Structural Concepts DOS4837R Owner’s 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” L ong (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.

. Model DOS4823R & DOS4837R: Service Top Cutout dimensions must be 27.15” Wide x 48.65” Long (with a

Note 3
minimum 1.42” perimeter) for proper clearance and fit of Drop-In Refrigerated Merchandiser. These combi ned
dimensions require a 30” minimum counter top space for cutout.

888 E. Porter Road · Muskegon, MI 49441 Phone: [phone] Fax: [phone] www.structuralconcepts.com

I:\Oper Manuals\Impulse\DOS3623R_DOS3637R_DOS4823R_DOS4837R_20-09155.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 AC RYLIC

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

5. UNITS WITH FRONT
WALL, IF DESIRED.

REFRIGERATION PACKAGE SLIDE-OUT (AS SHOWN BELOW) MUST MAINTAIN AT

BETWEEN REAR OF CABINET AND WALL TO ALLOW FOR SERVICE.

REFRIGERATION PACKAGE SLIDE-OUT CAN HAVE REAR OF CABINET FLUSH TO

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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a

C

F

f

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a

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R

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C

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l

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h

W

g

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i

d

i

l

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f

f

O

e

s

a

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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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