Structural Concepts DOS3623R Installation Manual
SELF-SERVICE DROP-IN
REFRIGERATED
MERCHANDISERS WITH
STRAIGHT GLASS
Model DOS3623R
is Shown at Right
READ AND SAVE THESE INSTRUCTIONS
P/N 20-09155
INSTALLATION &
OPERATING MANUAL
Model DOS3623R 38 1/8”L x 28 5/8”D x 23 1/4”H (Upper Display Case Only)
38 1/8”L x 28 5/8”D x 47 1/4”H (Upper Display Case + Drop-In Refrigeration Unit)
Model DOS3637R 38 1/8”L x 28 5/8”D x 36 3/4”H (Upper Display Case Only)
38 1/8”L x 28 5/8”D x 60 3/4”H (Upper Display Case + Drop-In Refrigeration Unit)
Model DOS4823R 50 1/8”L x 28 5/8”D x 23 1/4”H (Upper Display Case Only)
50 1/8”L x 28 5/8”D x 47 1/4”H (Upper Display Case + Drop-In Refrigeration Unit)
Model DOS4837R 50 1/8”L x 28 5/8”D x 36 3/4”H (Upper Display Case Only)
50 1/8”L x 28 5/8”D x 60 3/4”H (Upper Display Case + Drop-In Refrigeration Unit)
Note 1. Internal counter height must be at least 28” for refrigeration and proper air flow space.
. Models DOS3623R & DOS3637R: Service Top Cutout dimensions must be 27.15” Wide x 36.65” Long (with a
Note 2
minimum 1.42” perimeter) for proper clearance and fit of Drop-In Refrigerated Merchandiser. These combined
dimensions require a 30” minimum counter top space for cutout.
Note 3
. Model DOS4823R & DOS4837R: Service Top Cutout dimensions must be 27.15” Wide x 48.65” Long (with a
minimum 1.42” perimeter) for proper clearance and fit of Drop-In Refrigerated Merchandiser. These combined
dimensions require a 30” minimum counter top space for cutout.
888 E. Porter Road · Muskegon, MI 49441 Phone: 231.798.8888 Fax: 231.798.4960 www.structuralconcepts.com
I:\Oper Manuals\Impulse\DOS3623R_DOS3637R_DOS4823R_DOS4837R_20-09 155.pub
Rev D Date: 8.27.2013
TABLE OF CONTENTS
OVERVIEW / NSF® TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING….…….....…..
CUSTOMER CABINET PROVISIONS…………………..…………………..…….………….....…………...
CLEARANCE AND AIR FLOW ...………………………..…………………..…….………….....…………....
VENTING INSTRUCTIONS FOR AIR INTAKE / EXHAUST (FOR ALL CASES) ..……….....…………..
INSTALLATION: SKID REMOVAL / LOWERING INTO COUNTER (BASE) / SEALING ..……………..
START-UP AND OPERATION / TEMERATURE SETTINGS ..…………………………..…………….….
MAINTENANCE FUNDAMENTALS: SHELF / SHELF REMOVAL / MINI-LED LIGHT FIXTURES …...
MAINTENANCE FUNDAMENTALS: REMOVING REAR DOORS AND PERFORATED ACRYLIC
PLENUM ...……………………………….………………………………………………………..…….
MAINTENANCE FUNDAMENTALS: EVAPORATOR COIL FANS ACCESS AND REMOVAL …..…...
MAINTENANCE FUNDAMENTALS: HONEYCOMB AIR DIFFUSERS ………………………………….
REFRIGERATION FUNDAMENTALS: ACCESS TO CONDENSER COIL / SERVICING /
TEMPERATURE CONTROL MODULE ……………………………………………………………...
REFRIGERATION SLIDE-OUT EXPLODED PICTORIAL ……………………………………..……….….
SERIAL LABEL LOCATION & INFORMATION LISTED / TECH INFO & SERVICE …………....……...
TROUBLESHOOTING (BY TRAINED SERVICE PROVIDERS ONLY) ……………………………...…..
TROUBLESHOOTING (BY TRAINED SERVICE PROVIDERS ONLY) - CONDENSING SYSTEM ….
TROUBLESHOOTING (BY TRAINED SERVICE PROVIDERS ONLY) - EVAPORATOR SYSTEM ….
CLEANING SCHEDULE ....………………………………………………………...…...………………….….
CAREL® TEMPERATURE CONTROLLER INFORMATION ………………..…………………………….
TECHNICAL SERVICE CONTACT INFORMATION & WARRANTY INFORMATION ………….……...
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OVERVIEW / NSF® TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING - PAGE 1 of 2
OVERVIEW
These Structural Concepts merchandisers are
designed to merchandise packaged products at 41 °F
(5 °C) or less product temperatures.
Product must be pre-chilled to 41 °F (5 °C) or less
prior to being placed in merchandiser.
Cases should be installed and operated according to
this operating manual’s instructions to insure proper
performance.
Improper use will void warranty.
NSF® TYPE
This unit is designed for the display of products in ambient
store conditions where temperatures and humidity are
maintained within a specific range.
For NSF® Type 1 Conditions (most cases): ambient
conditions are to be at 55% maximum humidity and
maximum temperatures of 75 °F (24 °C).
For NSF® Type 2 Conditions: ambient conditions are
to be at 60% maximum humidity and maximum
temperatures of 80 °F (27 °C).
If unsure if unit is NSF® Type 1 or 2, see tag next to
serial label. See SERIAL LABEL LOCATION &
INFORMATION LISTED / TECH INFO & SERVICE
section in this manual for sample serial labels.
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
Condenser Pan is Hot!
Disconnect and allow to cool
before cleaning or removing from case.
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OVERVIEW / NSF® TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING - 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, NSF
TYPE, COMPLIANCE and WARNINGS.
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
Each case has its own wiring diagram folded and in
its own packet.
Wiring diagram placement may vary; it may be
placed near ballast box, field wiring box, raceway
cover, or other related location.
CAUTION
CAUTION! ADVERSE CONDITIONS / SPACING ISSUES
Performance issues caused by adverse conditions are NOT covered
by warranty.
Unit must be kept at least 15-feet from exterior doors, overhead HVAC
vents or any air curtain disruption to maintain proper temperatures.
So not exposed to direct sunlight or heat sources (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).
CAUTION! CHECK CONDENSATE PAN POSITION AND PLUG
Water on flooring can cause extensive damage!
Condensate pan MUST BE positioned directly under condensate drain.
Condensate overflow pan plug MUST BE plugged into receptacle.
Before powering up unit, check the following:
WIRING DIAGRAM FORMAT & LOCATION
Each case has its own wiring diagram folded and in its own packet.
Wiring diagram placement may vary; it may be placed near ballast
box, field wiring box, raceway cover, or other related location.
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CUSTOMER CABINET PROVISIONS
Customer Cabinet Provisions
Customer provided cabinet must adhere to the minimum requirements in ANSI/UL Std. 471 and ANSI/
NSF Std. 7.
Among the factors that are to be taken into consideration when judging the acceptability of a cabinet or
similar enclosure are mechanical strength, resistance to impact, moisture-absorptive properties, flame
resistance, resistance to distortion at temperatures to which the material may be subjected under
conditions of use, and resistance to corrosion.
Customer provided cabinet or similar enclosure shall have the strength and rigidity necessary to resist
conditions of intended use without increasing the risk of fire or injury to persons due to total or partial
collapse. Cabinet or similar enclosure must be strong enough to hold weight of cabinet and intended
product load. Dry weight (no product in case) exceeds 500 pounds.
A nonmetallic cabinet or similar enclosure (or part of an enclosure) shall have a flame spread index of not
more than 200 when tested in accordance with the Standard for Tests for Surface Burning
Characteristics of Building Materials, UL 723.
The cabinet or similar enclosure shall be constructed and assembled to reduce the risk of fire due to the
emission of molten metal, burning insulation, flaming particles, or the like, through openings onto
flammable material, including the surface over which the refrigeration is mounted.
A sheet metal cabinet or similar enclosure is to be judged for acceptability with respect to its
size, shape, metal thickness. Sheet metal such as galvanized or stainless shall be 0.30 inch
(22 gage) or greater.
Steel enclosures shall be protected against corrosion by metallic or nonmetallic coatings, such
as plating or painting.
The refrigeration access panel/door shall be arranged so that main power switch, refrigeration controller
and refrigeration package are accessible without removing parts other than access panel/door.
A hinged or pivoted panel shall be positioned or arranged so that when it is in an open position
falling or swinging due to gravity or vibration will not cause injury to persons.
For electrical protection when installed in its intended manner, louvers and other openings in the
enclosure shall be constructed and located to reduce the risk of unintentional contact with moving, live or
hot parts such as fan blades and condensate trays. The minor dimension of such openings shall not
exceed 3 inches—See Table 6.1 for Clearance from Openings. Tools are required to remove covers,
panels or grilles unless interlock is provided.
Ventilation openings/louvers shall be free of sharp edges and burrs and have spaces large enough to
allow for easy cleaning. Louvers that may be subject to splashes, spills, and overhead drips shall be of a
drip-deflecting design.
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CLEARANCE AND AIR FLOW
Service Top Cutout Dimensions
Note: See Manual Cover for Service Top Cutout
Dimensions.
Clearance Dimensions
The Refrigerated section must maintain airflow clearance.
Dimensions are as follow.
1. 4" Minimum Spacing from bottom of refrigeration frame
to bottom of cabinet or floor required for adequate air flow.
2. 9 1/2" Countertop / Facia enclosure space on cabinets
or counter to allow for pullout system slide-out.
3. 15" Minimum opening in back of cabinet or counter
(to pull out refrigeration system).
4. Back of counter / cabinet ventilation must be at specific
space to allow for proper air intake and exhaust. See
illustration at right.
5. Front of counter ventilation must be at least 2” to allow
proper air intake and exhaust. See illustration at right.
6. Obstruction or restriction of air can void warranty.
Note: See Venting Instructions sections (next page)
for more specific Air Intake and Air Exhaust
clearance dimensions.
9 1/2” (SEE
NOTE 2)
15”
(SEE NOTES
3 & 4)
4” (SEE NOTE 1)
2” MIN. (SEE NOTE 5)
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ABOVE ILLUSTRATION APPLIES
TO ALL MODELS
VENTING INSTRUCTIONS FOR AIR INTAKE / EXHAUST - ALL CASES
ILLUSTRATION BELOW REFLECTS REAR VIEW OF CABINET AFTER
POSITIONED ON CUSTOMER-SUPPLIED COUNTER/BASE
WARNING!: The MINIMUM intake and exhaust areas must be allowed (as illustrated
below) or case temperatures may fluctuate beyond safe parameters!
NOTES:
1. THE IDEAL CONDITION FOR REAR OF CABINET IS TO HAVE COMPLETE OPEN SPACE (WITH NO DOORS
OR BLOCKING OF AIRFLOW WHATSOEVER).
2. SHOULD CABINET DOORS BE DESIRED (AS SHOWN BELOW) LOUVERS (or SCREENING) MUST BE
PROVIDED.
LOUVERS (or SCREENING) MUST BE 2” OR CLOSER TO EACH OTHER VERTICALLY.
LOUVER (or SCREENING) MUST EXTEND AT LEAST 4” BEYOND EACH END OF REFRIGERATION UNIT.
THIS SHEET REFLECTS THE MINUMUM REQUIRED VENTILATION. ADDITIONAL VENTILATION IS
RECOMMENDED AND WILL HELP MAINTAIN ACCEPTABLE MERCHANDISING TEMPERATURES.
3. SEE REFRIGERATION FUNDAMENTALS FOR VIEW OF CONDENSING UNIT AFTER SLIDE-OUT.
4. UNITS WITH REAR
LEAST A 3-FOOT SPACE BETWEEN REAR OF CABINET AND WALL TO ALLOW FOR SERVICE.
5. UNITS WITH FRONT REFRIGERATION PACKAGE SLIDE-OUT CAN HAVE REAR OF CABINET FLUSH TO
WALL, IF DESIRED.
REFRIGERATION PACKAGE SLIDE-OUT (AS SHOWN BELOW) MUST MAINTAIN AT
4” Minimum Air
Exhaust Space
Louvers (or screening) must extend at least
4” beyond each end of refrigeration unit.
2” Maximum Vertical
Space Between
Louvers
4” Minimum
Air Exhaust
Space
Cabinetry MUST provide access space
to allow rear slide-out of refrigeration
package. Measure before building!
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4” Minimum Air
Exhaust Space
INSTALLATION: SKID REMOVAL / LOWERING INTO COUNTER (BASE) / SEALING
1. Remove Case From Skid
Caution: Case must always remain supported or
center of gravity may allow case to fall. Slide to
rear of skid and tip backward off skid while
maintaining support. See illustration below.
Seal
Along
Upper
Display
F
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F
f
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W
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O
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s
a
o
d
i
k
S
m
d
l
o
H
y
l
m
r
i
Case
Here
Seal
Along
Here
Drop-In
Refrigerated
Section
Slide
Skid
Out
2. Display Case Design
As shown above-left, SCC® service drop-in
refrigerated unit consists of two sections:
> The upper display case
> The drop-in refrigerated section
As both sections make up one conjoined unit, it
is heavy and cumbersome.
See next section for instructions on lowering
drop-in refrigerated section into counter.
3. Lowering The Drop-In Refrigerated Section
Into The Counter (Base)
A concerted team effort may be required for
lowering drop-in section into customer supplied
counter (base). See top-right illustration.
The following is a proven method to lower the
drop-in section into the customer supplied
counter (base); however, it may NOT be the only
method. A fork lift is required to use this method.
A. Spread the forks (of fork lift) apart to fit under
either side of the upper display case (the
extended part of the unit that rests on counter).
B. Carefully raise into position above counter.
C. Place ¾” blocks of wood under two opposing
sides where it is to be lowered.
D. Lower into the opening of the counter.
E. After it is lowered all the way into the opening, it
will be resting on the two small wood blocks at
opposite sides.
Customer
Supplied Counter
(Base)
F. Place a small protective piece of ABS or wood
shim into place (to protect the counter) and use a
small pry bar to slightly raise the unit upward.
G. After unit is slightly raised, remove the wood piece
from under unit; then slowly lower into place,
allowing unit to gingerly rest on countertop without
scratching or marring surface.
H. Use the same process used on the
opposite side.
4. Seal Upper Display Case to Base
NSF® listed industrial grade silicone
sealant is recommended.
Clip tip to allow a Ø1/8” to Ø3/16”
hole.
Beginning at case rear, run a
consistent, solid bead of silicone
around entire perimeter.
See illustration of sample industrial
grade silicone sealant at right.
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