Structural Concepts GCD456R Owner’s Manual

READ AND SAVE THESE INSTRUCTIONS

INST ALLATION AND

G-SERIES

COMBINATION COLD MERCHANDISERS
>> BLOWER COIL UNITS (STANDARD) >> GRAVITY COIL UNITS (OPTIONAL) >> THREE (3) UPPER SECTION VARIABLES:

 DELI PRODUCTS: BLOWER COILS (NO GRAVITY COILS NOR ICE TRAYS)
 MEAT PRODUCTS: GRAVITY COILS WITH PLATTER COILS (NO BLOWER COILS)
 SEAFOOD PRODUCTS: GRAVITY COILS WITH ICE TRAYS (NO BLOWER COILS)

: SERVICE UPPER / SELF SERVICE LOWER “TALL DOMES”

OPERATING MANUAL

MODEL GCDT656RLB
(LOWER BASE UNIT)
WITH FLAT GLASS

MODEL GCDT656RLB

(LOWER BASE UNIT)

WITH CURVED GLASS

PART NO.

20-17016

MODEL GCD856R (SHOWN W/OPTIONAL SECURITY GRID)

MODEL GCDT856RLB (LOWER BASE UNIT WITH ANGLED GLASS).

MODEL GCDT856RLB (LOWER BASE

UNIT WITH CURVED GLASS)

Models Included in Operating Manual

GCD456R, GCDT456RLB, GCD656R, GCDT656RLB,

GCD856R, GCDT856RLB, GCD1256R, GCDT1256RLB

I:\Oper Manual\G-Series\GCDT456RLB_GCDT656RLB_GCDT856RLB_GCDT1256RLB_20-17016.pub

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

: GLASS RAISED FOR ILLUSTRATIVE PURPOSES ONLY)

NOTE

MODEL GCDT1256RLB (LOWER BASE UNIT)

Rev i Date: 5.1.2014

TABLE OF CONTENTS / MODEL LENGTH, DEPTH & HEIGHT

TABLE OF CONTENTS ………………………………………………………………………………………....

OVERVIEW / TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING DIAGRAM / PLUGS .
INSTALLATION: REMOVAL FROM SKID, REMOVING VERTICAL LOWER FRONT PANEL …….…..
INSTALLATION: POSITIONING & ALIGNING CASE / BOLTING & CAULKING UNITS TOGETHER ...
INSTALLATION: FRAME SUPPORT RAIL SHIMMING ……………………………………………………..
INSTALLATION, CONT.: ADJUSTING LEVELERS ………………………………………………………….
INSTALLATION: TEMPERATURE & DEFROST CONTROL / REAR PANEL REMOVAL /
THERMOMETERS ...………………………………………………………………………………...….

STORE PERSONNEL SECTION ONLY ..……………………………………………………….……….……

OPERATION: DRIVERS / BALLASTS / T’BLOCK / CONTACTOR, ETC., GENERAL LAYOUT ............

OPERATION: MAIN PWR SWITCH / THERMOSTAT (S.C. UNITS ONLY) / SCALE STAND ………….
OPERATION: BLOWER COIL UNIT (DELI CASE) REFRIG. LINES / DRAINS / TXV, ETC…………….
OPERATION: PLATTER COIL / GRAVITY COIL (MEAT CASE): REFRIG. LINES / DRAINS / TXV…...

OPERATION: GRAVITY COIL / ICE TRAYS (SEAFOOD CASE): REFRIG. LINES / DRAINS / TXV ....

OPERATION: (MODEL GCDT1256RLB GRAVITY COIL UNIT) DRAIN CONNECTIONS / AXIAL
FANS ………………………………………………………………………………………………...…...
OPERATION: GRAVITY COIL UNITS - ADJUSTABLE DECKING (4° AND 8° ANGLES) /
HUMIDICATION FEATURE (MISTING/FOGGING DEVICE) ……..………………………………..

OPERATION: DISPLAY CASE START-UP / LIGHT SWITCHES / REAR STORAGE & SHELVING .....

OPERATION: DISPLAY CASE START-UP, LIGHTS, TEMPERATURE CONTROLLER, SST ………...
STOCKING / MAINTAINING PROPER PRODUCT CONDITION / IMPORTANT PROCEDURES ……..
MAINTENANCE: REAR SLIDING DOORS / STANDARD LIGHT FIXTURES ……….…………………...

MAINTENANCE: BRACKET RETAINERS / SHELVES / LOAD LIMITS …………………………………..
MAINTENANCE: PRODUCT PLACEMENT / PAN PLACEMENT (MEAT CASE) ...……………………...

MAINTENANCE: CUTTING BOARD/REAR LEDGE LOWERING .......…………………………………….

CLEANING SCHEDULE (INTERIOR) - TO BE PERFORMED BY STORE PERSONNEL………….…..
CLEANING SCHEDULE (EXTERIOR) - TO BE PERFORMED BY STORE PERSONNEL…………..…

TROUBLESHOOTING - TO BE PERFORMED BY STORE PERSONNEL ……………...…...……….….

TRAINED SERVICE PROVIDERS SECTION ONLY ………………………………………………….…….

REFRIGERATION PACKAGE LAYOUT: MODEL GCD456R SELF-CONTAINED UNIT ………………..
REFRIGERATION PACKAGE LAYOUT, CONT.: MODEL GCD856R SELF-CONTAINED UNIT ……...

CLEANING SCHEDULE (INTERIOR) - TO BE PERFORMED BY TRAINED SERVICE PROVIDERS ..
TROUBLESHOOTING - TO BE PERFORMED BY TRAINED SERVICE PROVIDERS ONLY …………
PREVENTIVE MAINTENANCE - TO BE PERFORMED BY TRAINED SERVICE PROVIDERS ONLY .

MAINTENANCE - FRONT GLASS ALIGNMENT & ADJUSTMENT VIA CLAMSHELL SCREWS ……..
MAINTENANCE, CONT. - FRONT GLASS ALIGNMENT VIA FRAME SUPPORT RAILS ……………...
MAINTENANCE, CONT. - FRONT GLASS ALIGNMENT VIA LEVELERS ………………..……………...

GENERAL TECHNICAL INFORMATION (PARTS LIST / SERIAL LABEL INFO / TEMPERATURE
CONTROLLER INFORMATION / TECHNICAL SERVICE INFORMATION, ETC.) ...…………..

SERIAL LABEL INFORMATION & LOCATION ..……………………………………...…....……………..…

CAREL TEMPERATURE CONTROLLER (THERMOSTAT) INFORMATION …………………………….

TECHNICAL SERVICE CONTACT INFORMATION & WARRANTY INFORMATION ...……….……......

2

3-4

5
6
7
8

9

10
11

12
13-14
15-16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32
33-34

35-37

38

39

40
41-42

43

44
45-47

48

2

OVERVIEW / TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS - PAGE 1 of 2

OVERVIEW

 Upper Section: This merchandiser is designed to

merchandise unpackaged product at a range of 33 °F
to 38 °F (1 °C to 3 °C) product temperatures.

 Lower Section

: This merchandiser is designed to
merchandise packaged product at 41 °F (5 °C) or less
product temperatures.

 Product Pre-Chill Requirement

: Product must be
pre-chilled to above listed temperatures prior to being
placed in merchandiser.

 These cases should be installed and operated

according to this operating manual’s instructions to
ensure proper performance. Improper use will void
warranty.

 Improper use will void warranty.

TYPE 1 vs. TYPE 2 CONDITIONS

This unit is designed for the display of products in ambient
store conditions where temperatures and humidity are
maintained within a specific range.

 For Type 1 Conditions (most cases): ambient

conditions are to be at 55% maximum humidity and
maximum temperatures of 75 °F (24 °C).

 For 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 designed for 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 sheet contains important warnings to prevent

injury or death.

 Please read carefully!

PRECAUTIONS, CORD/PLUG MAINTENANCE &
WIRING DIAGRAM INFORMATION

 See next page for PRECAUTIONS, CORD/PLUG

MAINTENANCE and WIRING DIAGRAM information.

WARNING

ELECTRICAL

HAZARD

WARNING

KEEP

HANDS
CLEAR

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.

CAUTION! CHECK BOTH CONDENSATE PAN AND OVERFLOW PAN

Water on floor can cause extensive damage! Before powering up unit:

 Condensate pan MUST BE positioned directly under condensate drain.
 Overflow pan MUST HAVE single plug connected to its box. Units with

optional Clean Sweep™ MUST HAVE two plugs connected.

3

OVERVIEW / TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS - PAGE 2 of 2

PRECAUTIONS

 This sheet contains important precautions to prevent

damage to unit or merchandise.

 Please read carefully!
 See previous page for specifics on OVERVIEW,

CONDITION TYPE, COMPLIANCE and WARNINGS.

WIRING DIAGRAM

 Wiring diagram is folded and in its own packet.

CAUTION! LAMP REPLACEMENT GUIDELINES

CAUTION

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 warranted.
 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/small rooms 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).

WIRING DIAGRAM FORMAT & LOCATION

 Each case has its own wiring diagram folded & 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.

4

INSTALLATION: REMOVAL FROM SKID, REMOVING VERTICAL LOWER FRONT PANEL

1. Remove Case From Skid (Rails)

 Remove shipping brace that may be securing case

to skid.

 Support case to prevent tipping.
 Caution! Levelers can be damaged if case hits floor

with heavy force!

 Carefully slide unit to

rear of skid and tip
backward off skid.

 Illustration may not

reflect every feature
or option of your
particular case.

Slide Skid Out

Case can be repositioned with pallet truck when front
lower panel is removed. Blocking may be necessary to
obtain adequate height.

2. Remove Case From Skid (Casters)

Remove shipping brackets that may be securing
casters to skid

 Place ramp up against skid (to allow case to

smoothly slide off from skid).

 Maintain support of case at all times or center of

gravity may cause case to fall.

 Unlock Casters. Roll unit to rear of skid.



Roll down ramp
and off from skid.

Note: Illustrations

shown reflect a

general outline of
sample cases and do
not reflect features or

options of your

Support

while

rolling case

own ramp.

particular model.

Ramp

Slots

Hooks

3. Removing Vertical Lower Front Panel

Removing Lower Front Panel

No screw removal is required to remove lower front panel.



 Simply lift lower front panel slots up and off case hooks.
 Replace in same manner it was removed.

5

Lower Front Panel

(Reversed to Show Slots

INSTALLATION, CONT.: POSITIONING & ALIGNING CASE / BOLTING & CAULKING UNITS TOGETHER

4. Position & Align Case Alongside Other
Cases

 Before adjusting levelers (or shimming frame

support rails), make certain that case is in proper
position and, if required, aligned with adjoining case.

 This may require the repositioning of the case you

are installing or

5. Bolting and Caulking Units Together

Follow these steps to assure a secure, level lineup.
A. Begin lineup leveling from highest point of floor.

B. After ‘first’ case is level, apply industrial grade butyl

caulk on non-visible areas (at case end). Use
industrial grade silicone sealant on visible areas
(at case end). See caulk/silicone illustrations at

lower-left.
C. Form Two (2) Caulk/Sealant Lines
and Refrigeration). See illustration at mid-right for
outline of caulk/sealant lines.

Sanitation Bead Refrigeration Bead

the already positioned case.

: (Sanitation

D. Line up ‘second’ case bolt-hole to bolt-hole to ‘first’

case.

E. Using SCC-supplied bolts (and/or screws) found in

installation packet, insert bolts in bolt hole locations
(shown below). You may need to remove decking
to access lower bolt holes.

F. Caution! Front of cases MUST be flush with each

other! After leveling, cases are to be same height.

G. Using SCC-supplied nuts & bolts, lightly tighten

each of the 5 to 8 bolts in a cross-wise pattern.
Work your way around the pattern, tightening more
firmly at each pass. Do not

firmly tighten one bolt

and then start on the next!

H. After the cases are bolted together, level the

‘second’ case. Repeat this process for each case
to be adjoined.

I. After all lined-up cases are level, seal all seams

with industrial grade silicone sealant.

Refrigeration

Bead

Approximate hole
locations pointed at
with arrows ( )

for bolting units

together.

Butyl is to be used on

non-visible areas.

Silicone is to be used

on visible areas.

Sanitation

Bead

Sanitation

Bead

Refrigeration

Bead

Refrigeration

Bead

6

INSTALLATION, CONT.: FRAME SUPPORT RAIL SHIMMING

6. Frame Support Rails Must Be Shimmed

 Illustration below shows case with frame

support rails.

 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.

 Caution: If glass scrapes against edges of case or

against each other, see TROUBLESHOOTING ­FRONT GLASS ALIGNMENT ISSUES section in

this manual.

Frame Support

Rails

Note: Above Illustration May Not Depict An Exact

Representation Of Your Particular Unit Being Installed.

7

INSTALLATION, CONT.: ADJUSTING LEVELERS

7. Adjust Levelers

 After case is in position, adjust case so it is

level and plumb see illustration below.

 You may need to remove front and/or rear

Toe-Kick to access levelers.

 Use adjustable wrench (and possibly a pry bar)

to adjust leveler.

Adjustable

Wrench

Pry Bar

Block

Leveler

Toe-Kick

Base

Frame

 Do not use pry bar on toe-kick (it may buckle).
 Do not use pry bar on end panel (it may chip).
 Use pry bar ONLY on base frame to avoid

damaging case.

 Use a block to reach base frames with pry bar.
 Note: Illustration below may not exactly reflect

every feature or option of your particular case.

8

INSTALLATION: TEMPERATURE & DEFROST CONTROL / REAR PANEL REMOVAL / THERMOMETERS

8. Temperature & Defrost Control

 Both temperature controller and defrost controller

are remotely controlled.

 Consult store management for guidance and

instructions.

9. Rear Panel Removal

 No screw removal is required.
 Lift lower front panel slots up and off case hooks.
 Replace in same manner it was removed.

Enlarged View

Of Hooks (To Attach

Thermometers Are Located in

Upper Storage Areas (Typical)

Rear Panel’s Slots)

10. Thermometer Placement & Purpose

 Front thermometers are located against rear

plenums.

 Rear thermometers are located in rear storage

bins above shelves (at angled positions).

 Also, rear thermometers are in upper section

just inside rear doors (as shown below).

 Thermometers may be either spirit-filled or

digital. They reflect internal air temperature only
(not actual food temperature).

 Use probe thermometers to determine actual

product temperatures.

Lower

Rear Panel Slots

Thermometers Are

Also located in

Rear Storage

Areas (Typical)

Lower Rear Panel

(Reversed to Show Slots)

9

STORE PERSONNEL’S SECTION ONLY

STORE PERSONNEL

SECTION ONLY

10

OPERATION: DRIVERS / BALLASTS / TERMINAL BLOCK / CONTACTOR, ETC., GENERAL LAYOUT

1. Ballasts and Field Wiring Box

 Electrical raceways contain various electrical

components.

 Access to these components can be made

simply by removing raceway cover.

Electrical Component Raceway (For Multiple Model Layouts) is Shown Below

(Your Case’s Model and Layout May Vary)

Drivers/Ballasts

Terminal Block

Contactor

 See illustrations below for general layouts.
 Caution! Only certified electricians are to

access electrical components!

Driver: Front Fan

Ballast Drivers

(Alternate Placement)

Model GCDT1256RLB is Shown Below

(Your Component Layout May Vary)

11

OPERATION, CONT.: MAIN POWER SWITCH / THERMOSTAT (S.C. UNITS ONLY) / SCALE STAND

2. Main Power Switch

 Self-Contained units have main power switch

at case rear.

 When main power switch is turned on, power

is provided to entire case.

 See illustration below.

3. Thermostat

 Self-Contained units have temperature

controlled by thermostat.

 Thermostat is located at case rear (as shown as

illustration below).

 See OPERATION, CONT.: DISPLAY CASE

LIGHTS, TEMPERATURE CONTROLLER, SST

section in this manual for additional information.

 See entire Carel Controller section in this manual

for detailed information including programming,
user interface and operating parameters.

4. Scale Stand / Power Outlets / CAT5
Receptacle

 Depending upon the model, there can be one or

several scale stands.

 Scale stands have power outlets for scale stand

plug, etc.

 Scale stands also may have CAT5 receptacles for

on-line connection capability.

 See illustration below.

CAT5

Receptacle

Power Outlets

Main

Power Switch

Thermostat

12

OPERATION, CONT.: BLOWER COIL UNIT (DELI CASE) REFRIG. LINES / DRAINS / TXV, ETC.

5. Blower Coil Unit (Deli Case) Refrigeration Lines / Stub-Ups / Drain, TXV , Etc.

 Illustration on this sheet is applicable to model GCDT856RLB only.
 See next page for illustration pertaining to model GCDT656RLB.
 Blower coil units do not have gravity coils nor platter coils.
 Two (2) trough drains are in each case. One (1) is at each end of case (as illustrated on next page).
 See illustration below for locations of components under upper and lower section decks.

Shutoff

Valve

Filter

Dryer

TXV

Fan

Shroud

Fan

Assembly

(Typical)

TXV

Fan

Shroud

Fan

Assembly

(Typical)

Drain

Shutoff

Valve

TXV Fan

Assembly

(Typical)

Assembly

(Typical)

Fan

Shroud

Note: Model GCDT856RLB (Shown Above) May Not

Depict An Exact Representation Your Unit Being Installed.

13

TXV Filter Dryer Fan Shroud Drain Fan

OPERATION, CONT.: BLOWER COIL UNIT (DELI CASE) REFRIG. LINES / DRAINS / TXV, ETC.

6. Blower Coil Unit (Deli Case) Refrigeration Lines / Stub-Ups / Drain, TXV , Etc.

 Illustration on this sheet is applicable to model GCDT656RLB only.
 See previous page for illustration pertaining to model GCDT856RLB.
 Blower coil units do not have gravity coils nor platter coils.
 Two (2) trough drains are in each case. One (1) is at each upper section / one is at lower section.
 See illustration below for locations of components under upper and lower section decks.

Solenoid Valve

Assembly

TXV

Fan

Assembly

(Typical)

Fan

Shroud

Fan

Shroud

Fan

Assembly

(Typical)

Drain

Solenoid Valve

Assembly

Depict An Exact Representation Your Unit Being Installed.

Fan Assembly

(Typical)

(Typical)

Note: Model GCDT656RLB (Shown Above) May Not

14

TXV Fan Shroud Drain Fan Assembly

OPERATION, CONT.: PLATTER COIL / GRAVITY COIL (MEAT CASE): REFRIG. LINES / DRAINS / TXV

7. Platter Coil Unit (Meat Case) Refrigeration Lines / Stub-Ups / Drain, TXV, Etc.

 Illustration on this sheet is applicable to model GCDT856RLB only.
 See next page for illustration pertaining to model GCDT656RLB.
 Platter coil units also have gravity coils above. No ice trays.
 Two (2) trough drains are in each case. One (1) is at each upper section / one is at lower section.
 Also, see illustration below for locations of components under upper and lower section decks.

Drain

Shutoff

Valve

Solenoid Valve

Assembly

EPR

Filter

Dryer

TXV

Platter Coils

(Meat Case Only)

Drain

Shutoff

Valve

TXV Fan

Assembly

(Typical)

Assembly

(Typical)

Fan

Shroud

Note: Model GCDT856RLB (Shown Above) May Not

Depict An Exact Representation Your Unit Being Installed.

15

TXV Filter Dryer Fan Shroud Drain Fan