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:

PN 54382

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 CDRs.

HV[L]56RSS	HV[L]RSS
Angled Base - Full Ends		HV48RSS.3635A
	Straight Base		HV[L]48RSS	HV28RSS.3635B
	Cutaway Ends	Modified Base
			Straight Base - Full Ends	Modified Base
		Cutaway Ends
				Cutaway Ends

	HV[L]39RSS (including Q3713)	HV42[L]RSS	HV[L]56RSS
	Straight Base - Full Ends			HV36112RSS.4863A
		Angled Base - Full Ends	Straight Base
	HV7439RSS.3713A		Full Ends	Metal End Panel With Sink
	Angled Base - Full Ends

HV[L]RSSRD	HVK[L]RSS	RG2Z5080	HV36112RSS.4922B
Straight Base - Full Ends	“K” Series		With Patisserie in Top Section
Rear Sliding Doors - Plexi Plenum	Straight Base - Full Ends		[See Patisserie Section in Manual]
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			Rev J Date: 8.25.2011

TABLE OF CONTENTS

		TABLE OF CONTENTS ……………………………………………………………………………………...		2
		MODELS LISTED IN MANUAL (AND DETERMINING THEIR RESPECTIVE CASE DIMENSIONS)		3
		OVERVIEW / NSF® TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING ...……...…..		4-5
		INSTALLATION: REMOVAL FROM SKID, REMOVING LOWER FRONT PANELS ..……...…….…..		6
		INSTALLATION: ADJUSTING FRONT PANELS / ADJOINING UNITS / GLASS SHELVING ……….		7
		INSTALLATION: ELEC. CONNECTIONS / LOCKING CASTERS / ADJUSTING LEVELERS ………		8
		INSTALLATION: REFRIG. LINES / STUB-UPS / DRAINS / WIRING DIAGRAMS / VENTILATION ..		9
		INSTALLATION: DISPLAY CASE START-UP …………………………………………………………….		10
		DRAIN, HOSE AND BRACKET PLACEMENT ………………………………..…………..……….……..		11
		NIGHT AIR CURTAIN OPERATING INSTRUCTIONS (OPTIONAL) …………..…………...………….		12-13
		SECURITY GRID INFORMATION ……………………………………………………..……..….………...		14-15
		MAINTENANCE FUNDAMENTALS - STANDARD LIGHT FIXTURES ...…………..……..…….……...		16
		MAINTENANCE FUNDAMENTALS - LED LIGHTS/BRACKETS/SHELVES/DRAIN/TXV VALVE ….		17
		MAINTENANCE FUNDAMENTALS - REFRIG. PKG., TEMP. CONTROLLER, EVAP. PAN ………..		18
		MAINTENANCE FUNDAMENTALS - REAR DOORS / REAR PLENUM / MAGNETIC AIR FILTER .		19
		MAINTENANCE OF PATISSERIE AREA (MODEL HV36112RSS.4922B ONLY) …………………...		20-21
		GENERAL CLEANING [TO BE PERFORMED BY STORE PERSONNEL] ………………..……...…..		22
		TROUBLESHOOTING [TO BE PERFORMED BY STORE PERSONNEL] ..………..…….……….….		23
		GENERAL CLEANING [BY TRAINED SERVICE PROVIDERS ONLY] ……………………...………...		24
		TROUBLESHOOTING [TO BE PERFORMED BY TRAINED SERVICE PROVIDERS ONLY] ……...		25-27
		TROUBLESHOOTING [BY TRAINED SERVICE PROVIDERS ONLY] - CONDENSING SYSTEM....		28
		TROUBLESHOOTING [BY TRAINED SERVICE PROVIDERS ONLY] - EVAPORATOR SYSTEM...		29
		PREVENTIVE MAINTENANCE [TO BE PERFORMED BY TRAINED SERVICE PROVIDER]……...		30
		MAINTENANCE FUNDAMENTALS - HONEYCOMB AIR DIFFUSERS [TO BE PERFORMED BY
		SERVICE TECHNICIANS ONLY] …………………………………………………………………………..		31
		SERIAL LABEL INFORMATION & LOCATION ..……………………………………...…....…………..…		32
		TEMPERATURE CONTROLLER - CAREL® ...…. ……………………..……..…………………...……..		33-35
		TECHNICAL SERVICE CONTACT INFORMATION & WARRANTY INFORMATION ...……….….....		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	to be at 60% maximum humidity and maximum
	These Structural Concepts Encore® self-service	temperatures of 80 °F [27 °C].
		If unsure if unit is NSF® Type 1 or 2, see tag next to
	cases are designed to merchandise packaged
		serial label. See SERIAL LABEL LOCATION &
	products at 41 °F [5 °C] or less product temperatures
		INFORMATION LISTED / TECH INFO & SERVICE
	(unless custom cases with wire rack shelving).
		section in this manual for sample serial labels).
	Cases should be installed and operated according to
	this operating manual’s instructions to insure proper	COMPLIANCE
	performance. Improper use will void warranty.
		Performance issues when in violation of applicable
	NSF® TYPE	NEC, federal, state and local electrical and plumbing
	This unit is designed for the display of products in	codes are not covered by warranty.
		See below compliance guideline.
	ambient store conditions where temperatures and
	humidity are maintained within a specific range.	WARNINGS
	For NSF® Type 1 Conditions (most cases): ambient
		Following are important warnings to prevent injury or
	conditions are to be at 55% maximum humidity and
	maximum temperatures of 75 °F [24 °C].	death.
		Please read carefully!
	For NSF® Type 2 Conditions: ambient conditions are
		See next page for PRECAUTIONS.

COMPLIANCE

This equipment MUST be installed in compliance with

all applicable NEC, federal, state and local

electrical and plumbing codes.

WARNING

WARNING

Risk of electric shock. Disconnect power before servicing unit.

ELECTRICAL

CAUTION! More than one source of electrical supply is

employed with units that have separate circuits.

HAZARD

Disconnect ALL ELECTRICAL SOURCES before servicing.

WARNING

WARNING

KEEP

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

Fan blades may be exposed when deck panel is removed.

HANDS

Disconnect power before removing deck panel.

CLEAR

WARNING

WARNING

Condenser Pan is Hot!

HOT

Disconnect and allow to cool

SURFACE

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.

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

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.

CAUTION

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.

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!

Before powering up unit, check the following:

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

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.

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	Support
	general outline of
		while
	sample cases and do
		rolling
	not reflect features or
		case
	options of your
		down
	particular model.	ramp.

Ramp

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.

Upper

Panel

Support

Angled

Lower

Front

Panel

Remove screws. Lift out.

Lower Panel Support

*Apply Upward Pressure

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.

	Deck
	Support
Front Panel
Upper Support	Typical
	Side
Vertical Lower	Panel
Front Panel
	Display
Front Panel	Case
	Base
Lower Support

6

INSTALLATION: ADJUSTING FRONT PANELS / ADJOINING UNITS / GLASS SHELVING

4. Adjusting Upper Front Panels

Remove screw cover and loosen adjustment 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.

Remove Screw	IN / OUT
Cover Cap
	UP
Loosen	or
Adjustment	DOWN
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		Upper
		areas (at case end).		Front
	C. Form Two (2) Caulk/Sealant Lines: (Sanitation			Panel
		and Refrigeration). See illustration at mid-right for					IN / OUT
		outline of caulk/sealant lines.
	D. Line up ‘second’ case bolt-hole to bolt-hole to
		‘first’ case.	Approximate hole		Sanitation Bead		Refrigeration Bead
	E.	Using SCC-supplied bolts (found in installation
			locations pointed
		packet), insert bolts in bolt hole locations (shown
				at with arrows
		at right). You may need to remove decking to
			(	) for bolting
	F.	access lower bolt holes.	units together.
		Caution! Front of cases MUST be flush with each
		other! After leveling, cases are to be same height.				Sanitation
	G. Using SCC-supplied nuts & bolts, lightly tighten				Deck
						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					Refrigeration
		with industrial grade silicone sealant.
							Bead
	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 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 before placing product in case.

Sneeze

Guard

Glass

Shelves

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.

Note: Wiring process must be performed by 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.

Ballast

Wireway	Raceway
	Cover
	Ballast Box
Inner Support	Case
	Rear
Side View	Case Rear

Front Ballast	Electrical Leads
Box Covers	Access
d	d
e	e
k	k
c	c
o	lo
L	n
	U

Adjustable

Wrench

Pry Bar

Block

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		Drain Stub-Up (may be
Line Stub-Ups		at case center in
Access		extended length cases)

See Drain, Hose and Bracket Placement 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	Main Power
	Controller
		Switch
	Light Switch

Deck removal

(for coil fans

access)

Coil

Fans

Raceway

Cap

		Plug
Receptacle

Raceway Receptacle, Plug and Cap

Sample Carel®

Controller Face

Sample CPC®

Controller Face

10

							NOTE: BELOW ILLUSTRATIONS MAY
	DRAIN, HOSE AND BRACKET PLACEMENT ILLUSTRATIONS						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		Hose thru bracket
directly over
Reservoir
“CopeVap”		Drain Trap
Reservoir		Clear PVC
	Clamp	Tube

1. Hot Gas “CopeVap” Evaporator System.

Use Hose Clamp to Secure Hose to Adapter

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

Suction

Accumulator

Hot

Serpentine

Coil

Receiver

Refrigeration

Assembly

Base

Elec. Box, Hot

Gas Condensate

Overflow

Fan

Shroud

Filter

Drier

Wicking

Material

Compressor Pan Shipment Screw (1 at each side)

Clear PVC

Tube

	Drain
Evap. Pan	Trap
Positioning	Evaporator
Bracket
	Pan

	Evaporator Pan	Drain
		Trap
	Evap. Pan Positioning Bracket

3A. Front View of	3B. Isometric View of
Electrical Heat Rod Evaporator System	Electrical Heat Rod Evaporator System

11