Structural Concepts HV42LRSS Installation Manual

READ AND SAVE THESE INSTRUCTIONS

INSTALLATION &

OPERATING MANUAL

SELF-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 MANUAL” SECTION FOR
ADDITIONAL INFORMATION REGARDING SPECIFIC CASE DIMENSIONS OF STANDARD MODELS AND

HV[L]56RSS

Angled Base - Full Ends

HV[L]RSS

Straight Base

Cutaway Ends

HV48RSS.3635A

Modified Base
Cutaway Ends

HV[L]48RSS

Straight Base - Full Ends

PN 54382

CDRs.

HV28RSS.3635B

Modified Base
Cutaway Ends

HV[L]39RSS (including Q3713)

Straight Base - Full Ends

HV7439RSS.3713A

Angled Base - Full Ends

HV[L]RSSRD

Straight Base - Full Ends

Rear Sliding Doors - Plexi Plenum

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

Oper Manuals\Standard\Self_Service_Refrig_Oper_Manual_54382.pub

HV42[L]RSS

Angled Base - Full Ends

HVK[L]RSS

“K” Series

Straight Base - Full Ends

HV[L]56RSS

Straight Base

Full Ends

RG2Z5080

HV36112RSS.4863A

Metal End Panel With Sink

HV36112RSS.4922B

With Patisserie in Top Section

[See Patisserie Section in Manual]

Rev J Date: 8.25.2011

TABLE OF CONTENTS

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

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

DRAIN, HOSE AND BRACKET PLACEMENT ………………………………..…………..……….……..
NIGHT AIR CURTAIN OPERATING INSTRUCTIONS (OPTIONAL) …………..…………...………….
SECURITY GRID INFORMATION ……………………………………………………..……..….………...

MAINTENANCE FUNDAMENTALS - STANDARD LIGHT FIXTURES ...…………..……..…….……...
MAINTENANCE FUNDAMENTALS - LED LIGHTS/BRACKETS/SHELVES/DRAIN/TXV VALVE ….
MAINTENANCE FUNDAMENTALS - REFRIG. PKG., TEMP. CONTROLLER, EVAP. PAN ………..
MAINTENANCE FUNDAMENTALS - REAR DOORS / REAR PLENUM / MAGNETIC AIR FILTER .

MAINTENANCE OF PATISSERIE AREA (MODEL HV36112RSS.4922B ONLY) …………………...

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]……...

MAINTENANCE FUNDAMENTALS - HONEYCOMB AIR DIFFUSERS [TO BE PERFORMED BY
SERVICE TECHNICIANS ONLY] …………………………………………………………………………..

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

22

23

24

25-27

28

29

30

31

32

33-35

36

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. All CDR dimensions
are identical to standard model dimensions.

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

Standard 2287 2595 2613 2613A 2613B 2852C 3153 3916
HVK3696RSS.5159A HVK36144RSS.5159B HVK48RSS HVK56RSS
HVK74RSS HVK74RSS.5142A HVK96RSS HVK96RSS.5142
HVK4296RSS HV28RSS HV28RSS.3635B HV38RSS HV38RSSRD
HV48RSS HV48RSS.2917 HV48RSS.3620 HV48RSS.3635A
HV48RSS.3735A HV56RSS HV56RSS.3935A HV56RSS.4203
HV74RSS HV74RSS.2846B HV74RSS.2852 HV74RSS.3905B
HV96RSS HV96RSS.3905 HV96RSS.4105 HV96RSS.5161
HV112RSS HV112RSS.2852D HV114RSS HV144RSS HV34144RSS
HV34144RSS.4993 HV34144RSS.4993A HV3638RSS HV3648RSS
HV3656RSS HV3674RSS HV3696RSS HV36112RSS
HV36112RSS.4992B HV36112RSS.4863A HV4256RSS HV4274RSS
HV4296RSS HV5656RSS HV7439RSS HV38RSSRD HV48RSSRD
HV56RSSRD HV74RSSRD HV96RSSRD HV112RSSRD
HV74RSS.4104 HVLD48RSS.4125 RG2Z5080 SB4566R

OVERVIEW / NSF® TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING - 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

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

electrical and plumbing codes.

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 / WIRING - PAGE 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, NSF

TYPE, COMPLIANCE and WARNINGS.

CAUTION

LED lamps reflect specific size, shape and overall design.

Any replacements must meet factory specifications.

CAUTION

Fluorescent lamps have been treated to resist breakage

and must be replaced with similarly treated lamps.

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

requires GFCI (Ground Fault Circuit Interrupter) protection,

the use of a GFCI breaker is strongly recommended.

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

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).

CAUTION! CHECK EVAPORATOR PAN POSITION AND PLUG

Water on flooring can cause extensive damage!

 Evaporator pan MUST BE positioned directly under condensate drain.
 Evaporator pan plug MUST BE securely plugged into receptacle.

Before powering up unit, check the following:

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

 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 base at both ends of 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.

Ramp

Upper

Panel

Support

Angled

Lower

Front

Panel

Remove

screws.

Lift out.

Lower Panel Support

*Apply Upward Pressure

Front Panel

Upper Support

Vertical Lower

Front Panel

Front Panel

Lower 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 lineup leveling from highest point of floor.
B. After the ’first’ case is level, apply industrial grade

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

C. Form Two (2) Caulk/Sealant Lines

: (Sanitation

and Refrigeration). See illustration at mid-right for

Upper

Front

Panel

IN / OUT

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
access lower bolt holes.

Approximate hole

locations pointed

at with arrows

( ) for bolting

units together.

Sanitation Bead Refrigeration Bead

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

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 (or Sneeze Guard)

Glass shelving and (on certain cases sneeze guards)
will be packed separately.

 Caution! Two installers may be required to

Sneeze

Guard

properly lift and install of large pieces.

 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.

IN / OUT

UP

or

DOWN

Refrigeration

Bead

7

INSTALLATION: ELECTRICAL CONNECTIONS / LOCKING CASTERS / ADJUSTI NG 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

d

e

k

c

o

L

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

10. 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

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.

11. 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.

12. 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.

 Caution! Check that evaporator pan is

plugged into receptacle inside base. If not,
water may drain onto floor, causing damage!

 Lower rear panel back into place.

Cutout

Refrigeration

Line Stub-Ups

Access

 See Drain, Hose and Bracket Placement

Drain Stub-Up (may be

at case center in

extended length cases)

section in Operating Manual for details.

13. 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.

14. 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.

9

INSTALLATION: DISPLAY CASE START-UP

15. Display Case Start-Up

A. Case

 Turn main power on at case rear.

From the front of the case, lift deck to check that



the coil fans are functioning properly.
Coil fans, (and in self-contained units, the



compressor motor) should turn on.

B. Lights

 Turn lights on.

 Self-Contained units: Switch at rear.
 Remote cases: NO SWITCH (lights
come on when main power switch is
turned on).

 All lights should come on at the same time. First

time lighting may require a short warm-up period
for the bulbs.
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 at right.

 LED Lights: If lights do not come on, check that

plug is properly inserted into socket.

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

 Check that compressor symbol light is on.

Depending upon SCC-Supplied temperature



controller, compressor is identified with either:

Compressor symbol (common in Carel®
temperature controllers).

Snowflake symbol (common in CPC®
temperature controllers).

 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.

 Remote units (without temperature controller on

case): Verify that refrigeration requirements listed
on serial label (found on the case) are being met.

D. 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.

Temperature

Controller

Light Switch

Deck removal

(for coil fans

access)

Coil

Fans

Raceway Receptacle, Plug and Cap

Sample CPC®

Controller Face

Raceway

Receptacle

Main Power

Switch

Cap

Plug

Sample Carel®

Controller Face

10

DRAIN, HOSE AND BRACKET PLACEMENT ILLUSTRATIONS

NOTE: BELOW ILLUSTRATIONS MAY

NOT EXACTLY REFLECT EVERY

PARTICULAR CASE’S FEATURES

Three Evaporator Systems Are Illustrated Below:

Illustration #1: Hot Gas “CopeVap” Evaporator
System. “Copevap” is built into Compressor Unit.

Illustration #2: Hot Gas Evaporator System.
Illustration 3A/3B : Electrical Heat Rod Evaporator

System. Note: Separate Evaporator Pan.
Warning! Regardless of Evaporator, the Hose and

Drain Trap MUST BE secured and positioned over
Evaporator Pan to prevent water seepage / spillage.
When sliding out Condenser Unit, be careful that
drain is not pulled from proper position.

Note: Drain

Bracket

positioned

directly over

Hose thru bracket

Reservoir

Drain Trap

“CopeVap”

Reservoir

Clamp

Clear PVC

Tube

2. Hot Gas Evaporator System.
 Hot gas serpentine coil is routed through a condensate

reservoir allowing water to be heated. This system
uses a wicking material (partially submersed) with
warm condenser air passing through it for evaporation.

 Also incorporates an overflow reservoir with heating

element to ensure complete condensate removal.

This area of your unit

may widely vary (due to

display case options).

Sight Glass

Scroll

Compressor

Receiver

Elec. Box, Hot

Gas Condensate

Overflow

Fan

Shroud

Filter
Drier

1. Hot Gas “CopeVap” Evaporator System.

Use Hose Clamp

to Secure Hose

to Adapter

Clear PVC

Tube

Evap. Pan

Positioning

Bracket

3A. Front View of

Electrical Heat Rod Evaporator System

Drain
Trap

Evaporator
Pan

Suction

Accumulator

Hot

Serpentine

Coil

Refrigeration

Assembly

Evaporator Pan

Evap. Pan Positioning Bracket

3B. Isometric View of

Electrical Heat Rod Evaporator System

Base

Wicking

Material

Compressor Pan
Shipment Screw
(1 at each side)

Drain
Trap

11