Structural Concepts HV38R Owner’s Manual

READ AND SAVE THESE INSTRUCTIONS

INSTALLATION &

OPERATING MANUAL

SERVICE REFRIGERATED DISPLAY CASE (SELF-CONTAINED & REMOTE)

PLEASE NOTE THE FOLLOWING:

1. YOUR SPECIFIC MODEL NUMBER IS ON THE SERIAL LABEL ON CASE REAR (NEAR MAIN POWER SWITCH).

2. ILLUSTRATIONS SHOWN BELOW LIST “[L]” TO REFLECT VARYING CASE LENGTH DIMENSIONS.

3. CASES SHOWN REFLECT FULL & OPEN END PANELS / STRAIGHT OR ANGLED BASES. YOURS MAY DIFFER.

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

PN 54480

CDRs.

HV[L]R - Angled Base &

Full Ends

HVK[L]R

Straight Base - Full Ends

HV[L]R - Angled Base

Cutaway Ends

HVC48R - Straight Base &
Full Ends (Standard Case)

HVK144R.5140B

Straight Base - Full Ends

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

I:\Oper Manual\Standard\Encore_Service_Refrig_Oper_Manual_54480.pub

Rev G Date: 6.3.2011

TABLE OF CONTENTS

TABLE OF CONTENTS ……………………………………………………………………………………...
MODELS LISTED IN MANUAL (AND DETERMINING THEIR RESPECTIVE CASE DIMENSIONS)
OVERVIEW / NSF® TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS …………………...…..

INSTALLATION: REMOVAL FROM SKID, REMOVING LOWER FRONT PANELS ..……...…….…..
INSTALLATION: ADJUSTING FRONT PANELS / ADJOINING UNITS / GLASS SHELVING ……….
INSTALLATION: ELEC. CONNECTIONS / LOCKING CASTERS / ADJUSTING LEVELERS ………
INSTALLATION: FRONT GLASS ALIGNMENT & ADJUSTMENT (CURVED & FLAT) ……………...
INSTALLATION: REFRIG. LINES / STUB-UPS / DRAINS / WIRING DIAGRAMS / VENTILATION ..
INSTALLATION: DISPLAY CASE START-UP …………………………………… ……………………….

OPTIONAL NIGHT AIR CURTAIN INSTALLATION & OPERATING INSTRUCTIONS ……………...
DRAIN, HOSE AND BRACKET PLACEMENT ILLUSTRATIONS …………..…………..……….……..

MAINTENANCE FUNDAMENTALS - STANDARD LIGHT FIXTURES ...…………..……..…….……...
MAINTENANCE FUNDAMENTALS - LED LIGHTS/BRACKETS/SHELVES/DRAIN/TXV VALV E ….
MAINTENANCE FUNDAMENTALS - REFRIG. PKG., TEMP. CONTROLLER, EVAP. PAN ………..
MAINTENANCE FUNDAMENTALS - REAR SLIDING DOORS ………………………………………...

GENERAL CLEANING [TO BE PERFORMED BY STORE PERSONNEL] ………………..……...…..
TROUBLESHOOTING [TO BE PERFORMED BY STORE PERSONNEL] ..………..…….……….….
GENERAL CLEANING [BY TRAINED SERVICE PROVIDERS ONLY] ……………………...………...
TROUBLESHOOTING [TO BE PERFORMED BY TRAINED SERVICE PROVIDERS ONLY] ……...

TROUBLESHOOTING [BY TRAINED SERVICE PROVIDERS ONLY] - CONDENSING SYSTEM....

TROUBLESHOOTING [BY TRAINED SERVICE PROVIDERS ONLY] - EVAPORATOR SYSTEM...
PREVENTIVE MAINTENANCE [TO BE PERFORMED BY TRAINED SERVICE PROVIDER]……...

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

TEMPERATURE CONTROLLER - CAREL® ….…………………………………………………………..

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

21-23

24
25
26
27

28-30

31

2

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 at rear of case (near main power switch).
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 number. CDR dimensions are
usually identical to standard model dimensions.

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

Model HVC38R
Model HVC48R
Model HVC48R.4718

Model HVK48R
Model HVK56R
Model HVK74R
Model HVK112R

Model HVK74R.4692
Model HVK74R.4889
Model HVK96R.4891A

Model HV38R

Model HV48R.3462

Model HV48R
Model HV56R
Model HV74R
Model HV96R
Model HV112R

Model HV48R.3659
Model HV48R.4107
Model HV56R.2965A
Model HV56R.3986
Model HV56R.4108
Model HV74R.3225A
Model HV74R.4109
Model HV74R.5140
Model HV96R.4110
Model HV112R.3002A
Model HV112R.4111
Model HVK96R.5140A
Model HVK144R.5140B

3

OVERVIEW / NSF® TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS - PAGE 1 of 2

OVERVIEW

 These Structural Concepts Encore® self-service

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

 Cases should be installed and operated according to

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

NSF® TYPE

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

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

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

 For NSF® Type 2 Conditions: ambient conditions are

This equipment MUST be installed in compliance with

all applicable NEC, federal, state and local

electrical and plumbing codes.

to be at 60% maximum humidity and maximum
temperatures of 80 °F [27 °C].

 If unsure if unit is NSF® Type 1 or 2, see tag next to

serial label. See SERIAL LABEL LOCATION &
INFORMATION LISTED / TECH INFO & SERVICE
section in this manual for sample serial labels).

COMPLIANCE

 Performance issues when in violation of applicable

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

 See below compliance guideline.

WARNINGS

 Following are important warnings to prevent injury or

death.

 Please read carefully!
 See next page for PRECAUTIONS.

COMPLIANCE

WARNING

ELECTRICAL

HAZARD

WARNING

KEEP
HANDS
CLEAR

WARNING

HOT

SURFACE

WARNING

Risk of electric shock. Disconnect power before servicing unit.

CAUTION! More than one source of electrical supply is

employed with units that have separate circuits.

Disconnect ALL ELECTRICAL SOURCES before servicing.

WARNING

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

Fan blades may be exposed when deck panel is removed.

Disconnect power before removing deck panel.

WARNING

Condenser Pan is Hot!

Disconnect and allow to cool

before cleaning or removing from case.

4

OVERVIEW / NSF® TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS - PAGE 2 of 2

PRECAUTIONS

 Following are important precautions to prevent

damage to unit or merchandise.

CAUTION

LED lamps reflect specific size, shape and overall design.

Any replacements must meet factory specifications.

CAUTION

Lamps have been treated to resist breakage

and must be replaced with similarly treated lamps.

Use the required GFCI (Ground Fault Circuit Interrupter)

when electrical code mandates such circuit breaker.

When GFCI is required, DO NOT use standard GFI receptacle.

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

TYPE, COMPLIANCE and WARNINGS.

CAUTION

CAUTION

CAUTION

CAUTION

CAUTION! ADVERSE CONDITIONS / SPACING ISSUES

 Performance issues caused by adverse conditions are NOT covered

by warranty.

 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 will increase noise level.

Whisper Cool compressor blanket or remote unit may resolve noise
level issues.

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

(self-contained units only).

5

INSTALLATION: REMOVAL FROM SKID, REMOVING LOWER FRONT PANELS

1. Remove Case From Skid (Levelers)

 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.

3A. Removing Angled Lower Front Panels

Upper panel support.

 Remove screws located behind upper

front panel.

Lower panel support.

Most applications, screws secure the



lower panel support (located below front
panel) to the unit.

See illustration at right.

3B. Removing Vertical Lower Front Panels

Front Panel Upper Support

 Lift Front Glass.

Remove the caps and screws holding



Deck Support in place.

Front Panel Lower Support

For most display cases, screws secure



Front Panel Lower Support to Base.

 Remove screws holding Front Panel

Lower Support to Display Case Base.

Vertical Lower Front Panel can now be removed (see
illustration at lower right).

*Alternate applications (for cases without lower panel
screws): Apply upward pressure to lower panel

support to disengage lower support panel tabs from
slots located in the base at both ends of the unit.

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.

Upper

Panel

Support

Angled

Lower

Front

Panel

Remove

screws.

Lift out.

*Apply Upward Pressure

Front Glass

Front Panel

Upper Support

Vertical Lower

Front Panel

Front Panel

Lower Support

Ramp

Lower Panel
Support

Support
while
rolling
case
down
ramp.

Deck
Support

Typical
Side
Panel

Display
Case
Base

6

INSTALLATION: ADJUSTING FRONT PANELS / ADJOINING UNITS / GLASS SHELVING

4. Adjusting Upper Front Panels

 Remove screw cover and loosen adjustment

Remove Screw

Cover Cap

screws.

 Adjust alignment and tighten screws.
 See illustration at mid-right.

5. Bolting and Caulking Units Together

Follow these steps to assure a secure, level lineup.

Loosen

Adjustment

Screws

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

C. Form Two (2) Caulk/Sealant Lines

: (Sanitation

Upper

Front

Panel

IN / OUT

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 installation

packet), insert bolts in bolt hole locations (shown
at right). You may need to remove decking to

Approximate hole

locations pointed

at with arrows

( ) for bolting

units together.

Sanitation Bead Refrigeration Bead

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

Deck

Sanitation

Bead

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.

6. Glass Shelving

Glass shelving will be packed separately.

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

before placing glass shelving onto brackets!

 Plastic edging must NOT be removed from glass

shelves. Contact Structural Concepts for
replacement edging (see TECHNICAL
SERVICE CONTACT INFORMATION section).

 Check that glass shelving is in proper position

Glass

Shelves

before placing product in case.

 See illustration at lower-right.

IN / OUT

UP

or

DOWN

Refrigeration

Bead

7

INSTALLATION: ELECTRICAL CONNECTIONS / LOCKING CASTERS / ADJUSTING LEVELERS

7. Electrical Connections

A. Rear Wire-Ways

 Remove screws from rear wire-way cover to

access electrical leads.

 Wiring runs case to case through base cut-outs.
 Knockout is provided in bottom of wire-way for

stub-up connection.

 See illustration at top-right.

Note: Wiring process must be performed by
certified electricians only.

 Voltage rating is on serial label at case rear.

B. Rear Ballast Box

 Remove 4 screws from ballast box face.
 Remove screws from rear panel (if any).
 Remove 3 screws from inner support.
 Knockouts are located on side and rear of box

for making electrical connections.

Note

: Wiring process must be performed by

certified electricians only.

 Serial label (at case rear) lists voltage rating.

C. Front Ballast Box

 Remove front panel.
 Stub-up connections are in ballast box.
 Remove ballast box covers.
 Knockouts are on sides and front of ballast

assembly for making electrical connections.

: Wiring process must be performed by

Note

certified electrician only.

 Voltage rating is on serial label at case rear.

8. Cases With Casters: Lock and Unlock

 To lock casters, press down on lever.
 To unlock casters, pull lever up.
 See illustration at right.

9. Cases With Levelers: Adjust Levelers

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

and plumb (see illustration at right).

 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.

 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.
 See illustrations at right.

Wireway

Inner Support

Side View

Front Ballast

Box Covers

ed

k

Loc

Pry Bar

Block

Ballast

Raceway

Cover

Ballast Box

Case
Rear

Case Rear

Electrical Leads
Access

d

e

k

c

o

l

n

U

Adjustable

Wrench

Base

Frame

Leveler

Toe-Kick

8

INSTALLATION: FRONT GLASS ALIGNMENT & ADJUSTMENT - LEVELERS

10. Front Glass Alignment & Adjustment via Levelers (For Curved and Flat Front Glass)

 Proper alignment of the front glass is important to create and maintain a seal inside the 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.

1. Side-to-Side Leveling: Place a level on top of

display case (parallel to the front glass). Raise or

lower either side of the case by rotating levelers to

center the level bubble.

2. Front-to-Back Leveling: Place a level on top of

case, perpendicular to front glass. Raise or lower

either side of case by rotating levelers to center the

level bubble. Double-check the side-to-side level.

Case with Curved

Front Glass

Case with Flat

Front Glass

5. Verification: After inserting shims (or adjusting levelers), open and shut
the front glass to confirm proper fit.

 Verify (again) that front glass is properly aligned at left-hand and right-

hand side of the case.

 If not, repeat the shimming procedure (or leveler adjustment) until the

front glass is properly aligned along both sides of the case.

—- Front Glass —-

END

PANEL

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

hitting it), adjust levelers at

the BACK LEFT CORNER

of case DOWNWARD.

CURVED

FRONT

GLASS

LIFT

END
PANEL

4. If FRONT-RIGHT CORNER
is too close to end panel (or
hitting it), adjust levelers at the
BACK RIGHT CORNER of
case DOWNWARD.

CURVED

FRONT

GLASS

LIFT

9

INSTALLATION: REFRIG. LINES / STUB-UPS / DRAINS / WIRING DIAGRAMS / VENTILATION

11. Refrigeration Line Stub-Up Connections
(Remote Units)

 Remove front panel.
 Refrigerant stub-up access opening is at the

front on the left hand side of the base (see
illustration at top-right).

 Stub-up connections are accessed from inside

the case.

 Remove interior ABS decks.
 Remove fan shroud assembly.

 Line connections are in the tub front, on the left

hand side

 Remove foam material from the entry hole

provided in the tub drain trough.

 Route refrigerant lines through access hole.

 Run case-to-case connections through

cutouts in base.

 Sweat the high and low pressure

Cutout

Refrigeration

Line Stub-Ups

Access

Drain Stub-Up (may be

at case center in

extended length cases)

connections.

 Fill access hole with suitable filler to insure

watertight integrity of tub.

 Illustration at top-right may not reflect every

feature or option of your particular case.

12. Refrigeration Drain Connection
(Remote Units)

 Depending upon drain access needs, either front

or rear panel may be removed to gain access to
drain stub-up.

 1.5” male PVC stub-up connection is under the

case on the right hand side.

 Drain stub-up may be at case center in extended

length cases.

 Connect tub drain to floor drain. Maintain

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

 Illustration at top-right may not reflect every

feature or option of your particular case.

13. Evaporator Pan / Drain Position
(Self-Contained Units)

 Remove the Rear Panel by lifting up & out.
 Slide the Condenser Unit out from case.
 Condenser Unit access is now available.
 Insure that the evaporator pan is installed under

the PVC condensate drain trap.

 Check that the condensate pan is plugged

into the receptacle inside base. If not, pan
will overflow onto floor causing damage!

 Lower rear panel back into place.

 See Drain, Hose and Bracket Placement

section in Operating Manual for details.

14. Electrical 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 condenser fan cover,
ballast box, raceway cover, or other related
location.

15. Ventilation and Clearance

 Self-Contained refrigerated cases must

maintain airflow clearance of 6” (minimum) to
12” (recommended) at front and rear.

 Restriction of air can void warranty.
 Illustration below may not reflect every feature

or option of your particular case.

Check air grilles for obstructions.
Maintain airflow clearance of 6” (min.)
to 12” (recommended) at front & rear.

10