Structural Concepts SB5735 Installation Manual

READ AND SAVE THESE INSTRUCTIONS

INSTALLATION &

OPERATING MANUAL

SELF-CONTAINED REFRIGERATED
SERVICE / SELF-SERVE UNITS

P/N 54100

SB5766.3923A

Model SB5735………...34 1/2”L* x 33”D** x 58 7/8”H~

Model SB5754.3924……....54”L* x 33”D** x 58 7/8”H~

Model SB5766.3923..….…66”L* x 33”D** x 58 7/8”H~
Model SB5766.3923A….…66”L* x 33”D** x 58 7/8”H~
Model SB5766.4999…...…66”L* x 33”D** x 58 7/8”H~
Model SB5766.5106..….…66”L* x 33”D** x 58 7/8”H~

* With End Panels
** 47 1/8” With Rear Ledge upright
~ With Adjustable Levelers Extended 1 5/8” Below Base Frame

Certification: NSF-7, CRMA, UL/CSA

SB5754.3924

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

I:\Oper Manuals - PUB\Starbucks\SB5735_SB5766-3923A_SB5754-3924_54100.pub

SB5735

Rev I Date: 3.5.2013

TABLE OF CONTENTS

OVERVIEW / NSF® TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS .…..
REFRIGERATION ASS’Y REMOVAL, CASE REMOVAL AND LEVELER ADJUSTMENT …………..
START-UP AND OPERATION …………...…...…..……………………………………………….…………
SECURITY ………….……………...….…………...…...…..…………………………………………………...
MAINTENANCE AND OPERATION ..…………...…...…..……………………………………………..……
ELECTRICAL FUNDAMENTALS ………...…...…..…………………………………….………… …...…….
REFRIGERATION FUNDAMENTALS ..………………...…..……………………………………..…………
HOT GAS CONDENSATE EVAPORATIVE SYSTEM OPERATION………...…..………………...……..
LOAD LEVEL GUIDELINES [APPLICABLE TO ALL MODELS] ………………………………………...
SERIAL LABEL LOCATION & INFORMATION LISTED / TECH INFO & SERVICE …………….…….

ILLUSTRATED PARTS BREAKDOWN FOR MODEL SB5766.3923/3923A (SIMILAR TO OTHER
MODELS) ………………………………...

……………………………..……………………………….....……

PARTS LIST FOR MODEL SB5766.3923/3923A (SIMILAR TO OTHER MODELS) ....…………...……

ILLUSTRATED PARTS BREAKDOWN / PARTS LIST FOR MODEL SB5735 CONDENSER PKG ...

CLEANING SCHEDULE [TO BE PERFORMED BY STORE PERSONNEL] ……………...….….....….

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

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 - HONEYCOMB AIR DIFFUSERS [TRAINED SERVICE
PROVIDERS ONLY] …………………………………………………………………………………...

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

CAREL® CONTROLLER - USER INTERFACE DISPLAY & SUMMARY TABLE OF ALARM AND
SIGNALS: DISPLAY, BUZZER AND RELAY ……………………….………………..…...……….
CAREL® CONTROLLER - SUMMARY TABLE OF OPERATING PARAMETERS (AFTER

PROGRAMMING KEY) ………………..…………………………………………………….....….…..

QUARTERLY PREVENTIVE MAINTENANCE FORM …..…………………...……………………….....…

SCC TECHNICAL SERVICE CONTACT INFORMATION & STARBUCKS LIMITED WARRANTY ....

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25-26
27-29

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2

OVERVIEW / NSF® TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS - PG 1 of 2

OVERVIEW

 These Structural Concepts merchandisers are

designed to merchandise pre-chilled packaged
products at 41 °F [5 °C] or less product temperatures.

 This self-contained refrigerated unit is a barista serve

unpackaged food and customer self serve packaged
food and drink case.

 Cases should be installed and operated according to

this operating manual’s instructions to ensure 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

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

 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

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 is Hot!

Disconnect and allow to cool

before cleaning or removing from case.

3

OVERVIEW / NSF® TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS - PG 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, NSF

TYPE, COMPLIANCE and WARNINGS.

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.

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 & PLUG

Water on flooring can cause extensive damage!

 Condensate pan is DIRECTLY UNDER condensate drain.
 Condensate pan plug is securely plugged into receptacle.
 Overflow pan has plug connected to its box. Units with optional

Before powering up unit, check and confirm that:

Clean Sweep™ MUST HAVE 2 plugs connected.

4

REFRIGERATION ASSEMBLY REMOVAL, CASE REMOVAL AND LEVELER ADJUSTMENT

1. Removing Refrigeration Assembly

 Note: Retain screws that are removed from the

CASE shipping brackets (Screws will be used as

Toe-Kick fasteners).

 Remove front panel.
 Lift front panel upward from the lower edge,

approximately one half inch to detach from the
retainer hooks.

 Remove all shipping brackets from units base and

compressor.

 Reuse shipping bracket screws for Toe-Kick

mounting.

 Note: Make sure all hoses and power cords are

disconnected before completely removing
compressor from unit.

 The compressor base is on casters. Roll the

assembly out half way straight out from the front
of the case.

 Carefully lower assembly to floor.
 After compressor unit is removed, roll out of the

Refrigeration Assembly

Shipping Brackets.

Note: Illustration shown may

differ slightly from your case.

Refrigeration

Assembly

way while locating and setting case.

2. Removing Case from Skid

 Slide case halfway off back of skid.
 Lower case onto back rear levelers.
 Tilt case back enough to free skid.
 Slide skid out from front of case, lower case to

floor.

3. Leveling Case

 Levelers may need to be adjusted for proper height

Do NOT grab

rear ledge

to move case!

clearance to fully insert unit.

 Tools needed: level, pry bar, and adjustable

wrench.

 Using a level, find the highest point on the case.
 Level the case to that highest point by turning the

levelers up or down to the desired level position.

Pry Bar

5

Leveler

Base

Frame

Toe-Kick

START-UP AND OPERATION

1. Merchandiser Start-Up

 Remove rear toe-kick (by removing four screws,

two at each end).

 Turn main power on. Switch (220V) is up and

under rear raceway on right side of case.

The Controller display will illuminate.



Coil fans should turn on. From inside case, check



for discharge air from front baffle to confirm that

fans are functioning properly.

When the case is in a start up mode or has been



idle for a long period of time, the unit will require

75 minutes in order to pull-down temperature.

Self-Contained refrigerated cases must maintain



front airflow clearance of approximately twelve

inches and rear airflow clearance of approximately

six inches.

 Obstruction / restriction of air voids warranty.

The interior case temperature is to reach 2 °C /



35 °F to 5 °C / 41 °F.

Note: Case temperature is set at the factory, as



determined by the case size. Temperature is

controlled by a thermostat.

If a temperature setting change is required, refer



to the Temperature Controller section of this

operating manual.

Note: According to product displayed, Set point



should be -6 °C / 22 °F to -3 °C / 26° F. This will

maintain the product temperature range. Settings

lower than this can cause product to freeze

.

2. Set Point & Differential Adjustment Guideline

 Caution! The Differential MUST be adjusted

either up or down in tandem with the Set point.

 For example, if the Set point is raised from 22 °F

to 26 °F (a 4 °F increase), the Differential must

also be raised by 4 °F from (11 °F to 15 °F).

 Keeping the Set point and Differential

temperatures ‘in tandem’ will maintain product

temperature and prevent excessive compressor

cycles.

3. See Next Page For Fluorescent Light Guidelines

Controller

Display

Light Switch

Main Power Switch

(access at underside)

Rocker Switch

ON

OFF

Honeycomb Air Diffuser. See PREVENTIVE MAINTENANCE -

HONEYCOMB AIR DIFFUSERS [SERVICE TECHNICIANS

ONLY] section in this manual for cleaning instructions.

6

START-UP AND OPERATION, CONTINUED

Light Switch

ON

3. Fluorescent Light Guidelines

 Turn lights on. All of the lights should come on at the

same time. First time lighting may require a short warm
up period for the bulbs. Slightly dim or a flickering of
new bulbs is normal. If lights do not turn on, check that
all of the light plugs are in.

Removal of lamps:

 Grasp lamp firmly and carefully pull downward and out

from socket.

 See photos at mid-right.

Installation of lamp:

 Align pins with slot.
 Insert pins into socket and push upward into place.
 See photos below.

Standard

Fluorescent

Light Fixtures

OFF

Rocker Switch

7

SECURITY

Anti-Theft Grid Installation (Optional Item only on Model SB5766)

 Position Anti-Theft Grid so that the locking rods extend down pointing towards the floor.

 Insert grid extensions into the forward air return louver.
 With “U” shackle released from the padlock base, insert the locking “U” of the padlocks through the sta-

tionary locking bracket.

 Rotate “U” shackle 90 degrees and pull up through grid; secure “U” shackle into padlock base.

Note: Due to possible design modification, actual Anti-Theft Grid construction and positioning may differ
than depicted below.

Anti-Theft

Grid Extensions

Anti-Theft

Grid

Return

Air Grille

8

MAINTENANCE AND OPERATION

1. Crumb Tray

 Located in back of case under ledge.
 Pull out to empty and clean. Replace

promptly.

 Note: Make sure drawer is pushed in tight to

maintain refrigeration efficiency.

2. Removing the Rear Doors

 Move the rear doors toward the center of the

case.

 Individually lift each door up into the upper

door frame track at the top of the case.

 Pivot the bottom of the door out.

 Slip out of the upper door frame track.

3. Installing Rear Doors

 Doors are not interchangeable, and must be

installed as labeled.

 Note: Doors are labeled in the lower

corners to identify their proximity to the
interior of the case (inner or outer door).

 Inner door must be installed first in the inner

door track.

 Insure that the door pull handle is to the

outside and to the left of the case.

 Insert the door into the upper inside track and

lower door onto the inside lower track.

 Move inner door to the left.
 Install the outer door with the door pull handle

to the right and the chrome door stop to the
inside lower right.

 Insert the door into the upper and outer track

and lower door onto the outer lower track.

4. Removing Interior Shelving

 Remove any product from the display area.
 Remove the ABS shelving.
 Turn off light switch prior to unplugging shelf

light.

 Unplug shelf light.
 Remove the complete shelf assembly

 Use even upward pressure to disengage

the shelf assembly support brackets from
the adjustment slots.

Crumb

Tray

Right Hand or Outer Door must

come out first and go back in last.

ABS Shelf

9

Shelf Light Assembly

MAINTENANCE AND OPERATION, CONTINUED

5. Removing and Replacing Toe-Kicks Panels

 Front and rear kicks be removed first and

installed last when performing maintenance.

6. Removing Front Toe-Kick

Remove the two screws located on the upper
front of the toe-kick at both ends.

7. Removing rear Toe-Kick

Remove four screws at both ends of the grille.

8. Removing Side Toe-Kicks

Note: Side toe kicks are captive by the rear kick
panel in the back of the unit.

 Remove screws to the rear toe-kick.
 Remove front kick panel.
 Remove screws at front of side toe-kicks.

Front Kick Panel

Side Kick Panel

Side Kick Panel

Screw Location

Front Kick Support

Screw Location

Side Kick

Panels

Rear Kick Panel
Support Screws

Front Kick Panel

10

MAINTENANCE AND OPERATION, CONTINUED

9. Service Area, Ambient / Refrigerated

 Note: Illustrations at right may not depict an

exact representation of every particular unit.

 Access is through rear doors.
 Lift air baffle straight up then rotate 90 degrees

so the arrows on the tag point down and tag is

Air Baffle

(slots down)

to the rear of the case. Lower the baffle, with slots
facing up, back down into the air channel.

 To close, reverse the procedure.
 Note: Removing the baffle facilitates cleaning

interior by providing easy removal of refuse to the
crumb tray.

Air Baffle

(Suspended)

Air Baffle

(slots up)

11

ELECTRICAL FUNDAMENTALS

1. Electrical: Access and Connections

Connections must be performed by a certified
electrician.

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

2. Electrical Leads

 Remove rear Toe-Kick panel.
 The electrical leads are located inside the 4 x

4 electrical box at the rear lower right hand
base of the case.

3. Light Ballast Access

 Remove 6 screws from rear wireway cover to

access electrical connections and ballasts.

4. Evaporator Fans Access

 Remove lower decking.

 A finger hole is provided to lift up and pull

out decking.

5. Removing Fan Assembly

 Unplug the fans.
 Remove screws from the fan supports.
 Remove fan assembly from the shroud

assembly.

6. Temperature & Defrost Control

 The case temperature Set Point is set at the

factory, as determined by the case size and
sensor probe location.
The temperature is controlled by a



thermostat.
If a temperature setting change is required,



follow the Programming Steps in the
Temperature Controller section of this
operating manual.
If service is required to the temperature



control unit, call Structural Concepts. This
maintenance should be performed by a
certified technician.

Rear

Wireway

Light Switch

Electrical

Leads

Temperature

Controller

Ballasts

12

Main Power Switch

Electrical

Leads