with
cord and plug of same type.
CAUTION
CAUTION! POWER CORD AND PLUG MAINTENANCE
Risk of electric shock. If cord or plug becomes damaged,
replace only with cord and plug of same type.
CAUTION! ADVERSE CONDITIONS / SPACING ISSUES
Performance issues caused by adverse conditions are NOT covered
by warranty.
End panels must be tightly joined or kept at least 6-inches away from
any structure to prevent condensation.
Unit must be kept at least 15-feet from exterior doors, overhead HVAC
vents or any air curtain disruption to maintain proper temperatures.
Unit must not be exposed to direct sunlight or any heat source (ovens,
fryers, etc.).
Tile floors, low ceilings or small rooms will increase noise level.
Whisper Cool compressor blanket or remote unit may resolve noise
level issues.
Keep at least 8-inch clearance above unit for air discharge
(self-contained units only).
5
INSTALLATION: SKID REMOVAL / ALIGNING CASE / FRAME SUPPORT RAILS
1. Remove Unit From Skid
Caution! To prevent damage, support case
while sliding skid out from under case.
Note: Illustration below reflects general outline of
sample case and does not reflect any particular
model or options).
Carefully Slide
Skid Out From
Under Unit
2. Position & Align Case Alongside Others
Before adjusting levelers, make certain that the
case is in proper position and, if required, aligned
with adjoining case(s).
This may require repositioning of the case you
are installing or
the already positioned case.
3. Frame Support Rails
Illustration below shows case with frame support
rails (sample case - may not exactly reflect your
particular model).
Shims will be provided with all cases that have
frame support rails.
Use shims to level case.
Note: After case is in position, it must be
sealed to floor to prevent entry or leakage of
liquid or moisture.
Case
Front
Frame
Support Rails
6
INSTALLATION, CONTINUED: SNEEZE GUARD ASSEMBLY SELF-INSTALLATION (RETROFITTING)
Sneeze Guard Self-Installation (Retrofitting)
Cases may be ordered without sneeze guards.
Should customer wish to attach sneeze guards AFTER
case has been delivered, it is the responsibility of
Do Not Use Screws
Longer Than 1” As They
May Penetrate Electrical
Wiring or Heat Tape.
customer (and their chosen contractor) to do so.
Structural Concepts is not responsible for damage to
case or sneeze guard as it pertains to methods
employed or components chosen in retrofit process.
If your model is similar to model GP441RRLB (shown on
this sheet) do not use screws longer than 1” or they may
penetrate through top board and into electrical wiring
or heat tape. Each model may vary. Carefully check
panel thickness and surrounding electrical components
before drilling holes or attaching screws into your unit.
Note: Model shown may not exactly reflect specifics of
your particular model or options.
Top View of Model
GP441RRLB
Top View of Model
GP441RRLB
Do Not Use Screws
Longer Than 1” As
They May Penetrate
Electrical Wiring or
Heat Tape.
Do Not Use Screws
Longer Than 1” As
They May Penetrate
Electrical Wiring or
Heat Tape.
1” Thick Panel
(To Attach
Sneeze Guard
Bases)
Side View of Model GP441RRLB
(Partially Disassembled For Illustrative Purposes Only)
7
CASE START-UP / THERMOMETER FUNCTION & LOCATION
1. Case Start-Up
Case will energize when properly field-wired.
Refrigeration system will supply cold air to rear drawers,
rear door compartment and front grab-n-go section upon
being energized.
Front refrigerated section shown below. Light switch
(if any) will turn on light at front of case.
When properly field-wired, coil fans should turn on. From
inside of the case, check for discharge air from the air
diffusing honeycomb to confirm that fans are functioning
properly. See next page for honeycomb location.
When case is in start-up mode (or has been idle for a
long period of time), unit requires 75 minutes of run time
to pull-down temperature.
2. Thermometer Function & Placement
Note 1: Thermometers provides temperature to three (3)
separate areas in the case.
Note 2
: Thermometers reflect warmest air temperature in
merchandiser. They do not provide actual food
temperature.
Note 3
: Use probe thermometers to determine actual
product temperatures.
Thermometer to
Refrigerated Front
Grab-N-Go Section
Thermometer to
Refrigerated Pan System
(Behind Sneeze Guards)
Case Front
Glove Box
Holder
Glove Box Holder
Thermometer to
Refrigerated Rear Drawers
and Rear Door Compartment
Refrigerated
Rear Drawers
Refrigerated Rear Door
Compartment
-- View of Case Rear (Model GP837R Only) --
Refrigerated
Rear
Drawers
8
LED LIGHT REMOVAL/REPLACEMENT, PLUG/CORD POSITIONING, PROPER PLUG INSERTION
1. LED Light Removal / Replacement
If case is provided with LED lights they will rarely
require change-out.
Contact Structural Concepts’ Technical Service
Dept. for replacement parts (see Technical Service
section of this guide).
To remove LED light fixture, disconnect existing
LED light from brackets and self-adhesive tape.
Then, firmly grasp LED light while applying outward
pressure to brackets.
Twist the LED out and away from the bracket to
release
2. Plug and Cord Positioning
Plug is to connect to LED light at raceway side of
case.
Before attaching LED light to case, verify that plug
connects to LED properly (without cord doubling
back).
See photos of proper vs. improper connections
below.
LED Light
3. Proper Plug Insertion Into LED Light
Plug must be inserted into LED light properly or
the LED will not light up.
Oval form of plug is to connect to the oval form
of LED light.
See illustrations below.
Proper Connection
Plug’s
Oval Form
Improper Connection
Bracket (Typ.)
Honeycomb
LED
Light
9
FLUORESCENT LIGHT REMOVAL/REPLACEMENT (MODEL GP841R.5184 / FLUORESCENTS ONLY)
Light Fixture
Removal of lamp:
Rotate lamp (1/4-turn) either direction to disengage
(upper or lower) pins/contacts from lamp mounting
sockets.
Remove bulb by applying even pressure from the
back side at the bulb ends and pulling the
remaining contact from the sockets.
See illustration at below-left.
Fluorescent
Light
Installation of lamp:
Align pins with slot.
Insert pins into socket by rotating the bulb
1/4-turn to secure either the (upper or lower)
pinned contacts into the sockets.
Rotate the remaining bulb contacts (1/4 turn)
into the remaining lamp mounting socket
contacts.
See illustration below.
Standard
Fluorescent
Light Fixtures
10
DECKING, EVAPORATOR COIL FAN DISCHARGE, TXV LOCATION (MODEL GP837R ONLY)
1. Coil Fan Discharge
When Main Power Switch is turned on, refrigeration section will energize (see CASE START-UP section in
this manual).
Evaporator coil fans should turn on. From inside of the case, check for discharge air from fans to confirm
that they are functioning properly.
When the case is in a start up mode or has been idle for a long period of time, the unit will require 75
minutes of run time to pull-down temperature.
See below illustration.
2. TXV
TXV is under TXV Access Panel (at Customer Front-Left of Case).
Decking must be removed for access.
See illustration below for location.
Note: Partially disassembled view below shown for illustrative purposes only.
3. Model GP837R Layout is Shown Below
See next page for decking, evaporator coil fan discharge and TXV location on model GP841R.5184.
TXV
Evap. Fan
(Typ.)
Evaporator
Coils
Evap. Fan
Shroud
View of Case With Decking, Rear Plenum and End Panel
Shown Removed for Illustrative Purposes Only
11
DECKING, EVAPORATOR COIL FAN DISCHARGE, TXV LOCATION (MODEL GP841R.5184 ONLY)
1. Coil Fan Discharge
When Main Power Switch is turned on, refrigeration
section will energize (see CASE START-UP section
in this manual).
Evaporator coil fans should turn on. From inside
of the case, check for discharge air from fans to
confirm that they are functioning properly.
When the case is in a start up mode or has been
idle for a long period of time, the unit will require
75 minutes of run time to pull-down
temperature.
See below illustration.
2. TXV (Thermostatic Expansion Valve)
TXV is under access panel (at customer front-
right of case).
Decking must be removed for access.
See illustration below for location.
Note: Partially disassembled view below shown
for illustrative purposes only.
3. Model GP741.5184 Layout is Shown Below
See previous page for decking, evaporator coil
fan discharge and TXV valve location on model
GP837R.
Evap. Fan (Typ.)
View of Case With Decking and End Panel
Evap. Fan Shroud
Removed for Illustrative Purposes Only
12
TXV Evaporator
Coils
DECKING, EVAPORATOR COIL FAN DISCHARGE, TXV LOCATI ON - SNEEZE GUARD AREA
1. Coil Fan Discharge
When Main Power Switch is turned on, refrigeration section will energize (see case start-up section).
Coil fan should turn on. From inside of the case, check for discharge air from front fans, to confirm that
the fan is functioning properly.
When the case is in a start up mode or has been idle for a long period of time, the unit will require
75 minutes of run time to pull-down temperature.
See below illustration.
2. TXV (Thermostatic Expansion Valve)
TXV is under TXV access panel (at customer front-left of case).
Decking must be removed for access.
See illustration below for location.
Note: Illustrations shown may not exactly reflect
every feature or option of your particular case.
Evaporator Fans
Evaporator Fan
Shroud
View of Case With Decking, Rear Plenum and End Panel
Removed for Illustrative Purposes Only
13
TXV
Evaporator
Coils
DECKING, EVAPORATOR COIL FAN DISCHARGE, TXV LOCATION - REAR (MODEL GP837R)
1. Coil Fan Discharge
When main power switch is turned on, rear refrigeration section (accessible through door and drawers) will
energize (see case start-up section).
Unit cooler fan should turn on. Check for discharge air to confirm that the fan is functioning properly.
When the case is in a start up mode or has been idle for a long period of time, the unit will require
75 minutes of run time to pull-down temperature.
See below illustration.
2. TXV (Thermostatic Expansion Valve)
TXV is behind unit cooler fan (see illustration below).
See illustration below for location.
Note: Illustrations shown may not exactly reflect
every feature or option of your particular case.
Unit Cooler
Fan
TXV (Behind Unit
Cooler Fan)
View of Case With Rear Door and Drawers
Removed for Illustrative Purposes Only
14
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