Structural Concepts GHBSS5R.4986A Installation Manual

READ AND SAVE THESE INSTRUCTIONS

INSTALLATION &

G-SERIES

G-SERIES HIGH-VOLUME SELF-SERVICE REFRIGERATED DISP L AY CASES

PLEASE NOTE THE FOLLOWING:

1. YOUR MODEL NUMBER IS LOCATED ON THE SERIAL LABEL (USUALLY AT CASE
REAR). HOWEVER, LABEL LOCATIONS MAY VARY DEPENDING UPON MODEL.

2. SEE SERIAL LABEL LOCATION & INFORMATION SECTION IN THIS MANUAL
FOR SAMPLE LABELS.

3. CASES SHOWN IN THIS MANUAL REFLECT FULL & OPEN END PANELS /

STRAIGHT OR ANGLED BASES. YOURS MAY DIFFER.

4. SEE “MODELS (AND THEIR RESPECTIVE CASE DIMENSIONS) LISTED IN THIS
MANUAL” SECTION FOR ADDITIONAL INFORMATION REGARDING SPECIFIC
CASE DIMENSIONS OF STANDARD MODELS AND

OPERATING MANUAL

CDRs.

20-01693

GHSS656R / Optional Night

Air Curtain / Locking Security

Cover / Rear Doors

With Perforated Acrylic Plenum

GHBSS5R.4986A (Remote)

GHSS1075RLB.5422

GHSS456R /
Optional Night Air Curtain
& Locking Security Cover

GHSS660R w/Optional Perforated

Plexiglas® Sliding Doors

GHBSS5R.4986A (Remote)

GHSS652RLB

Without End Panel

GHSSEH656RLB (Remote)

GHSS660R Shown With

Optional Night Air Curtain

GHSSAC652R

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

I:\Oper Manual\Standard\G-Series_Self-Service_Refrig_Oper_Manual_20-01693.pub

GHSSACS857R

Includes Scale Stand With

Isolated Ground Receptacle

GHDSS850R

Rev N Date: 4.14.2014

TABLE OF CONTENTS

TABLE OF CONTENTS ………………………………………………………………………………………...
MODELS LISTED IN MANUAL (AND DETERMINING THEIR RESPECTIVE CASE DIMENSIONS) …
OVERVIEW / TYPE 1 vs. 2 / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS …...

INSTALLATION: REMOVAL FROM SKID, REMOVING LOWER FRONT PANELS ..……...…….……..
INSTALLATION: ADJUSTING FRONT PANELS / ADJOINING UNITS / GLASS SHELVING ………….
INSTALLATION: ELECTRICAL CONNECTIONS / BALLAST BOX / LED DRIVER (REMOTE UNITS).
INSTALLATION: ELECTRICAL CONNECTIONS / BALLAST BOX / LED DRIVER

(SELF- CONTAINED UNITS) …….…………………………………………………………………....

INSTALLATION: UNDERSIDE FIELD ACCESS COMPONENTS (REMOTE MODEL
GHSSEH456RLB DISPLAYED) ……………………………………………………………………….
INSTALLATION: TOPSIDE FIELD ACCESS COMPONENTS AND TOPSIDE REFRIGERATION
LINE ROUTE (REMOTE MODEL GHSS675RLB.5422A DISPLAYED) ………………………….
INSTALLATION: ELECTRICAL CONNECTIONS / OPTIONAL SCALE STAND ………………………..

INSTALLATION: FRAME SUPPORT RAILS / SEALING TO FLOOR / LOCKING CASTERS ………....

INSTALLATION: REFRIG. LINES / STUB-UPS / DRAINS / WIRING DIAGRAMS / VENTILATION …..
INSTALLATION: DISPLAY CASE START-UP (CASE / LIGHTS / TEMPERATURE CONTROLLER /
SATURATED SUCTION TEMPERTURE) …………………………………………………………..

MAINTENANCE: STANDARD LIGHT FIXTURES …………………………………………………………..

MAINTENANCE: LED LIGHTS/BRACKETS/SHELVES/DRAIN/TXV ..………………………………....…

MAINTENANCE: REFRIGERATION PACKAGE ILLUSTRATION (FROM SELF-CONTAINED
MODEL GHDSS850R) ……………………………………………………………………………..…..
MAINTENANCE: REFRIGERATION PACKAGE ILLUSTRATION (FROM SELF-CONTAINED
MODEL GHSS660R) …………………………………………………………………………………...
MAINTENANCE: OPTIONAL SLIDING REAR DOORS / PERFORATED ACRYLIC PLENUM ………..

MAINTENANCE: OPTIONAL NIGHT AIR CURTAIN ATTACHMENT & OPERATING INSTRUCTIONS .

GENERAL CLEANING (TO BE PERFORMED BY STORE PERSONNEL) ………………..……...……..
TROUBLESHOOTING (TO BE PERFORMED BY STORE PERSONNEL) ..………..…….……….…….

GENERAL CLEANING (BY TRAINED SERVICE PROVIDERS ONLY) ……………………...……...…...

TROUBLESHOOTING (BE PERFORMED BY TRAINED SERVICE PROVIDERS ONLY) ………..…...

TROUBLESHOOTING - CONDENSING SYSTEM (BY TRAINED SERVICE PROVIDERS ONLY) ......

TROUBLESHOOTING - EVAPORATOR SYSTEM (BY TRAINED SERVICE PROVIDERS ONLY) .....

PREVENTIVE MAINTENANCE (TO BE PERFORMED BY TRAINED SERVICE PROVIDER ONLY)...

HONEYCOMB AIR DIFFUSER REMOVAL/INSTALLATION (TO BE PERFORMED BY TRAINED
SERVICE PROVIDER ONLY) …..……………………………………………………………………..

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

CAREL® CONTROLLER - PROGRAMMING THE INSTRUMENT….…………………………….……....

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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25-27

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MODELS LISTED IN THIS MANUAL (AND DETERMINING THEIR RESPECTIVE CASE DIMENSIONS)

DETERMINING YOUR MODEL AND ITS CASE DIMENSIONS:

Note 1. Your model number can be found on serial label (usually at case rear). However, serial
label placement can sometimes vary depending upon model. See SERIAL LABEL INFORMATION

& LOCATION section in this manual for serial label samples.

Note 2. Dimensions of most models can be found at www.structuralconcepts.com. Simply enter

the case model number into the Product Number Search box. Click the product specification

link for complete dimensions.
Note 3. If your specific model is not found, contact technical service (phone number is listed at
Technical Service section in this manual) for dimensions.
Note 4. CDRs (Customer Design Requests) are listed with a 4-digit suffix. Dimensions are very
similar to standard model (pre-suffix) dimensions.

THIS OPERATING MANUAL ENCOMPASSES THE FOLLOWING MODELS (AND/OR THEIR
RESPECTIVE CDRs):

G-Series GHDSS850R

G-Series GHBSS5R.4986A

G-Series GHSS436R
G-Series GHSS460R.5976
G-Series GHSS636R
G-Series GHSS656R
G-Series GHSS660R
G-Series GHSS852R
G-Series GHSS652RLB
G-Series GHSS656RLB
G-Series GHSS675RLB.5422A
G-Series GHSS852RLB
G-Series GHSS856RLB
G-Series GHSS875RLB.5422
G-Series GHSS1075RLB.5422
G-Series GHSSAC452R
G-Series GHSSAC457R
G-Series GHSSAC652R
G-Series GHSSAC852R
G-Series GHSSAC1252R
G-Series GHSSACS657R
G-Series GHSSACS857R
G-Series GHSSACS1257R

G-Series GHSSEH456RLB
G-Series GHSSEH556RLB
G-Series GHSSEH652RLB
G-Series GHSSEH656RLB
G-Series GHSSEH856RLB
G-Series GHSSEH1056RLB
G-Series GHSSEH1256RLB

3

OVERVIEW / TYPE 1 vs. 2 / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS - PG 2 of 2

OVERVIEW

 These Structural Concepts G-Series® Self-Service

merchandisers are designed to merchandise
packaged products at 41 °F (5 °C) or less product
temperatures (unless custom cases with wire rack
shelving).

 Product must be pre-chilled at 41 °F (5 °C) or less

prior to being placed in merchandiser.

 Cases should be installed and operated according to

this operating manual’s instructions to ensure proper
performance.

 Improper use will void warranty.

TYPE 1 vs. TYPE 2 UNITS

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 Type 2

conditions, see identifying label on your case.

Location varies depending upon model.

COMPLIANCE

 Performance issues when in violation of applicable

NEC, federal, state and local electrical and plumbing
codes are not covered by warranty.

 See below compliance guideline.

WARNINGS

 This page contains important warnings to prevent

injury or death.

 Please read carefully!

PRECAUTIONS and WIRING DIAGRAMS

 See next page for PRECAUTIONS and WIRING

DIAGRAM information.

WARNING

ELECTRICAL

HAZARD

WARNING

KEEP
HANDS
CLEAR

WARNING

HOT

SURFACE

COMPLIANCE

This equipment MUST be installed in compliance with

all applicable NEC, federal, state and local

electrical and plumbing codes.

WARNING

Risk of electric shock. Disconnect power before servicing unit.

CAUTION! More than one source of electrical supply is

employed with units that have separate circuits.

Disconnect ALL ELECTRICAL SOURCES before servicing.

WARNING

Hazardous moving parts. Do not operate unit with covers removed.

Fan blades may be exposed when deck panel is removed.

Disconnect power before removing deck panel.

WARNING

Condensate Pan and/or Overflow Condensate Pan is Hot!

Disconnect and allow to cool

before cleaning or removing from case.

4

OVERVIEW / TYPE 1 vs. 2 / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS - PG 2 of 2

PRECAUTIONS

 Following are important precautions to prevent

damage to unit or merchandise.

 Please read carefully!

 See previous page for specifics on OVERVIEW,

TYPE, COMPLIANCE and WARNINGS.

CAUTION! LAMP REPLACEMENT GUIDELINES

LED lamps reflect specific size, shape and overall design.

CAUTION

Any replacements must meet factory specifications.

Fluorescent lamps have been treated to resist breakage and

must be replaced with similarly treated lamps.

CAUTION! GFCI BREAKER USE REQUIREMENT

If N.E.C. (National Electric Code) or your local code

requires GFCI (Ground Fault Circuit Interrupter) protection,

you MUST use a GFCI breaker in lieu of a GFCI receptacle.

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.

WIRING DIAGRAM

 Each case has its own wiring diagram folded and in its

own packet.

 Wiring diagram placement may vary; it may be placed

near ballast box, field wiring box, raceway cover, or
other related location.

CAUTION

CAUTION! ADVERSE CONDITIONS / SPACING ISSUES

 Performance issues caused by adverse conditions are NOT 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 or small rooms increase noise level. Whisper

Cool compressor blankets or remote units resolve noise level issues.

 Keep at least 8-inch clearance above unit for air discharge

(self-contained units only).

CAUTION! CHECK CONDENSATE PAN POSITION AND PLUG

Water on flooring can cause extensive damage!

 Condensate pan MUST BE positioned directly under condensate drain.
 Condensate pan plug MUST BE securely plugged into receptacle.
 Check that overflow pan is fully functional.

Before powering up unit, check the following:

5

INSTALLATION: REMOVAL FROM SKID, REMOVING VERTICAL LOWER FRONT PANELS

1. Remove From Skid (Rails or Levelers)

 Remove shipping brace that may be securing

case to skid.

 Support case to prevent tipping.
 Caution! Frame Support Rails (or 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

Note: 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 particular model.

Ramp

Support
while
rolling
case
down
ramp.

3. Removing Vertical Lower Front Panels

Note: No screw removal required: Simply lift lower front panel up (off hooks) and out (away from case).

Note: Illustration below reflects case unit with front flat

glass. Your case may not reflect every

feature or option of this particular case.

However lower front panel removal illustration will apply.

Hooks For Lower

Front Panel

Note

Lower Front Panel

Removed & Reversed

For Illustrative

Purposes Only

Slots For Lower

Front Panel

6

View of Front Panel

(Removed & Reversed)

INSTALLATION: ADJUSTING FRONT PANELS / ADJOINING UNITS / GLASS SHELVING

4. Bolting and Caulking Units Together

Follow these steps to assure a secure, level lineup.

A. Begin all lineups 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).

Approximate hole

locations pointed

at with arrows

( ) for bolting

units together.

Sanitation Bead Refrigeration Bead

Use industrial grade silicone sealant on visible
areas (at case end).

C. Form Two (2) Caulk/Sealant Lines

: (Sanitation

Deck

Sanitation

Bead

and Refrigeration). See illustration at mid-right for

outline of caulk/sealant lines.

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

‘first’ case.

E. Using SCC-supplied bolts (found in hole locations

OR

in installation packet), insert bolts in bolt hole

Refrigeration

Bead

locations (shown at top-right). You may need to
remove decking to access lower bolt holes.

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

other! After leveling, all cases 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.

 See illustration at top-right.

5. Glass Shelving

If your unit has glass shelving, it will be packed
separately.

Caution! Carefully remove from packaging.

 Grasp firmly and carefully install.
 Caution! Check that plastic edging is intact

Glass

Shelves

before placing glass shelving onto brackets!

 Plastic edging must NOT be removed from glass

shelves. Contact Structural Concepts for
replacement edging (see TECHNICAL

Note: Illustration above reflects dual case unit with

glass in end panels. Your case may not reflect

every feature or option of this particular case.

SERVICE CONTACT INFORMATION section).

 Check that glass shelving is in proper position

before placing product in case.

 See illustrations at mid and lower-right showing

both curved and flat front glass (optional).

Glass

Shelves

7

INSTALLATION: ELECTRICAL CONNECTIONS / BALLAST BOX / LED DRIVER (REMOTE UNITS)

6. Electrical Connections (Remote Units)

Ballast / LED Driver

Remove front panel. See INSTALLATION:
REMOVAL FROM SKID, REMOVING VERTICAL
LOWER FRONT PANELS section in this manual for

instructions.

 Stub-up connections are in ballast box.
 Remove ballast box / LED driver box cover.

Note: Illustration reflects remote Model GHBSS5R.4986A

with front panel removed for illustrative purposes only.
See next page for self-contained model GHDSS850R.

 Knockouts are on the underside of ballast box /

LED driver box making electrical connections.

 Voltage rating is on serial label at case rear.
 Remote case Illustration shown below reflects flat

front glass. Your case may differ (but electrical

layout will be accurate).

 Note: Wiring process must be performed by

certified electrician only.

Ballast / LED

Wire

Route

PBV

Driver

Terminal

Strip

Ballast Box /

LED Driver Box

8

INSTALLATION: ELECTRICAL CONNECTIONS / BALLAST BOX / LED DRIVER (SELF-CONTAINED)

7. Electrical Connections (Self-Contained
Units)

Front Ballast / LED Drivers

Remove front panel. See INSTALLATION:
REMOVAL FROM SKID, REMOVING VERTICAL
LOWER FRONT PANELS section in this manual for

instructions.

 Stub-up connections are in ballast box.

Note: Illustration reflects self-contained Model

GHBSS5R.4986A with lower-front panel and electrical

raceway cover removed for illustrative purposes only.

See previous page for remote model GHDSS850R.

 Remove electrical raceway cover.

 Knockouts are on the underside of electrical race

way for making electrical connections.

 Voltage rating is on serial label at case rear.
 Self-contained case Illustration shown below

reflects curved front glass. Your case may slightly
differ (but electrical layout is accurately portrayed).

 Wiring process must be performed by certified

electrician only.

Ballast / LED

Driver

Wire Route

PBV

Main Power

Switch

Temperature

Controller

Terminal

Strip

Contactor

Ballast / LED

Driver

(Optional)

9

INSTALLATION: UNDERSIDE FIELD ACCESS COMPONENTS (MODEL GHSSEH456RLB DISPLAYED)

8. Underside Field Access Box Components
and Underside Refrigeration Line Route

 On certain models, field access components (a

variety of which is shown below) are at underside.

 Model GHSSEH456RLB is illustrated below; your

underside component layout may vary.

Note: Illustration Reflects Remote

Model GHSSEH456RLB With

Underside Electrical Components.

Your Case May Vary.

Dixell®
Display

Terminal Blocks

 Caution! Only certified electricians are to perform

electrical connectivity duties.

 To access large field access box, two screws (at

case front) must be removed and box slid out.

Remove Screws (Typ.)

to Slide Out Large Field

Access Box From

Fuse Block

Underside Of Case

Refrig.

Lines

Transformer

4” x 4” Field

Access Box

LED

Drivers

Temperature

Controller

10

LED

Drivers

INSTALLATION: TOPSIDE FIELD ACCESS COMPONENTS (MODEL GHSS675RLB.5422A DISPLAYED)

9. Topside Field Access Box Components
and Topside Refrigeration Line Route

 On certain models, field access components

(a variety of which is shown below) are topside.

 Model GHSS675RLB.5422A is illustrated below;

your topside component layout may vary.

 Caution! Only certified electricians are to

perform electrical connectivity duties.

Note: Illustration Reflects Remote
Model GHSS675RLB.5422A With

Topside Electrical Components.

Your Case May Vary.

Temperature

4” x 4”

Controller

Field Access Box

LED Drivers

Screw (Typ.)

 To access large field access box, two screws (at

case rear) must be removed and cover lifted up

and off.

 *Note: See MAINTENANCE: OPTIONAL NIGHT

AIR CURTAIN ATTACHMENT... section in this

manual for night curtain operating instructions.

Terminal Blocks

Fuse Block

*Optional Night

Air Curtain

Large Field

Access Box

Model GHSS675RLB.5422A

Shown Above

Transformer

Refrigeration

Lines

(Top Exit)

Dixell®

Display

11