Structural Concepts GCD656H Installation Manual
READ AND SAVE THESE INSTRUCTIONS
INST ALLATION AND
G-SERIES
SERVICE/SELF-SERVICE COMBINATION MERCHANDISER:
> SERVICE HEATED UPPER
> SELF SERVICE REFRIGERATED LOWER
> SELF-CONTAINED REFRIGERATION
> NON-REFRIGERATED REAR STORAGE
> SCALE STANDS WITH CAT 5 RECEPTACLE & DUAL RECEPTACLES
OPERATING MANUAL
SCC P/N
20-27143
Structural Concepts Corporation · 888 E. Porter Road · Muskegon, MI 49441 Phone: 231.798.8888 Fax: 231.798.4960 · www.structuralconcepts.com
Oper Manual\G-Series\G-Series_GCD856H_20-27143.pub
MODEL GCD856H
(SHOWN WITH OPTIONAL NIGHT CURTAINS)
Rev B Date: 5.20.2014
TABLE OF CONTENTS / MODEL LENGTH, DEPTH & HEIGHT
TABLE OF CONTENTS ...………………………………………………………………………………………..
OVERVIEW / TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING DIAGRAM / PLUGS ..
INSTALLATION: REMOVAL FROM SKID ADJUSTING LEVELERS …………………………...……...…..
INSTALLATION, CONTINUED: REMO VING LOWER FRONT PANEL ………………………………..…..
INSTALLATION, CONTINUED: REAR PANEL AND GRILLE REMOVAL ……………………………..…..
INSTALLATION, CONTINUED: ALIGNING, BOLTING & CAULKING UNITS TOGETHER …………......
CASE START-UP: MAIN POWER SWITCH / TEMPERATURE CONTROLLER / SST ………..………...
CASE START-UP: REFRIGERATED SECTION / THERMOMETER AND LIGHT SWITCH ………….....
CASE START-UP, CONTINUED: HEATED SECTION / SCC HEATED TEMPER ATURE CONTROLS .
OPERATION: DRIVERS / BALLASTS / TERM’L BLK / CONTACTOR / PHASE SELECTOR SWITCH .
OPERATION, CONTINUED: FRONT GLASS ALIGNMENT & ADJUSTMENT VIA CLAMSHELL …..….
OPERATION, CONTINUED: EV AP . COILS / REFRIG. LINES / DR AI N / TXV / HEATER RODS ……....
OPERATION, CONTINUED: DRAIN ROUTE / SCALE STANDS / REAR STORAGE (NON-REFRIG.) .
OPERATION, CONTINUED: CONDENSING UNIT ACCESS / ILLUSTRATED PARTS BREAKDOWN .
OPERATION, CONTINUED: CLEAN SWEEP CONDENS’G COIL CLEANING SYSTEM (OPTIONAL) .
MAINTENANCE: UPPER REAR SLIDING DOORS / FLUORESCENT LIGHT FIXTURES ……………...
MAINTENANCE, CONTINUED: PHASE SELECTOR (SINGLE VS. 3-PHASE) / PAN PLACEMENT ….
MAINTENANCE, CONTINUED: OVERHEAD CERAMIC HEATERS …………………………………..…..
MAINTENANCE, CONTINUED: CERAMIC METAL HALIDE LIGHT FIXTURES ………………………....
MAINTENANCE, CONTINUED: BRACKET RETAINERS / ADJUSTING SHELVES / LOAD LIMITS …..
MAINTENANCE, CONTINUED: HON EY COMB AIR DIFFUSERS …………………………… ……… …… .
MAINTENANCE, CONTINUED: CUTTING BOARD/ REAR LEDGE REMOVAL ………………….……....
CLEANING SCHEDULE - TO BE PERFORMED BY STORE PERSONNEL (INTERIOR) ..……………..
CLEANING SCHEDULE - TO BE PERFORMED BY STORE PERSONNEL (EXTERIOR) ……………...
CLEANING SCHEDULE - TO BE PERFORMED BY TRAINED SERVICE CONTRACTORS ONLY …...
TROUBLESHOOTING - GENERAL ISSUES ………………….……………………..…………...……….…..
TROUBLESHOOTING - EVAPORATOR SYSTEM (QUALIFIED SERVICE TECHNICIANS ONLY) …...
PREVENTIVE MAINTENANCE (TO BE PERFORMED BY TRAINED SERVICE PROVIDER) ………....
SERIAL LABEL INFORMATION & LOCATION ..……………………………………...…....……………....…
CAREL® CONTROLLER - PROGRAMMING THE INSTRUMEN T… .…… …… ……… …… …….………...
CAREL® CONTROLLER - USER INTERFACE, SUMMARY TABLES OF ALARMS & SIGNALS …..….
CAREL® CONTROLLER - Summary Table of Operating Parameters (After Programming Key) …...…..
TECHNICAL SERVICE CONTACT INFORMATION & WARRANTY INFORMATION ...……….…….......
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OVERVIEW / TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS - PAGE 1 of 2
OVERVIEW
Caution: This case should be installed and operated
according to this operating manual’s instructions to
ensure proper performance. Improper use will void
warranty.
TEMPERATURE SETTINGS - UPPER SECTION
Upper Section: This section is to merchandise
unpackaged product at a wide range of temperatures.
Food must be cooked to an internal temperature of at
least 165 °F (74 °C) before placing in case.
Caution
: You must use a food probe to determine
actual product temperatures.
See CASE START-UP: HEATED SECTION / SCC
HEATED TEMPERATURE CONTROLS section in this
manual for instructions on adjusting temperature
settings.
TEMPERATURE SETTINGS - LOWER SECTION
Lower Section: This section is to merchandise
packaged product at 41 °F (5 °C) or less temperatures.
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.
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.
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INSTALLATION: REMOVAL FROM SKID / ADJUSTING LEVELERS
1. Remove Case From Skid (Via 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
particular model.
2. Adjust Levelers
After case is in position, adjust case so it is level
and plumb.
You may need to remove front and/or rear toe-kick
to access levelers.
Use adjustable wrench (and/or a pry bar) to adjust
leveler.
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.
See illustrations at lower-right.
Support while
rolling case
own ramp.
Ramp
Adjustable
Wrench
Pry Bar
Leveler
(Typical)
Leveler (Typical)
5
INSTALLATION, CONTINUED: REMOVING LOWER FRONT PANEL
3. Removing 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.
Hooks
Hooks
Hooks
Lower Front
Panel
Lower Front
Panel (Shown
Reversed For
View of Slots)
Slots
Slots
Slots
6
INSTALLATION, CONTINUED: REAR PANEL AND GRILLE REMOVAL
4. Removing Rear Panel and Grille
No screw removal is required.
Lift lower rear panel and/or grille slots up and off case hooks.
Replace in same manner they was removed.
See illustration below.
Lower
Rear Panel Slots
Lower Rear Grille
(Reversed to Show Slots)
Lower Rear Panel
(Reversed to Show Slots)
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INSTALLATION, CONTINUED: ALIGNING, BOLTING & CAULKING UNITS TOGETHER
5. Aligning, 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 the ’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 lines are shown in below
illustration.
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.
Sanitation Bead Refrigeration Bead
: Sanitation
F. Caution! Front of cases MUST be fl ush 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
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CASE START-UP: MAIN POWER SWITCH / TEMPERATURE CONT ROLLER / SST
Case Start-Up
1. Main Power Switch
Case must be properly field wired or plugged into
receptacle for it to energize.
Main power switch is located at lower-right of case
rear. See illustration below-right.
Turn on main power switch.
2. Temperature Controller (All Self-Contained
Units and some Remote Units)
Check that temperature controller symbol
light (shown at right) is on.
After case has run for a few minutes,
check that temperature has started to drop.
If temperature controller does not begin cooling in
a few minutes see TEMPERATURE
CONTROLLER - CAREL® section in this
manual for additional information
Verify that refrigeration requirements listed on
the serial label (found on the case) are met.
3. Saturated Suction Temperature (Remote
Units)
See serial label on case for suction
temperature requirements and BTU
requirements.
See serial label on case for defrost schedule
and temperature termination parameters.
Carel® Temperature
Controller
Main Power
Switch
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CASE START-UP, CONTINUED: REFRIGERATED SECTION / THERMOMETER AND LIGHT SWITCH
4. Thermometer Location & Purpose
Thermometers is located customer left, on rear
plenum.
Thermometers is digital and reflects internal air
temperature only (not actual food temperature).
Use probe thermometers to determine actual
product temperatures.
Digital Thermometer
(For Refrigerated Section)
Thermometer
5. Light Switch Location & Purpose
Light switch is located at customer right on rear
plenum.
See illustration below for location.
Note: Main power switch MUST be turned on for
lights to illuminate.
6. Decking
Lift decking up just enough to verify that
evaporator fans are rotating.
This will confirm that refrigeration unit is running
properly.
Caution! Do not raise decking ALL THE WAY
UP, as rotating fans are at underside.
Decking
(For Refrigerated Section)
Light Switch
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CASE START-UP, CONTINUED: HEATED SECTION / SCC HEATED TEMPERATURE CONTROLS
7. Main Power Switch / Overhead Lights
Case must be field wired.
When power is supplied, throw main power
switch and case will power-up.
Heated overhead light switch is at case rear,
right side (see illustration below).
8. Product Heating Temp. Controllers
Well and overhead ceramic heaters are
controlled by Structural Concepts
Temperature Controllers.
These controllers are located on rear
wireway cover.
To set temperatures, follow these steps:
Press preheat as soon as main power
switch is turned on. LED indicator will
come on. When unit is preheated, it will
shut off automatically.
Wells / overhead are set at a factory
default of “5”.
To raise temperature, press “UP” key .
To lower temperature, press “DOWN” key.
If controller is set to “0”, relays will
de-energize.
Setting ”1” is minimum heat.
Setting “9” is maximum heat.
The HEAT LED indicates that the relay is
energized and heater is “On”.
After unit is adjusted, the control will automatically
save the user setting approximately 5 seconds
after user stops adjusting the setting.
When case is turned off, its last settings are kept in
memory. When turned back on, case will come
back up at last temperature saved on each.
Note: During peak usage, slightly higher settings
may be required to maintain recommended
product heating temperatures.
9. Case Temperature
Well temperature is dependent upon both the
waterless well temperature and the overhead ceramic
heater temperatures.
Preheat to 170 °F (77 °C) on case temperature dial
(photo shown below-left) before placing food into
case.
Caution Temperature reflects internal case
temperature ONLY (not product temperature).
Use a food probe to determine ACTUAL product
temperatures!
Case
Temperature
Dial
Structural Concepts Temperature
Controller at Rear Panel (Typical).
Factory Default Setting is “5”.
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OPERATION: DRIVERS / BALLASTS / TERMINAL BLOCK / CONTACTOR / PHASE SELECTOR SWITCH
1. Drivers, Ballasts and T-Block, Etc.
Electrical raceways contain various electrical
components.
Access to these components can be made
simply by removing raceway cover (screws
must be removed during process).
See illustrations below for general layouts.
Caution! Only certified electricians are to
access electrical components!
Return raceway to case after access.
Drivers/Ballasts
Terminal Block
(Alternate Placement)
2. Phase Selector Switch
See PHASE SELECTOR SWITCH
(SINGLE-PHASE VS. THREE-PHASE) / PAN
PLACEMENT IN WELLS section in operating
manual for specifics.
Phase Selector Switch
Terminal Block
Drivers/Ballasts
Contactor
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