Structural Concepts GP441RG.6122 User manual

Rev Z Date: 8.1.2016
> REFRIGERATED SELF-SERVICE SALAD/SANDWICH /BEVERAGE (GRAB-N-GO)
> REFRIGERATED SELF-SERVICE GRAB-N-GO FRONT SECTION WITH HEATED SERVICE PIZZA DISPLAY
I:\Oper Manuals\G-Series_Grab-N-Go_GPXXXR_RR_DRLB_RHLB_RRLB_20-00045.pub
888 E. Porter Road · Muskegon, MI 49441 Phone: [phone] Fax: [phone] www.structuralconcepts.com
INSTALLATION
AND OPERATING
MANUAL P/N 20-00045
G-SERIES
READ AND SAVE THESE INSTRUCTIONS
Note: See MODEL APPLICABILITY section in this manual for a
complete list of models represented by this operating manual.
Model GP540RRLB.5571B
Model CDR5745A
Model GP236DRLB (Front Panel
To Be Attached As Part of Lineup)
Model GP440RHLB.5574
Model GP340DRLB.5580
Model GP441RG.6122 With Upper
Display Refrigeration Unit

2
TABLE OF CONTENTS / MODELS INCLUDED IN MANUAL
TABLE OF CONTENTS / MODELS INCLUDED IN MANUAL ……………………….…..………………...
MODEL APPLICABILITY ….…………………………………………………………………………………….
OVERVIEW / TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS ….….……...
INSTALLATION: SKID REMOVAL / ALIGNING CASE / FRAME SUPPORT RAILS ………….………..
CASE START-UP / THERMOMETER FUNCTION & LOCATIONS .………………..……………………...
LED LIGHT REMOVAL/REPLACEMENT, PLUG/CORD POSITIONING, PROPER PLUG INSERTION
FLUORESCENT LIGHT REMOVAL/REPLACEMENT …………………………………......……………......
DECKING, EVAPORATOR COIL FAN DISCHARGE, TXV LOCATION ……………………………..........
THERMOMETER PROBE / DEFROST PROBE LOCATIONS - TOP SECTION
(MODEL GP440RHLB.5574 ONLY) …………………………………………………………………...
MODEL GP236DRLB (DRY TOP UNIT) - REAR PANEL / FIELD ACCESS / TEMP. CONTROLLER ..
MODEL GP236DRLB (DRY TOP UNIT) - LED LIGHTS / THERMOM. / HONEYCOMB / EVAP. COIL .
MODEL GP540RRLB.5571B (SIMILAR TO GP440RRLB.5571) - OVERVIEW OF CASE ..……………
MODEL GP540RRLB.5572C - OVERVIEW OF CASE ………………………..……………………….…….
MODEL CDR5745A (SERVICE CASE ONLY) - OVERVIEW OF CASE FRONT .…………………….….
MODEL GP440RHLB.5574 (REFRIGERATED SELF-SVC GRAB-N-GO FRONT / HEATED SERVICE
PIZZA DISPLAY) …………………………………………………………………………………………
MODEL GP441RG.6122 (REFRIGERATED SELF-SERVICE GRAB-N-GO FRONT WITH UPPER
SELF-CONTAINED DISPLAY REFRIGERATED UNIT ATOP MERCHANDISER) ...…………....
MODEL GP441RG.6122 UPPER DISPLAY REFRIGERATED UNIT POWER CORD ROUTE &
CONDENSATE LINE …………………………………………………………………………………….
OPTIONAL NIGHT AIR CURTAIN INSTALLATION & OPERATING INSTRUCTIONS (GP541RR
SHOWN / APPLICABLE TO GP441RR, GP641RR & GP841RR) ...…………………………..…..
CLEANING SCHEDULE (TO BE PERFORMED BY STORE PERSONNEL) …...……………….............
CLEANING SCHEDULE (TO BE PERFORMED BY STORE PERSONNEL): STAINLESS STEEL ......
PREVENTIVE MAINTENANCE (TO BE PERFORMED BY TRAINED SERVICE PROVIDER) ..……….
PREVENTIVE MAINTENANCE (TO BE PERFORMED BY SERVICE TECHNICIANS ONLY) ..............
TROUBLESHOOTING (TO BE PERFORMED BY STORE PERSONNEL) ……..…………….….……….
TROUBLESHOOTING (TO BE PERFORMED BY TRAINED SERVICE PROVIDERS) ..…………….….
SERIAL LABEL LOCATION & INFORMATION LISTED / TECH INFO & SERVICE ………………........
TECHNICAL SERVICE CONTACT INFORMATION & WARRANTY INFORMATION …………………..
2
3
4-5
6
7
8
9
10
11
12
13
14-17
18
19-23
24-26
27
28
29
30-32
33
34
35
36
37
38
39

3
MODEL APPLICABILITY
CDR5745
CDR5745A (Service Panini With Dome)
GP236DRLB & GP340DRLB.5580 (Dry Top/
Lower Base)
GP440RRLB.5571
GP440RHLB.5574
GP440RRLB.5572DD
GP441RG.6122 (4' Grab-N-Go Case With
Self-Contained Refrigeration Atop)
GP441RR
GP540RRLB.5571B
THIS OPERATING MANUAL IS APPLICABLE TO THE FOLLOWING MANUALS*
* Please Note: This manual may ALSO be utilized on models that ARE NOT listed on this sheet.
GP540RRLB.5572C
GP540RRLB.5572CC
GP541RR.5692
GP640DRLB.5580A (LB = Lower Base)
GP640RRLB.5572AA
GP840RRLB.5572BB (LB = Lower Base Units)
GP641RRLB.6807C
GP84055RLB.6676A
GP841RRLB.6806D
GP104055RRLB.6676C

4
OVERVIEW
 Front Case Main Display Area:These cases are
designed to merchandise pre-chilled packaged food
and beverage products at 41 °Fahrenheit / 5 °Celsius
or less product temperatures.
 Rear Drawers and Condiment Pans:These areas are
also designed to merchandise pre-chilled packaged
food and beverage products at 41 °Fahrenheit / 5 °
Celsius or less product temperatures.
 Models with temperature variations: Please note that
certain customer-specific models may designate a
38 °F / 3 °C or less product temperature. This would
be for BOTH front case main display area AND rear
drawers/condiment pans areas.
 Product must be pre-chilled to your unit’s required
temperature being placed in refrigerated area of case.
 For heated service display areas, product must be
pre-heated to at least 150 °F / 66 °C or higher prior to
being placed in unit.
 This remote 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.
 This multi-functional unit is designed to perform
quietly with easy operation.
 Merchandising capabilities meet the required
standards for maintaining proper refrigerated food
temperatures and sanitation.
TYPE 1 Units
This unit is designed for the display of products in ambient
store conditions where temperatures and humidity are
maintained within a specific range.
As this unit is manufactured for Type 1 conditions, ambient
conditions are to be at 55% maximum humidity and
maximum temperatures of 75 °F (24 °C).
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
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
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
ELECTRICAL
HAZARD
WARNING
KEEP
HANDS
CLEAR
COMPLIANCE
This equipment MUST be installed in compliance with
all applicable NEC, federal, state and local
electrical and plumbing codes.
OVERVIEW / TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS - PAGE 1 of 2
WARNING
Units With Heated Surface (Stone) Pizza Display Areas Are Hot!
Allow to cool before cleaning.
WARNING
HOT
SURFACE
ATTENTION
CONTRACTORS

5
OVERVIEW / TYPE / COMPLIANCE / WARNINGS / PRECAUTIONS / WIRING / PLUGS - PAGE 2 of 2
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! 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
CAUTION! LAMP REPLACEMENT GUIDELINES
LED lamps reflect specific size, shape, color, light output and overall
design. Any replacements must meet factory specifications.
Fluorescent lamps have been treated to resist breakage and
must be replaced with similarly treated lamps.
CAUTION
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.
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.
POWER CORD AND PLUG MAINTENANCE
 Caution! Risk of electric shock.
 If cord or plug becomes damaged, replace only with
cord and plug of same type.
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.
6”

6
INSTALLATION: SKID REMOVAL / ALIGNING CASE / FRAME SUPPORT RAILS
1. Remove Unit From Skid
 Caution! To prevent damage, support case
while sliding skid out from under case.
 Note: Illustration below reflects general outline of
sample case and does not reflect any particular
model or options).
Carefully Slide
Skid Out From
Under Unit
2. Position & Align Case Alongside Others
 Before adjusting levelers, make certain that the
case is in proper position and, if required, aligned
with adjoining case(s).
 This may require repositioning of the case you
are installing or the already positioned case.
3. Frame Support Rails
 Illustration below shows case with frame support
rails (sample case - may not exactly reflect your
particular model).
 Shims will be provided with all cases that have
frame support rails.
 Use shims to level case.
 Note: After case is in position, it must be
sealed to floor to prevent entry or leakage of
liquid or moisture.
Case
Front
Frame
Support Rails

7
CASE START-UP / THERMOMETER FUNCTION & LOCATION
1. Case Start-Up
 Case will energize when properly field-wired.
 Refrigeration system will supply cold air to rear
drawers, rear door compartment and front grab-n
-go section upon being energized.
 Front refrigerated section shown below. Light
switch (if any) will turn on light at front of case.
 When properly field-wired, coil fans should turn
on. From inside of the case, check for discharge
air from the air diffusing honeycomb to confirm
that fans are functioning properly. See next
page for honeycomb location.
Thermometer to
Refrigerated Front
Grab-N-Go Section
 When case is in start-up mode (or has been idle
for a long period of time), unit requires 75
minutes of run time to pull-down temperature.
2. Thermometer Function & Placement
 A. Thermometers may provides temperature to
separate areas in the case.
 B. Thermometers reflect warmest air
temperature in merchandiser. They do not
provide actual food temperature.
 C. Use probe thermometers to determine
actual product temperatures.

8
LED LIGHT REMOVAL/REPLACEMENT, PLUG/CORD POSITIONING, PROPER PLUG INSERTION
spring. Disconnect plug from LED’s socket.
 Contact Structural Concepts’ Technical Service
Department for replacement parts (see the
Technical Service section of operating manual
for information).
Replacement of LED light:
 To replace LED light fixture, simply insert new
LED light at proper position (socket must be
near plug). Carefully snap into metal springs
so LEDs are held firmly in place.
 Note: LED light and plug must be connected in
a specific manner or they will not work.
 Make certain oval edge of plug connects to
oval edge of LED light.
 See illustrations below.
1. LED Style Light Switch
 Light switch is usually at customer-left near LED
light.
 See illustration below.
2. LED Style Light Fixtures
Removal of faulty LED light:
 LED lights rarely require change-out.
 To remove faulty LED light, simply grasp light near
retaining spring and carefully pull away from its
Plug’s
Oval Form
LED’s
Oval Form
Lamp Retaining Springs (Typ.)
LED Light / Plug Fixture Light Switch

Note: Illustrations Shown May Not
Reflect Every Feature or Option of
Your Particular Case.
9
FLUORESCENT LIGHT REMOVAL/REPLACEMENT (FLUORESCENTS ONLY)
Fluorescent
Light
Installation of lamp:
 Align pins with slot.
 Insert pins into socket by rotating the bulb
1/4-turn to secure either the (upper or lower)
pinned contacts into the sockets.
 Rotate the remaining bulb contacts (1/4 turn)
into the remaining lamp mounting socket
contacts.
 See illustration below.
Light Fixture
Removal of lamp:
 Rotate lamp (1/4-turn) either direction to disengage
(upper or lower) pins/contacts from lamp mounting
sockets.
 Remove bulb by applying even pressure from the
back side at the bulb ends and pulling the
remaining contact from the sockets.
 See illustration at below-left.
Standard
Fluorescent
Light Fixtures

10
TXV Evaporator
Coils
Evap. Fan (Typ.) Evap. Fan Shroud
1. Coil Fan Discharge
When Main Power Switch is turned on, refrigeration
section will energize (see CASE START-UP section
in this manual).
 Evaporator coil fans should turn on. From inside
of the case, check for discharge air from fans to
confirm that they 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 of run time to pull-down
temperature.
 See below illustration.
2. TXV (Thermostatic Expansion Valve)
 TXV is under access panel (at customer front-
right of case).
 Decking must be removed for access.
 See illustration below for location.
 Note: Partially disassembled view below shown
for illustrative purposes only.
DECKING, EVAPORATOR COIL FAN DISCHARGE, TXV LOCATION
View of Case With Decking and End Panel
Removed for Illustrative Purposes Only
Note: Illustrations Shown May Not
Reflect Every Feature or Option of
Your Particular Case.

11
THERMOMETER PROBE / DEFROST PROBE LOCATIONS - TOP SECTION (MODEL GP440RHLB.5574)
1. Thermometer Probe Location - Front Section
View below reflects partially disassembled case
(for illustrative purposes only).
 Thermometer probes are positioned either
vertically or horizontally. See approximate
location in illustration below.
 Thermometer probe is to be attached by spacer
and screw assembly.
 Spacer allows probe to garner accurate
temperature readings and transmit to thermometer.
2. Thermometer Notes
 Note 1: Thermometers reflect warmest air
temperature in merchandiser. They do not
provide actual food temperature.
 Note 2: Use probe thermometers to determine
actual product temperatures.
Model GP440RHLB.5574
Thermometer
Probes
Probe Plate
Note: Illustrations Shown May Not
Reflect Every Feature or Option of
Your Particular Case.

12
MODEL GP236DRLB (DRY TOP UNIT) - REAR PANEL / FIELD ACCESS BOX / TEMP. CONTROLLER
Model GP236DRLB Rear Panel / Field Access /
Temperature Controller (Customer Provided)
Illustration below shows general layout.
 Rear storage area is open with no shelving.
 Rear panel may be removed without screws (slot
to hook configuration).
 Field access box components are viewable by
removal of cover (for illustrative purposes only).
 Dixell® controller is customer maintained. See
your store manager for operational specifics.
Fuse Block
Terminal
Blocks
Ballasts
Dixell® Controller
Transformer
Dixell® Display
View of Rear Panel
Attached To Case
Rear Panel
(Removable)
Field Access Box /
Electrical Box
Rear Storage
Area (Open)

13
MODEL GP236DRLB (DRY TOP UNIT) - LED LIGHTS / THERMOMETER / HONEYCOMB / EVAP. COIL
Model GP236DRLB LED Lights / Thermometer / Honeycomb / Evaporator Coil
Illustration below is shown with end panel and deck pan removed for illustrative purposes only.
 LED lights are at nose, shelf and upper section (behind honeycomb).
 Light switch is at upper left below thermometer.
 Thermometer reflects warmest air temperature in merchandiser. They do not reflect actual food
temperature. Use probe thermometers to determine actual product temperatures.
 See MAINTENANCE FUNDAMENTALS - HONEYCOMB AIR DIFFUSERS section in this operating
manual for honeycomb cleaning specifics.
 Evaporator coil layout is shown rotated for layout purposes.
LED Lights
Honeycomb Thermometer
Evaporator Coil Layout
(Rotated For Viewing Purposes Only)
LED
Light
LED Light / Honeycomb
(Rotated View)
Light
Switch

14
MODEL GP540RRLB.5571B (SIMILAR TO GP440RRLB.5571) - OVERVIEW OF CASE FRONT
1. Thermometer Probe Location - Front Section
View below shows location of probe plate.
 Probe is positioned behind protective plate.
 See approximate location in illustration below.
 Thermometer probe is attached by spacer and
screw assembly.
 Spacer allows probe to garner accurate
temperature readings and transmit to
thermometer.
Honeycomb
Air Diffuser
Rear Plenum
Lower
Refrigerated Section
Light Switch
2. Thermometer
 Thermometer is located at front-right (as shown in
illustration below)
 Note 1: Thermometers reflect warmest air
temperature in merchandiser. They do not
provide actual food temperature.
 Note 2: Use probe thermometers to determine
actual product temperatures.
Thermometer
Probe Plate
Thermometer

15
MODEL GP540RRLB.5571B (SIMILAR TO GP440RRLB.5571) - OVERVIEW OF CASE REAR
1. Scale Stand and Outlet
 Scale stand and outlet provides support and
electrical means for scale.
 Caution! Use only approved plug for outlet.
2. Rear Sliding Doors
 Rear sliding doors are removable for cleaning
and/or serving.
Rear
Toe-Kick
Rear Storage
Area
 Use care when removing from case to prevent glass
breakage.
3. Rear Storage Area
 Rear storage area may be used for storing store
supplies.
 See cleaning section in manual.
4. Rear Toe-Kick
 Rear toe-kick may be removed by lifting up and off.
 No screw removal is required.
Scale Stand &
Outlet Rear Sliding Doors

16
MODEL GP540RRLB.5571B - SHELVING / CRUMB TRAY / DECKING AIR RETURN / HONEYCOMB
1. Adjustable Shelving
 Upper shelving can be tipped downward either 5°
or 10° for display purposes.
 Lower shelving may either be tipped downward
OR raised or lowered (by simply removing and
placing in notches above or below.
2. Air Discharge/Crumb Tray
 Air discharge crumb tray can be lifted up and out
to empty crumbs and residue.
3. Decking/Air Return
 Decking/Air return must remain free from product.
 Do not place product on this area as it will prevent
proper airflow and prevent proper cooling of case.
4. Honeycomb Air Diffuser
 Honeycomb air diffuser can be removed for
cleaning and/or replacement.
 See MAINTENANCE FUNDAMENTALS -
HONEYCOMB AIR DIFFUSERS (SERVICE
TECHNICIANS ONLY) section in this manual.
Air Discharge /
Crumb Tray
Decking / Air
Return
Honeycomb
Air Diffuser
Air Return
Upper Section
Adjustable Shelving
Lower Section
Adjustable Shelving

17
MODEL GP540RRLB.5571B - LED LIGHTING LAYOUT / FRONT GLASS / EVAP. COIL/TXV/FANS, ETC.
1. LED Lights
 Model GP540RRLB.5571B has LED lights only
(no fluorescent lights).
 Lights may be removed for servicing and/or re-
placement.
 See LED LIGHT REMOVAL/REPLACEMENT,
PLUG/CORD POSITIONING, PROPER PLUG
INSERTION section in manual for specifics on
care and maintenance.
2. Front Glass
 Caution! Only authorized service personnel are to
access front glass!
 Front glass may be raised for cleaning or servicing.
3. Evaporator Coil, TXV (Thermostatic Expansion
Valve), Fans, Etc.
 Caution! Only authorized service personnel are to
access area under deck!
 Rotating fans can cause injury!
Upper Section
LED Lights
Lower Section
LED Lights
Lower Skirt
LED Light
Front Glass
(May Be Raised)
Evaporator Coil, TXV, Fans, Etc.
(Under Decking)

18
MODEL GP540RRLB.5572C - OVERVIEW OF CASE
Model GP540RRLB.5572C Overview of Case
View below shows general layout of:
 Glass upper sneeze guard (and its glass shelf)
 Thermometer for upper section. Note: Lower
section thermometer is located on rear plenum.
 Probe (positioned behind protective plate on
rear plenum).
Honeycomb
Air Diffuser
Glass Upper Sneeze
Guard With Shelf
Drain Route (From
Upper and Lower
Sections To
Floor Drain)
Light Switch
 Light switch (located at front-left, just below honey-
comb).
 Frame support rails.
 Field sensor box.
 208V solenoid access box.
 Floor drain (from both upper and lower sections).
 Electrical raceway.
 Refrigeration lines.
Thermometer
Field Sensor / 208V
Solenoid Access
Frame
Support Rails
Refrigeration
Lines
Electrical
Raceway
Electrical
Raceway

19
MODEL CDR5745A (SERVICE CASE ONLY) - OVERVIEW OF CASE FRONT
1. Front Glass
 Front glass may be raised for cleaning or
service.
 A lock and key prevent front glass from being
raised. Store key in safe place.
Decking
2. Shelf and Bracket is Adjustable
 As illustrated below, brackets can be adjusted (up
or down).
Shelf &
Bracket
Upper Section
Lock/Key
Front Glass
May Be Raised
Front
Toe-Kick

20
MODEL CDR5745A (SERVICE CASE ONLY) - OVERVIEW OF CASE REAR
1. Scale Stand and Outlet
 Scale stand and outlet provides support and
electrical means for scale.
 Caution! Use only approved plug for outlet.
2. Rear Sliding Doors
 Rear sliding doors are removable for cleaning
and/or serving.
 Use care when removing from case to prevent
glass breakage.
3. Rear Storage Area and Shelves
 Rear storage area and shelves may be used for
storing store supplies.
 See cleaning section in manual.
Rear
Toe-Kick
Rear Storage
Area & Shelves
4. Rear Toe-Kick
 Rear toe-kick may be removed by lifting up and off.
 No screw removal is required.
5. Thermometer Bracket
 Digital thermometer is attached to a suspended
bracket toward rear of case.
 Rear door may be opened (by sliding right-to-left) to
view thermometer’s temperature.
 See illustration below-right.
 Note 1: Thermometers reflect warmest air
temperature in merchandiser. They do not
provide actual food temperature.
 Note 2: Use probe thermometers to determine
actual product temperatures.
Scale Stand &
Outlet Rear Sliding
Doors Thermometer Bracket
& Thermometer