Structural Concepts GCD856R Installation Manual

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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

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

8. Platter Coil Unit (Meat 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.
 Platter coil units also have gravity coils above. No ice trays.
 Two (2) trough drains are in each case. One (1) is at each end of case (as shown in illustration below).
 Also, see illustration below for locations of components under upper and lower section decks.

Drain

Shutoff

Valve

Solenoid Valve

Assembly

TXV

Filter

Dryer

Platter Coils

(Meat Case Only)

Drain

Valve

Fan

Assembly

(Typical)

Fan

Shroud

Fan

Shroud

Fan

Assembly

(Typical)

Note: Model GCDT656RLB (Shown Above) May Not

Depict An Exact Representation Your Unit Being Installed.

16

Drain Shutoff

TXV Filter Dryer

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

9. Gravity Coil Unit With Ice Trays (Seafood Case) Refrigeration Lines / Stub-Ups / Drain,
TXV, Etc.

 Ice trays have been removed for illustrative purposes.
 No blower coils are in upper section of case.
 Each of the three (3) sections has a drain.
 See illustration below for locations of components under upper decks.
 See previous sheets for location of components under lower decks.

Electrical

Pass-Through

TXV

Solenoid

EPR

Filter Dryer

TXV

TXV

Drain

Refrigeration Line

Pass-Through

Drain

Drain

Note: Model GCDT1256RLB (Shown Above) May Not

Depict An Exact Representation Your Unit Being Installed.

17

OPERATION, CONT.: (MODEL GCDT1256RLB GRAV. COIL CASE) DRAIN CONNECT’S / AXIAL FANS

10. Drain Connection

Lower front panel may be removed to access the
drain stub-up for upper section drain. See

INSTALLATION: REMOVAL FROM SKID,
REMOVING VERTICAL LOWER FRONT PANEL

section in this manual for removal instructions.

 After access, panels must be replaced in reverse

order they were removed.

 Connect tub drain to floor drain. Maintain

1/4”-fall per foot to provide proper drainage.

Axial Fans To Cool Front-Right

Lower Section of Case

Axial Fans To Cool Middle-Lower

Section of Case

 Note: Illustration below may not reflect every

feature or option of your particular case.

12. Axial Fan Access

 Rear axial fan cover panels may be removed

(via screw removal) to access axial fans.

 After access, panels must be replaced in reverse

order they were removed.

Axial Fans To Cool Front-Left

Lower Section of Case

Upper Section

Drain

Upper Section

Drains

P-Trap

(Lower Section)

Note: Model GCDT1256RLB (Shown Above).

Panels Have Been Removed to Show Axial Fans.

18

Refrigeration Line

Stub-Ups Access

OPERATION, CONT.: GRAVITY COIL UNITS - ADJ. DECKING (4° & 8° ANGLES) / HUMIDIFICATION

11. Adjustable Decking (Gravity Coil Cases)

 Decks can be angled to allow more consistent

water drainage.

 Ice pan brackets have hooks that are to be

placed in either lower or upper slots in uprights.

 Lower slots will raise decking 4°.
 Upper slots will raise decking 8°.
 To adjust, simply lift ice pan brackets up and

out of notches in uprights.

 Move bracket up, down or remove entirely from

case. See illustrations below.

Ice Pan

Bracket Hook

Ice Pan
Bracket

12. Humidification Feature

 Humidification feature allows the case to retain

proper humidity levels without ‘wetting’ the product.

 The ultrasonic nozzle produces a fine vapor fog

(“mist”) behind ice pan bracket that permeates entire
upper section of case.

 Misting prevents the ‘drying effect’ of refrigeration.
 See illustration immediately below.

Ice Pan
Bracket

Decking

8° Notch In

Upright

4° Notch In

Upright

Ultrasonic Nozzle

(Providing Humidification

To Upper Section of Case)

Note: Model GCDT856RLB

(Shown At Left) May Not Depict

An Exact Representation Your

19

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

13. Display Case Start-Up

A. Case

 Unit will begin operating when properly field wired.

Lift deck to check that coil fans are running.



Coil fans (and in self-contained units, compressor



motor) should turn on.

B. Light Switches

 Light switch for top section are usually at rear

of case at left. See illustration below.

 Light switch for lower section is usually at case

front at left (on rear plenum). See illustration
at lower left.

Light Switch for

Upper Section

 See next page for specifics regarding lighting

sequence, warm-up, receptacles, etc.
Lighting is wired in series so all lights must be



plugged in or receptacles capped for case
lights to be on.

C. Rear Storage Areas

 Illustrations below-right show rear storage areas.
 Rear sliding doors provide access.
 Rear sliding doors are removed for illustrative

purposes only.

D. Rear Shelving

 Rear shelving and bracketry is adjustable on 1”

rail slots.

 See illustrations below.

Light

Fixtures

Light Switch for

Lower Section

20

OPERATION, CONT.: DISPLAY CASE LIGHTS, TEMPERATURE CONTROLLER, SST

14. Display Case Start-Up, Continued

E. Lights

 Turn lights on.

All lights should come on at the same time.



First time lighting may require a short warm-up



period.
Slightly dim / flickering of new bulbs is normal. If



lights do not turn on, check raceway plugs.
Lighting is wired in series so all lights must be



plugged in or receptacles capped for case lights
to be on. See illustration below right.

F. Temperature Controller (All Self-Contained
Units and some Remote Units)

 If compressor is functioning, the compressor

symbol will be on (shown at left).

 Check that compressor symbol light is on.

After case has run for a few minutes, check that



temperature starts to drop.

 If temperature controller does not begin cooling (in

a few minutes) see temperature controller section
in this operating manual for instructions.

 Verify that refrigeration requirements listed on

serial label (found on the case) are being met.

 See TEMPERATURE CONTROLLER - CAREL®

section in this manual for additional information.

G. 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.

Raceway Receptacle, Plug and Cap

Raceway

Receptacle

Sample Carel® Controller Face

Cap

Plug

21

STOCKING / MAINTAINING PROPER PRODUCT CONDITION / IMPORTANT PROCEDURES

1. Stocking

 Improper temperature and lighting will cause

serious product loss. Discoloration, dehydration
and spoilage can be controlled with proper use
of the equipment and handling of product.

 Product temperature should always be

maintained at a constant and proper
temperature. This means that from the time the
product is received, through storage,
preparation and display, the temperature of the
product must be controlled to maximize life of
the product.

 These cases are not designed to “cool down”

product - but rather to maintain an item’s proper
temperature for maximum shelf life.

2. Maintaining Proper Product Condition

To achieve and maintain proper product condition:

1. Minimize processing time to avoid damaging

temperature rise to the product. Product should be
kept at proper temperature.

2. Keep the air in and around the case area free of

foreign gasses and fumes or food will rapidly
deteriorate.

3. Maintain the display merchandisers temperature

controls as outlined in the refrigerator section of this
manual.

4. Do not place any product into these refrigerators

until all controls have been adjusted and they are
operating at the proper temperature. Allow

merchandiser to operate at a minimum of 6
hours before stocking with any product.

5. When stocking, never allow the product to extend

beyond the recommended load limit. Air discharge
and return air flow must be unobstructed at all times
to provide proper refrigeration.

6. There are vents located at the base of the front of

the glass, just above the front rail. These vents
supply a continuous, gentle flow of air across the
front glass which inhibits condensation. Do not
place any signs or other restrictive objects on the
front of the refrigerator that will block these vents.

7. Keep the service doors closed (when applicable).

Refrigeration performance will be seriously affected
if left open for a prolonged period of time.

8. Avoid the use of supplemental flood or spot

lighting. Display light intensity has been designed
for maximum visibility and product life at the factory.
The use of higher output fluorescent lamps (H.O.
and V.H.O.), will shorten the shelf life of the

product.

9. In the Deli, Meat and Fish cases, completely cover
the product each night with a clean damp cloth or
butcher paper (never use plastic, as it does not allow
for proper circulation). Make sure the cloth or paper is
in direct contact with the product.

10. Turn and rotate the meat fairly often. The blood
which gives the pink color works its way downward
with time.

11. Cold coils remove heat and moisture from the
case and deposit this as frost onto the coil. Thus, a
defrost is required. Our humidity system induces
moisture into the case and helps slow down the
dehydration process. The only other moisture within
the case is that in the product itself. A single level of
meat will dry out faster than a fully loaded case of
3-4 levels of meat.

3. Important Procedures

1. Do not set temperature too cold, as this causes
product dehydration.

2. Product should be worked and rotated on a
regular basis, not to exceed a 4 hour period.

3. At night, turn off case lights and cover the product
with a damp (not wet) cloth similar to cheese cloth
(etc.). This should be washed out in the morning
and kept in a walk-in box during the day-so that it
is cool and moist when covering the product.

4. Clean humidity system a minimum of every 90
days for proper system operation.

22

MAINTENANCE: REAR SLIDING DOORS / STANDARD LIGHT FIXTURES

Warning! Disconnect power before providing
maintenance and service to unit.

Caution: Lamps are treated to resist breakage

Light

Fixtures

and must be replaced with similarly treated
lamps.

Note: Warranty will be void if claims arise from
negligence, misuse of goods, extreme
environmental conditions or improper
maintenance. See OVERVIEW / TYPE /

Light

Fixtures

COMPLIANCE / WARNINGS / PRECAUTIONS /
WIRING / PLUGS section in this operating
manual.

1. Rear Sliding Doors

Note: Doors are not interchangeable. There is an
inner and outer door. Outer door must be removed
first and replaced last.

 The outer door is the right hand door (from the

service side or rear of case).

 Move doors toward the center of the case.
 Individually lift each door up toward the top of the

case; pivot the bottom of the door out.

 Replace rear sliding doors in reverse order they

were removed.

Model GCDT1256RLB With End Panel

Removed For Illustrative Purposes Only

2. Light Fixtures

Note: Depending upon model and options, light
fixtures can have either single or dual lamps.

Light fixtures are located on underside of shelf
assemblies and at the top inside of case. See
illustration at upper right for locations.

Removal of lamps:

 Rotate lamp (1/4-turn) to disengage (upper or

lower) pins/contacts from mounting sockets.

 Remove bulb by applying even pressure from

back side at the bulb ends and pulling the re­maining contact from sockets.

 See illustrations at mid and lower-right.

Installation of lamps:

 Align pins with slot.
 Insert pins into socket by rotating the bulb

1/4-turn to secure either the (upper or lower) pin
contacts into the sockets.

 Rotate remaining bulb contacts (1/4-turn) into

remaining lamp mounting socket contacts.

 See illustrations at right.

3. Supplemental Flood Lighting / Food
Lighting Specifics

 Avoid the use of supplemental flood or spot

lighting.

 Display light intensity has been designed for

maximum visibility and product life at the factory.

 The use of higher output fluorescent lamps (H.O.

and V.H.O.), will shorten the shelf life of the
product.

23

MAINTENANCE, CONT.: BRACKET RETAINERS / ADJUSTING SHELVES / LOAD LIMITS

4. Bracket Retainer Removal

 To remove brackets, it may be necessary to remove the

nylon shipping bracket retainers.

 Pliers will be required to accomplish this task.
 See illustration at top-right for location of bracket

retainers.

5. Shelf Assembly Adjustment or Removal

 Shelf can be set at 0°, 5° or 10°.
 To adjust shelving lift upward and rotate to desired

angle.

 To remove, unplug the light cord and lift up and out.
 See illustrations at right and below.

6. Load Limits

 See labels along sides of case stating load limits.
 Do not allow product to exceed these limits.
 Doing so will prevent proper airflow, causing product

temperature to warm.

 For upper section, keep ice in trays. Do not allow ice to

spill over onto door tracks or behind trays.

Bracket

Retainer

Locations

Trays

Load

Limits

Bracket Notches

to Adjust Shelving

to 5° or 10°

Ice

Note:

Illustration
Shown May Not
Depict An Exact

Representation

Your Particular

Case.

24

MAINTENANCE, CONT.: PRODUCT PLACEMENT / PAN PLACEMENT (MEAT CASE)

7. Prohibited Product Placement

 Caution! DO NOT set product on misting

holes at case rear. Doing so can impede proper
humidity which is required to maintain seafood
and/or meat at proper color and proper condition.

 Caution! DO NOT set product on air return

(lower section - front of case). Doing so can
detrimentally affect product temperature.

 See illustration below for locations.

8. Aluminum Deck / Stainless Steel Pan
Placement (Meat Case Only)

 Caution! DO NOT place pans and decks in

wrong order onto case! Doing so can prevent
proper drainage and meat condition.

 Illustrations immediately below depict proper

order in which stainless steel pan and aluminum
deck are to be placed onto meat case.

Stainless

Steel Pan

Aluminum

Deck

Note:

Illustration Shown May

Not Depict An Exact

Representation Your

Particular Case.

Air

Return

Caution! DO NOT set
product on air return!

25

MAINTENANCE, CONT.: CUTTING BOARD / REAR LEDGE LOWERING

9. Rear Ledge Removal Steps

Illustrations below reflect step-by-step removal method.

1. Hinged support bracket is shown in its standard upright position.
2 & 3. While upright, rear ledge must be slid away from case and then rotated downward to vertical position.
3 & 4. From the shelf’s lowered position, lift from bottom edge upward to disengage shelf track (and attached
rear ledge) from bracket.

-1- -2- -3-

Hinged Support

Bracket

-4-

Shelf
Track

Hinged Support

Bracket

————— Rear Ledge Removal Steps —————

Note: For clarity, only Shelf Track is shown being

removed. Rear Ledge is attached to Shelf Track.

26

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

AREA FREQ. INSTRUCTIONS

Interior Daily Upper Section Pans (With Ice) (Seafood Case) / Upper Section Aluminum

Decking and Stainless Steel Pan (Meat Case): Remove from case. Submerse

pans in hot water while using an anti-bacterial soap solution. Rinse thoroughly and
dry. Ice must be new. Return to case.

Daily

Weekly

Weekly

Monthly

Upper Case Area: While upper pans are being cleaned, wipe down upper section

(including drain area) with hot water solution and anti-bacterial soap solution. Rinse
thoroughly.

Lower Decks: Wipe off decks with moist cloth dipped in mild soap and water
solution.

Tub and Drain (Upper Only): Keep clean and free of debris which could clog tub
and drain. To access drain area, remove upper decks.

 Direct the drain to a floor drain or a bucket.
 Run hose into drain to flush out debris. Carefully hose out the tub.
 Caution! Avoid splattering water over the case and surrounding areas!

Gravity Coil Tray Drip Assembly

: Caution! Authorized personnel must approve

and/or supervise this procedure! Turn off case. Lift rear sliding doors up and out
from unit. See MAINTENANCE FUNDAMENTALS - REAR SLIDING DOORS
section for instructions. Disconnect hose from hose connection spout (may require
removal of hose clamp). Remove thumbscrews holding gravity coil tray drip
assembly in place. Drop tray drip assembly downward. Lift ’lip’ of gravity coil
assembly up and off internal hook. Remove from unit. Submerse in hot water
using an anti-bacterial soap solution. Rinse thoroughly and dry. Return to case.
Reattach thumbscrews. Return rear sliding doors to case. Turn case back on.
Note

: Defrost timer MAY need to be reset. See illustrations below.

Note: Depending upon
model chosen, Gravity

Coil Assembly may not

be exactly as shown in

this illustration.

Drip Assembly ‘Lip’. Note:
‘Lip’ rests on internal hook

to hold Gravity Coil

Assembly in place.

Gravity Coil Assembly

Thumbscrew

27

Enlarged view of

Thumbscrew

Hose

Connection

Spout

CLEANING SCHEDULE (EXTERIOR) - TO BE PERFORMED BY STORE PE RSONNEL

AREA FREQ. INSTRUCTIONS

Exterior Daily

Daily

Daily

Daily Stainless Steel Surfaces:

All Glass / Mirrors: Clean side glass, front glass, glass shelves, and mirrors with

household or commercial glass cleaner. Clean out door track with moist cloth.

Rear Sliding Door Exterior Glass: Clean with household or commercial glass
cleaner.

End Panels, Front Panel, Toe-Kick, Rear Ledge Cutting Board, etc.: Wipe off
all surfaces with warm water and mild soap solution and non-abrasive cloth. Dry
thoroughly.

 Wash with a solution of hand dishwashing liquid detergent and water; or a

solution of baking soda and water. Rinse and polish dry with paper towel or soft
cloth.
Never use scouring powders or steel wool as they will scratch stainless steel.



Brighten by polishing with a cloth dipped in vinegar or in ammonia; sprinkle baking



soda on sponge and rub gently; rinse. Polish dry with paper towel.
Remove streaks or heat stains from stainless steel by rubbing with club soda.



Weekly

Wood, Laminate and Painted Surfaces (Including Rear Storage Area): Clean

with mild soap and water solution and a soft cloth .

Weekly

Acrylic (Sneeze Guard): Clean with warm water, mild soap solution and soft cloth;

acrylic cleaning solutions are also available.

 Caution! Never use ammonia-based cleaners on acrylic.
 Incorrect cleaning agents or abrasive cleaning cloths cause surface to

Monthly

Under Case Cleaning
to remove all dust and dirt. Replace front toe-kick (or rear grille) when complete.

‘cloud’ over time.

: Remove front toe-kick (or rear grille). Vacuum under case

28

TROUBLESHOOTING - TO BE PERFORMED BY STORE PERSONNEL

CONDITION TROUBLESHOOTING

Case Not Lining Up

See Installation Section for instructions on properly aligning
case (alongside other cases) and adjusting levelers.

Case Lights Are Not Working

Check that light switches are in the ON position.
Check for burned out bulbs. Turn lights off & replace.
Clean dirt and dust from the bulbs to prevent flickering.
Check to insure voltage at ballasts. If voltage is entering but not

exiting the ballast, ballast is faulty.

Control Display Is Flashing
Water Is On The Floor

Check that ALL lights are plugged in and receptacles capped.

Check Carel® Temperature Controller section in this manual.

Caution! Water on flooring can cause much damage! Until

cause is determined (and repaired), following these procedures:

 Use wet-dry vacuum (or mop & bucket) to remove standing

water.

 Use ‘catch pans’ for water to drain into. Swap out regularly

until case has completely drained.

Check that the drain trap is free of debris.

Check that the drain hose is correctly positioned over floor drain.

If unable to stop water from draining on floor, Contact Structural

Concepts Technical Service. See telephone number on final

page in this manual.

Fan Emits Excessive Noise

Fans Are Not Working

System Is Not Operating

Case Is Not Holding Temperature

Check that the case is aligned, level and plumb.

Check that the MAIN power switch (if present) is on.

Check that the MAIN power switch (if present) is on.

If a large amount of warm product was added to the case, it will

take time for the temperature to adjust. Product should be

pre-chilled before placing in display case.
Check Carel® Temperature Controller section in this manual to

confirm that proper settings are being maintained.

Check that the case is not in the sun or near a heat or air

conditioning vent.

Check that case is not located near outside doors: ambient

temperature fluctuation can hinder unit’s ability to maintain

proper case temperature.

29

TRAINED SERVICE PROVIDERS SECTION ONLY

TRAINED SERVICE

PROVIDERS

SECTION ONLY

30

REFRIGERATION PACKAGE LAYOUT: MODEL GCD456R SELF-CONTAINED UNIT

1. Refrigeration Package Layout

 Illustration shown reflects model GCD856R

refrigeration package.

 Note: Due to design variables, refrigeration

package components layout can slightly vary
in location.

Condenser Coil Fan, Fan

Housing & Motor (Typ.)

Refrigeration

U-Tubes

Wicking Material

(Optional)

 Illustration below may not reflect every feature or

option of your unit.

Hot Gas Loop

Condensate Pan

Condenser
Coil Housing

Receiver

Filter Dryer

Sight Glass

Overflow Pan (Under

Overflow Pan

Electrical Box)

31

Compressor

Electrical

Starter Unit

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

2. Refrigeration Package Layout, Continued

 Illustration shown reflects model GCD856R

refrigeration package.

 Note: Due to design variables, refrigeration

package components layout can slightly vary
in location.

Condenser Coil Fan, Fan

Refrigeration

U-Tubes

Wicking Material

(Optional)

Housing & Motor (Typ.)

 Illustration below may not reflect every feature or

option of your particular unit.

Hot Gas Loop

Condensate Pan

Condenser Coil

Housing

Overflow Pan (Under

Overflow Pan

Electrical Box)

Filter Dryer

Sight Glass

Electrical

Starter Unit

Receiver

Accumulator

Scroll

Compressor

32

CLEANING SCHEDULE (INTERIOR) - TO BE PERFORMED BY TRAINED SERVICE PROVIDERS ONLY

AREA FREQ. INSTRUCTIONS

Interior Quarterly Upper Section Pans (With Ice) (Seafood Case) / Upper Section Aluminum

Decking and Stainless Steel Pan (Meat Case): Remove from case. Submerse

pans in hot water while using an anti-bacterial soap solution. Rinse thoroughly and
dry. Ice must be new. Return to case.

Quarterly

Quarterly

Quarterly

Quarterly

Quarterly

Upper Case Area: Wipe down upper section (including drain area) with hot water

solution and anti-bacterial soap solution. Rinse thoroughly.

Tub and Drain (Upper and Lower): Keep clean and free of debris which could
clog tub and drain.

 To access drain area, remove the decks and (for lower section) the fan shroud.
 Direct the drain to a floor drain or a bucket.
 Run hose into drain to flush out debris. Carefully hose out the tub.
 Caution! Avoid splattering water over the case and surrounding areas!

Air Return Grille and Fan Shroud Area

: 1) Turn off power. 2) Remove decks

from case. 3) Clean with moist cloth.

Honeycomb Air Diffuser

Gravity Coil Tray Drip Assembly

: See next page in this manual for cleaning instructions.

: Caution! Authorized personnel must approve

and/or supervise this procedure! Turn off case. Lift rear sliding doors up and out
from unit. See MAINTENANCE FUNDAMENTALS - REAR SLIDING DOORS
section for instructions. Disconnect hose from hose connection spout (may require
removal of hose clamp). Remove thumbscrews holding gravity coil tray drip
assembly in place. Drop tray drip assembly downward. Lift ’lip’ of gravity coil
assembly up and off internal hook. Remove from unit. Submerse in hot water
using an anti-bacterial soap solution. Rinse thoroughly and dry. Return to case.
Reattach thumbscrews. Return rear sliding doors to case. Turn case back on.
Note

: Defrost timer MAY need to be reset. See illustrations below.

Note: Depending upon
model chosen, Gravity

Coil Assembly may not

be exactly as shown in

this illustration.

Drip Assembly ‘Lip’. Note:
‘Lip’ rests on internal hook

to hold Gravity Coil

Assembly in place.

Gravity Coil Assembly

Thumbscrew

33

Enlarged view of

Thumbscrew

Hose

Connection

CLEANING SCHEDULE (INTERIOR), CONT. - PERFORMED BY TRAINED SERVICE PROVIDERS ONLY

Preventive maintenance should be performed
every 90 days unless conditions warrant a more
frequent replacement cycle.

1. Honeycomb Air Diffuser Removal & Cleaning

A. Wedge non-metallic device of suitable strength (such
as a ballpoint pen) between honeycomb and end panel.
Caution

! Use care not to dislodge the heating wire (that
prevents condensation on the lamp assembly).
B. Apply pressure to collapse the honeycomb to allow it to
be pulled out of honeycomb retainer.
C. Pry downward and away from honeycomb retainer.

Clean honeycomb with warm water and soap solution.
Submerse if necessary. Use brush to dislodge stubborn
or sticky residue. Dry by using vacuum’s ‘blow mode’.

2. Honeycomb Air Diffuser Installation

D. Squeeze honeycomb into the honeycomb retainer.
E. Carefully slide honeycomb into place.
F. Adjust honeycomb so that it fits flat
Honeycomb must not be wavy or out of position.

against retainer.

Note: For honeycomb air diffusers in other locations,
these same general instructions apply.

Air

Diffuser

A

F

E

B

D

C

34

TROUBLESHOOTING - TO BE PERFORMED BY TRAINED SERVICE PROVIDERS ONLY

CONDITION TROUBLESHOOTING

Water Is On The Floor

Caution! Water on flooring can cause much damage! Until cause is determined
(and repaired), following these procedures:

 Use wet-dry vacuum (or mop & bucket) to remove standing water.
 Use ‘catch pans’ for water to drain into. Swap out regularly until case has

completely drained.

Check that the drain trap is free of debris.
Check that the drain hose is correctly positioned over floor drain.

Check store conditions. To prevent condensation in Type 1 environments,
maximum conditions are to be 55% humidity / 75 °Fahrenheit. For Type 2
environments, maximum conditions are to be 60% humidity / 80 °Fahrenheit.
See serial label (at case rear near main power switch) for Type of your case.

Check that overflow evaporator pan is plugged in and operating properly.

If unable to stop water from draining on floor, Contact Structural Concepts
Technical Service. See telephone number on final page in this manual.

Fan Emits Excessive
Noise

Check that the case is aligned, level and plumb.

Check evaporator fan for cleanliness.

Unplug fan motors; check motor shaft for excessive bearing wear.

Check that fan motors are securely mounted in brackets.

Verify that fan blades are securely mounted to fan motor.

Check that nothing is preventing blade rotation.

Check that the fan shroud is properly secured.

35

TROUBLESHOOTING, CONT. - TO BE PERFORMED BY TRAINED SERVICE PROVIDERS ONLY

CONDITION TROUBLESHOOTING

Fans Are Not Working

System Is Not Operating

Check that the MAIN power switch (if present) is on.

Check that fans are plugged in to fan shroud.

Check for foreign material obstructing fan performance.

Check that fan blades freely rotate within fan shrouds.

Check that power is going to fans.

Check that fan wiring is connected on terminal blocks.

Check that the utility power is on.

Check the circuit breaker box for tripped circuits.

Case Is Not Holding Temperature

If a large amount of warm product was added to the case, it will
take time for the temperature to adjust. Product should be
pre-chilled before placing in display case.

Check Carel® Temperature Controller section in this manual to

confirm that proper settings are being maintained.

Check that the case is not in the sun or near a heat or air

conditioning vent.

Check that case is not located near outside doors: ambient

temperature fluctuation can hinder unit’s ability to maintain proper
case temperature.

Check Set Point Temperature; it may be adjusted too high.

36

TROUBLESHOOTING, CONT. (CONDENSATE SYSTEM) - PERFORMED BY TRAINED SVC PROVIDERS

CONDITION TROUBLESHOOTING

Low Suction Pressure

High Suction Pressure

Check for low refrigerant.

Check that Expansion Valve isn’t restricted.

Check that Liquid Line or Filter isn’t restricted.

Check that Evaporator Motors are working.

Check for Superheat setting.

Check that the Thermostatic Element charge isn’t depleted.

Check that the Coil is not iced up.

Check that Refrigerant Charge isn’t too high.

Check that Compressor Valves aren’t faulty.

Check that there is no air seepage around Condensing Coil.

Check that the Cooling Load isn’t high.

Check that Superheat adjustment isn’t low.

Check TXV Bulb Installation
a. Poor thermal contact.
b. Warm location.

Check Compressor: Low capacity means it is undersized for its
application.

37

PREVENTIVE MAINTENANCE - TO BE PERFORMED BY TRAINED SERVICE PROVIDERS ONLY

WARNING! TURN OFF CASE BEFORE PERFORMING PREVENTIVE MAINTENANCE!

PREVENTIVE

FREQ. INSTRUCTIONS

MAINTENANCE

Case Exterior Quarterly Condensing Coil (Self-Contained Units Only):

 Remove rear grille (by lifting up and off).
 Use air pressure or industrial strength vacuum; clean dust and dirt that

may collect on the Condenser Coil.

 Caution! Coil fins are sharp. Handle with care!
 Replace rear grille to case.

Quarterly Refrigeration Package/Compressor Area (Self Contained Units Only):

Caution! Be certain to disconnect power from case before cleaning
refrigeration package!

 Warning! Condensate Pan Is HOT! Disconnect power from case and

allow to cool before cleaning pan!

 Slide/Roll compressor package out from under case.
 See REFRIGERATION FUNDAMENTALS section for in-depth

instructions on accessing the evaporator pan.

 Use a scrub-brush and a de-scaling solution such as CLR® (to

prevent corrosion, lime and rust). Follow instructions as to proper
dilution, safety precautions and scrubbing method.

 After thoroughly cleaning pan with scrub-brush and solution, rinse

thoroughly with clean water (in spray bottle) and wipe dry with sponge
or paper towel.

 Use moist cloth to wipe off dust & debris that collects on various parts

(fans, sight glass, overflow pan, etc.).

 Slide refrigeration assembly back under case.
 Replace front panel and lower grille via hooks (no screws required).

Quarterly

Under Case Cleaning: Once refrigeration package is clear of unit, vacuum
under case to remove all dust and dirt that may collect under case.

Case Interior Quarterly Tub, Coil, Drain, Fan Blades, Motors, Brackets:

Disconnect power from the case before cleaning the Tub, Coil, Fan, Motor
and Drain Area!

 Remove Decking, Sub-Deck and Fan Shroud.
 Use vacuum to clean Evaporator Coils.
 Clean Tub, Coil and Drain with warm water, clean cloth, brush and mild

soap solution.

 Remove any debris that may clog drain.
 Clean Fan Blades, Motors and Brackets by wiping down with moist

cloth.

Quarterly

Honeycomb: Check honeycomb air diffuser to determine whether it is dirty.

If dirty, remove from case. See PREVENTIVE MAINTENANCE:
HONEYCOMB AIR DIFFUSERS (TRAINED SERVICE PROVIDERS
ONLY) section of this manual (next page) for cleaning specifics.

38

MAINTENANCE - FRONT GLASS ALIGNMENT & ADJUSTMENT VIA CLAMSHELL ALLEN SCREWS

1. Front Glass Alignment & Adjustment via
Clamshell Allen Screw Adjustment

Caution! Glass is extremely heavy! Two people
may be required to perform this task.

 Make certain case is level and plumb.
 Lift glass to maximum upright position.

 Determine which side requires realignment.
 While maintaining tight grip on glass, loosen the

Allen screws nearest to misaligned side.

 Adjust the glass until properly positioned.
 Allen screws may now be tightened (taut, but not

overly tightened lest glass breakage occur).

 If other side needs alignment, repeat steps while

maintaining grip on glass.

Lift Handle

Clamshell

Upper

Allen Screw

Note: Above Illustration May Not Depict An Exact

Representation Of Your Particular Unit Being Installed.

39

Clamshell

Lower

MAINTENANCE, CONT. - FRONT GLASS ALIGNMENT VIA FRAME SUPPORT R AILS

T

2. Front Glass Alignment & Adjustment via Frame Support Rails

 Proper alignment of the front glass is important to maintain a seal inside case.
 Improper alignment can cause air leaks compromising the environment inside

the case and create condensation.

 Follow the five steps listed below to assure proper front glass alignment.
 Illustrations shown may not exactly reflect every feature or option of your

case.

Note: Illustrations

Shown May Not Depict

Representation Of Your

Particular Unit

An Exact

1. Side-to-Side Leveling

(parallel to front glass). Level the case by inserting shims under

the rails. Follow steps 3 and 4 below for specifics.

Case with Curved

Front Glass

Rails

: Place a level on top of display case

2. Front-to-Back Leveling:
 Place a level on top of case,

perpendicular to the front glass.

 Raise or lower either side of case

by shimming under the rails
(following steps 3 & 4 below).

 Double-check the side-to-side level.

END PANEL

3. If FRONT-LEFT CORNER
is too close to end panel (or

hitting it), insert shims under

PANEL

rail at the BACK LEFT

CORNER of case.

FRON

GLASS

Rails

LIFT

FRONT

Case with Flat

Front Glass

Rails

5. Verification:

 After inserting shims, open and shut the front glass.
 Verify (again) that the front glass is properly aligned at both left-hand and right-hand side of the case.
 If not, repeat shimming procedure until the front glass is properly aligned along both sides of the case.

LIFT

GLASS

40

END PANEL

PANEL

4. If FRONT-RIGHT CORNER is too
close to end panel (or hitting it), insert
shims under rail at the BACK RIGHT
CORNER of case.

MAINTENANCE, CONT. - FRONT GLASS ALIGNMENT VIA LEVELERS

3. Front Glass Alignment & Adjustment via Levelers

Setting The Case With Levelers:

Note: Below illustrations may not exactly reflect every
feature or option of your particular case.

 Illustration #1, at top-right shows pry bar, adjustable

wrench and various leveler styles.

 Begin with all feet touching the floor, so that the Case

does not wobble when the Curved Front Glass is
closed.

 Side-to-side: Place a level on top of display case

(parallel to the front glass). Raise or lower either side
of the case by rotating the levelers to center the level
bubble. See illustration #2, below left.

 Front-to-back: Place a level on top of the case,

perpendicular to the front glass, and follow the same
procedure. See illustration #3, below right.

 Double-check the level again, side-to-side.
 The Curved Front Glass should be evenly spaced

(approximately 1/8”) from the sides of the case. See
illustration #4a & 4b, on next page.

 If Curved Front Glass is NOT properly aligned, continue

with Alignment instructions, on next page. See
illustration #5a & 5b, on next page.

After Case is properly positioned, raise (or lower)
levelers with adjustable wrench.

 Turn levelers COUNTER-CLOCKWISE to lower.
 Turn levelers CLOCKWISE to raise.
 Note: Leveler illustrations may not reflect every style,

feature or option of your particular case.

1. Pry Bar, Adjustable Wrench,
and Various Leveler Styles

Pry Bar

Leveler

Toe-Kick

Adjustable

Wrench

Base

Frame

2. Case Front View
With Level at top

—- Curved Front Glass —-

41

Leveler

Base Frame

3. Case Side View
With Level at top

MAINTENANCE, CONT. - FRONT GLASS ALIGNMENT VIA LEVELERS

4. Front Glass Alignment & Adjustment via Levelers, Continued

Note: Below illustrations may not exactly reflect every feature or option of your particular case.

 Proper alignment of the Curved Front Glass is vitally important to create and maintain a seal inside the

Case. Air leaks caused by improper alignment will compromise the environment inside the case, and may
create condensation.

 If the FRONT-LEFT CORNER of the glass is too close to the end panel (or hitting it), the leveler at the

BACK LEFT CORNER must be adjusted. See illustration #5a, at lower left. Adjust the leveler one full
revolution (360°) CLOCKWISE. This action will raise the left-rear case area, thereby increasing distance
between the customer-left corner of the glass and its end panel.

 If the FRONT-RIGHT CORNER of the glass is too close to the end panel (or hitting it), the leveler at the

BACK RIGHT CORNER must be adjusted. See illustration #5b, at lower right. Adjust the leveler one
full revolution (360°) CLOCKWISE. This action will raise the right-rear cabinet area, thereby increasing
the distance between the customer-right corner of the glass and its end panel.

 After adjusting the levelers, open and shut the front glass and check again to see if the curved front glass

is properly aligned: It is to be evenly spaced (approximately 1/8”) from both sides of the case.

CURVED

END

PANEL

FRONT

GLASS

CURVED

FRONT

GLASS

END
PANEL

1/8" SPACE

4a. Case Front-Left View With
Proper Glass Alignment

END

PANEL

CURVED

FRONT

LIFT

GLASS

LIFT

5a. Case Front-Left View With Improper Glass
Alignment

LIFT

4b. Case Front-Right View With
Proper Glass Alignment

CURVED

FRONT

1/8" SPACE

END
PANEL

GLASS

LIFT

5b. Case Front-Right View With Improper
Glass Alignment

42

GENERAL TECHNICAL INFORMATION

GENERAL TECHNICAL

INFORMATION

(PARTS LIST / SERIAL

LABEL INFO /

TEMPERATURE

CONTROLLER

INFORMATION /

TECHNICAL SERVICE

INFORMATION), ETC.

43

SERIAL LABEL LOCATION & INFORMATION LISTED / TECHNICAL INFO & SERVICE

Serial Label Location & Information Listed / Technical Information & Service

 Serial labels are located near the electrical access on your case.
 Serial labels contain electrical, temperature & refrigeration information, as well as regulatory

standards to which the case conforms.

 For additional technical information and service, see the TECHNICAL SERVICE page in this

manual for instructions on contacting Structural Concepts’ Technical Service Department.

 See images below for samples of both refrigerated and non-refrigerated serial labels.

Y

S

A

SA

M

P

L

MPLE

E

N

O

ON

L

L

Y

O

Y

L

NL

LY

Y

A

S

----- Sample Serial Label For Refrigerated Case -----

S

A

MP

SA

S

LE

AM

M

O

LE

P

M

ON

P

LE ON

PLE

Y

L

N

----- Sample Serial Label For Non-Refrigerated Case -----

44

Read And Save These Instructions - Page 1 of 3

Integrated Electronic

Microprocessor Controller

Programming The Instrument

To Modify The Setpoint

Press and hold the “SET” key for at least 1 second.

Set

Prg

mute

Set

▲

aux

def

▼

▲

aux

3. Quickly press and release the “SET” key again.

Set

To Modify Defrost, Differential, Other Parameters

Prg

mute

2. Confirm by pressing “SET” key.

Set

▲

aux

4. Press “SET” to modify this selected parameter.

Set

▲

aux

6. Press the “SET” key to temporarily save the new

Set

value and return to the display of the parameter.

7. Press & hold the “Prg” key for at least 5 seconds

Prg

to save changes. This action will also mute the

mute

audible alarm (buzzer) & deactivate the alarm relay.

2. Use arrow keys ▲ ▼ on temperature

def

controller to increase (or decrease) the

▼

setpoint.

Prg

mute

1. Press & hold “Prg” & “SET” keys together
for five (5) seconds; display will flash “0”,

Set

representing password prompt.

Set

▲

aux

3. Press ▲ or ▼ to reach the

def

category to be modified.

▼

Set

▲

aux

5. Increase or decrease the value using

def

the ▲ or ▼ button respectively.

▼

Set

Prg

mute

Warning! Save Your Parameter Settings!

1. To store the new parameter values, PRESS and HOLD the “Prg” key for at least 5 seconds.

2. All modifications made to parameters will be lost if you do NOT press a button within 60 seconds. Should
this “timeout” occur, normal operational settings (prior to modifications being made) will resume.

3. If the instrument is switched off before pressing the “Prg” key, all modifications to parameters will be lost.

How To Change Reading From
Fahrenheit (°F) To Celsius (°C)

1. Press and hold “Prg” and “SET” keys

Set

together for at least 5 seconds; display

2. Confirm by pressing “SET” key.

4. Press “SET” to modify this selected
parameter.

6. Press “SET” key to temporarily save the
new value and return to the display of the
parameter.

will show “0” (password prompt).

def

3. Press ▲ or ▼ until reaching the
parameter “/ 5”.

▼

5. Press ▲ or ▼ to change value to

def

desired setting: “0” for Celsius (°C) or

▼

“1” for Fahrenheit (°F).

7. Press & hold “Prg” key for at least 5
seconds to save changes.

will automatically convert to new scale. No
conversion is required.

Note! All values

To Activate Manual Defrost

def

Press and hold “def” key for at least 5 seconds.

▼

To Activate / Deactivate Auxiliary Output

▲

Press and hold the “aux” key for 1 second.

aux

45

Prg

mute

To Reset Any Alarms With Manual

▲

Reset

aux

Press and hold the “Prg” and “aux”

key for at least 1 second.

Oper Manuals - PUB\Templates\Carel Controller\Carel Controller IR33.pub

This data derived from Carel Material: ir33 +030220441 - rel. 2.0 - 01.05.2006

Read And Save These Instructions - Page 2 of 3

Integrated Electronic

Microprocessor Controller

User Interface - Display

Summary Table of Alarm and Signals: Display, Buzzer and Relay

reset alarms w/manual reset / reset HACCP alarms / reset temp. monitoring

46

Read And Save These Instructions - Page 3 of 3

Integrated Electronic

Microprocessor Controller

Summary Table of Operating Parameters

CODE PARAMETER UOM* TYPE MINIMUM MAXIMUM DEFAULT

/5

Select Celsius (°C) or Fahrenheit (°F)

flag C 0 1

/c1 Calibration of probe 1 °C/°F C -20 20

/c2 Calibration of probe 2 °C/°F C -20 20

St Temperature set point °C/°F F r2 r1

rd Control delta °C/°F F 20 0.1

dl Interval between defrosts hours F 0 250

dt1 End defrost temperature, evaporator °C/°F F -50 200

dP1 Maximum defrost duration, evaporator min F 1 250

d6 Display on hold during defrost - C 0 2

For Case

Specific

Defaults

See Serial

Label

Located

Near

Electrical

Access

On Your

Case.

For
Additional
Technical

Information

Call

Structural

Concepts

Technical

Service
Dept. at

1(800)

433.9489

dd Dripping time after defrost min F 0 15

d/1 Display of defrost probe 1 °C/°F F - -

* Unit Of Measure

47

SCC TECHNICAL SERVICE CONTACT INFORMATION & WARRANTY INFORMATION

STRUCTURAL CONCEPTS CORPORATION TECHNICAL SERVICE

PHONE NUMBER: 1.800.433.9489 or For Your Master Service Agent See

WWW.STRUCTURALCONCEPTS.COM/Contact/Master_Service_Agents.asp

LIMITED WARRANTY

All sales by Structural Concepts Corporation (SCC) are subject to the following limited warranty. “Goods” refers to the product or products being sold by SCC.

Warranty Scope: Warranty is for equipment sold in the United States, Canada, Mexico and Puerto Rico. Equipment sold elsewhere may carry modified warranty.
Warranty; Remedies; Limitations. SCC warrants that if any Goods are found by an authorized representative of SCC not to be of good material or workmanship within one

year of the date of shipments SCC will, at its option after inspection by an authorized representative, replace any defective Good or pay the reasonable cost of replacement for
any such defective Goods, provided that written notice of the defect is given to SCC within 30 days of the appearance of such defect. If notice is not given within such period, any
claim for breach of warranty shall be conclusively deemed to have been waived and SCC shall not be liable under this warranty. If SCC is unable to repair or replace the defective
Goods, SCC shall issue a credit to the Purchaser for all or part of the purchase price, as SCC shall determine. The replacement or payment in the manner described above shall
be the sole and exclusive remedy of Purchaser for a breach of this warranty. If any Goods are defective or fail to conform to this warranty, SCC will furnish instructions for their
disposition. No Goods shall be returned to SCC without its prior consent.

SCC’s liability for any defect in the Goods shall not exceed the purchase price of the Goods. SCC SHALL HAVE NO LIABILITY TO PURCHASE FOR CONSEQUENTIAL
DAMAGES OF ANY KIND WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, PERSONAL INJURY, PROPERTY DAMAGE, LOST PROFITS, OR OTHER ECONOMIC
INJURY DUE TO ANY DEFECT IN THE GOODS OR ANY BREACH OF SCC, SCC SHALL NOT BE LIABLE TO THE PURCHASER IN TORT FOR ANY NEGLIGENT DESIGN
OR MANUFACTURE OF THE GOODS, OR FOR THE OMISSION OF ANY WARNING THEREFROM.

SCC shall have no obligation or liability under this warranty for claims arising from any other party’s (including Purchaser’s) negligence or misuse of the Goods or environmental
conditions. This warranty does not apply to any claim or damage arising for or cause by improper storage, handling, installation, maintenance, or from fire, flood, accidents,
structural defects, building settlement or movement, acts of God, or other causes beyond SCC’s control.

Except as expressly stated herein, SCC makes no warranty, express, implied, statutory or otherwise as to any parts or goods not manufactured by SCC. SCC shall warrant such
parts or Goods only (I) against such defects, (II) for such periods of time, and (III) with such remedies, as are expressly warranted by the manufacturer of such parts of Goods.
Notwithstanding the foregoing, any warranty with respect to such parts of Goods and any remedies available as a result of a breach thereof shall be subject to all of the
procedures, limitations, and exclusions set forth herein.

THE WARRANTIES HEREIN ARE IN LIEU OF ALL WARRANTIES, EXPRESS, IMPLIED, STATUTORY, OR OTHERWISE. IN PARTICULAR, SCC MAKES NO WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

No representative, agent or dealer of SCC has authority to modify, expand, or extend this Warranty, to waive any of the limitations or exclusions, or to make any different or
additional warranties with respect to Goods.

Period of Limitations. No claim, suit or other proceeding may be brought by Purchaser for any breach of the foregoing warranty or this Agreement by SCC or in any way arising
out of this Agreement or relating to the Goods after one year from the date of the breach. In the interpretation of this limitation on action for a breach by SCC, it is expressly
agreed that there are no warranties of future performance of the goods that would extend that period of limitation herein contained for bringing an action.

Indemnifications. Purchaser agrees to indemnify, hold harmless, and defend SCC if so requested, from any and all liabilities, as defined herein, suffered, or incurred by SCC as
a result of, or in connection with, any act, omission, or use of the Goods by Purchaser, its employees or customers, or any breach of this Agreement by Purchaser. Liabilities
shall include all costs, claims, damages, judgments, and expenses (including reasonable attorney fees and costs).

Remedies of SCC. SCC’s rights and remedies shall be cumulative and may be exercised from time to time. In a proceeding or action relating to the breach of this Agreement by
Purchaser, Purchaser shall reimburse SCC for reasonable costs and attorney’s fees incurred by SCC. No waiver by SCC of any breach of Purchaser shall be effective unless in
writing nor operate as a waiver of any other breach of the same term thereafter. SCC shall not lose any right because it has not exercised it in the past.

Applicable Law. This Agreement is made in Michigan and shall be governed by and interpreted according to Michigan law. Any lawsuit arising out of this Agreement or the Goods
may be handled by a federal or state court whose district includes Muskegon County, Michigan, and Purchaser consents that such court shall have personal jurisdiction over
Purchaser.

Miscellaneous. If any provision of this Agreement is found to be invalid or unenforceable under any law, the provision shall be ineffective to that extent and for the duration of
the illegality, but the remaining provisions shall be unaffected. Purchaser shall not assign any of its rights nor delegate any of this obligations under this Agreement without prior
written of SCC. This Agreement shall be binding upon and inure to the benefit of SCC and Purchaser and each of their legal representatives, successors and assigns.

SCC warrants its products to be free of defects in materials and workmanship under normal use and service for a period of one (1) year from the date of delivery.
This warranty is extended only to the original purchaser for use of the Goods. It does not cover normal wear parts such as plastic tongs, tong holders, tong cables, bag holders,

or acrylic dividers.
General Conditions. All service labor and/or parts charges are subject to approval by SCC. Contact the Customer Service Department in writing or call 231-798-8888.
All claims must contain the following information: (1) model & serial code number of equipment; (2) the date and place of installation; (3) the name and address of the agency

which performed the installation; (4) the date of the equipment failure; and (5) a complete description of the equipment failure and all circumstances relating to that failure.
Once the claim has been determined to be a true warranty claim by SCC’s Customer Service Department, the following procedure will be taken: (1) replacement parts will be sent

at no charge from SCC on a freight prepaid basis; (2) reimbursement for service labor will be paid if the following conditions have been met - (a) prior approval of service agency
was awarded from the Customer Service Department; and (b) an itemized statement of all labor charges incurred is received by the Customer Service Department. The cost of
the service labor reimbursement will be based on straight time rates and reasonable time for the repair of the defect.

If problems occur with any compressor, notify SCC’s Customer Service Department immediately. Any attempt to repair or alter the unit without prior consent from the Customer
Service Department will render any warranty claim null and void. This warranty and protection plan does not apply to any condensing unit or any part thereof which has been
subject to accident, negligence, misuse, or abuse, or which has not been operated in accordance with the manufacturer’s recommendations or if the serial number of the unit has
been altered, defaced, or removed.

Limit of Liability. The limit of liability of SCC toward the exchange cost of the original condensing unit, F.O.B. SCC, Norton Shores, MI, of each motor-compressor assembly
replaced during the warranty shall not exceed manufacturer's current established wholesaler’s exchange price and in no case shall the labor of removing or replacing the
motor-compressor or parts thereof be the responsibility of SCC.

48