Walk-In Coolers and Freezers Installation & Operations Manual

Transcription

1 Walk-In Coolers and Freezers Installation & Operations Manual 908 Highway 15 North New Albany, MS Phone: (800) Fax: (800)

2 TABLE OF CONTENTS INTRODUCTION...3 WARNING LABELS AND SAFETY INSTRUCTIONS...4 PRE-ASSEMBLY PROCEDURES...7 Inspection...7 Handling and Set-Up Precautions...7 Panel Storage...8 ASSEMBLY INSTRUCTIONS...9 Cam Fasteners...9 Ceiling And Wall Clearances...10 Leveling the Floor...11 Flooring Installation...11 Wall and Ceiling Assembly...12 Door and Frame Installation...12 Caulking...13 SERVICING PROCEDURES...14 Adjusting Door and Replacing Hinges...14 Cooler Door Frame Heater Replacement...15 Freezer Door Heater Repair...15 CLEANING PROCEDURES...18 Freezer Cleaning...18 Cooler Cleaning...18 SALE AND DISPOSAL...19 PANEL AND DOOR DESIGNATIONS...20 Panel Designation Legend...20 Door & Frame Designation Legend...21

3 INTRODUCTION Thank you for purchasing a Master-Bilt walk-in cooler or freezer. This manual contains important instructions for installing, using, and servicing Master-Bilt walk-ins. A parts list and assembly drawings are also included with your walk-in. Read all of these documents carefully before installing or servicing your walk-in. NOTICE Read this manual before installing your walk-in. Keep the manual and refer to it before doing any service on the walk-in. Failure to do so could result in personal injury or damage to the walk-in. NOTICE Installation and service of the refrigeration and electrical components of the walk-in must be performed by a refrigeration mechanic or licensed electrician. The portions of this manual covering refrigeration and electrical components contain technical instructions intended only for persons qualified to perform refrigeration and electrical work. This manual cannot cover every installation, use or service situation. If you need additional information, call or us. Please have the serial number of equipment available. Technical Service Department Master-Bilt Products 908 Highway 15 North New Albany, MS Phone: Fax: service@master-bilt.com 3

4 WARNING LABELS AND SAFETY INSTRUCTIONS This is the safety-alert symbol. When you see this symbol on your walk-in or in this manual, be alert to the potential for personal injury or damage to your walk-in. Be sure you understand all safety messages and always follow recommended precautions and safe operating practices. NOTICE TO EMPLOYERS You must make sure that everyone who installs, uses or services your walk-in is thoroughly familiar with all safety information and procedures. Important safety information is presented in this section and throughout the manual. The following signal words are used in the warnings and safety messages. DANGER: Severe injury or death WILL occur if you ignore the message. WARNING: Severe injury or death CAN occur if you ignore the message. CAUTION: Minor injury or damage to your walk-in can occur if you ignore the message. NOTICE: This is important installation, operation or service information. If you ignore the message, you may damage your walk-in. The warning and safety labels shown throughout this manual are placed on your Master-Bilt walkin at the factory. Follow all warning label instructions. If any warning or safety labels become lost or damaged, call our technical service department at (800) for replacements.! DANGER HIGH VOLTAGE. TURN POWER OFF BEFORE SERVICING. MAY HAVE MORE THAN ONE DISCONNECT SWITCH. DANGER Improper or faulty hook-up of electrical components of the walk-in can result in severe injury or death.! PELIGRO VOLTAJE DE GRAN POTENCIA. CORTAR LA ELECTICIDAD ANTES DE REPARAR. ES POSIBLE QUE TENGA MAS DE UN INTERRUPTOR.! DANGER HAUTE TENSION. COUPEZ LE COURANT AVANT DE REPARER. IL PEUT Y AVOIR PLUSIEURS INTERRUPTEURS. Installation of the refrigeration and electrical components of the walk-in must be performed only by a refrigeration mechanic or licensed electrician. All electrical wiring hook-up must be done in accordance with all applicable local, regional, or national standards. This label is located near the light fixture on the inside of the door frame. 4

5 All Master-Bilt walk-ins with standard swing doors are equipped with inside emergency door releases so you cannot get locked inside the walk-in even if the door has been locked from the outside. If you have a standard-type swing door it will have one of the following types of emergency releases. 1. A Safeguard Inside Release Latch is installed on all walk-ins with a standard-type door wider than 42 inches. This latch release will allow persons inside the walk-in to open the door even if the outside door handle has been locked. To open the walk-in door from the inside, push the latch handle toward the door. 2. An Emergency Door Release is installed on all walk-ins with a door width of 42 inches or less. This Emergency Door Release will allow persons inside the walk-in to open the door even if the outside door handle has been locked. To open the walk-in door from the inside, turn the Emergency Door Release knob to the left (counterclockwise) until the door can be pushed open. IMPORTANT! THIS DOOR is equipped with a SAFEGUARD LATCH with INSIDE RELEASE HANDLE YOU CANNOT BE LOCKED IN... with either Padlocking or Cylinder-locking models. Inside handle will always operate to open the door even if the latch is locked from the outside. This label is located near the safety release handle on the interior of Master-Bilt swing doors wider than 42". (Some special order doors may differ.) IMPORTANT! EMERGENCY DOOR RELEASE TURN KNOB COUNTERCLOCKWISE TO UNLOCK This label is located near the safety release knob on the inside of doors 42" or less. (Some special order doors may differ.) NOTICE TO EMPLOYERS Never allow small children inside or around your walk-in. They can become trapped inside and be injured or killed. 5

6 NOTICE TO EMPLOYERS It is the owner's responsibility to make sure all employees understand the safety precautions for entering and walking inside the walk-in. The floor surface and door ramp on your walk-in may become slippery if they get wet, dirty, or greasy. To reduce the possibility of anyone slipping or falling inside the walk-in, Master-Bilt recommends the following: Persons entering and walking inside the walk-in should use caution at all times. Non-skid shoes should be worn. The floor surface and door ramp should be kept clean and dry at all times. A regular schedule for cleaning the floor and door ramp of the walk-in should be established and followed. The cleaning procedure outlined in this manual is recommended. Non-skid floor strips or mats should be used on the floor surface and door ramp. These strips or mats can be purchased from Master-Bilt or a local vendor. This label is located below the light switch on the exterior of all Master-Bilt swing doors. 6

7 PRE-ASSEMBLY PROCEDURES Inspection for Shipping Damage You are responsible for filing all freight claims with the delivering truck line. Inspect all cartons and crates for damage as soon as they arrive. If damage is noted to shipping crates or cartons or if a shortage is found, note this on the bill of lading (all copies) prior to signing. If damage is discovered when the cabinet is uncrated, immediately call the delivering truck line and follow up the call with a written report indicating concealed damage to your shipment. Ask for an immediate inspection of your concealed damage item. Crating material MUST be retained to show the inspector from the truck line. Handling and Set-Up Precautions It is the responsibility of the installer to use safe unloading, handling, and construction practices. If you have any questions about proper installation of panels or accessories, contact your local sales representative or Master-Bilt. NOTICE Use material handling procedures appropriate to the job you are doing. Failure to use proper loading or handling procedures or to follow manual instructions can cause bodily injury or damage to your walk-in. Forklifts used to handle skids or panels must have forks at least four feet long and set far enough apart to adequately support panels or skids (see Figure #1). Forklifts must have the capacity to support panels weighing two pounds per square foot each. Figure #1 7

8 Panel Storage When panels must be stored at the job site prior to set-up, it is very important that they be stacked properly. NOTICE The panels should be stored on a level area eliminating the risk of the panels falling and injuring someone. The panels being stored should not be stacked over 2 skids high. Whenever possible, store panels indoors. Panels stored indoors may be stored in their original factory packaging. If it is necessary to store panels outdoors, stack them vertically on skids, with spacers between the panels. This protects the panel edges and provides proper ventilation. This method of stacking permits drain-off of moisture and guards against rust stains (see Figure #2). Figure #2 Panels should be covered with a waterproof covering to protect them from the weather. Master-Bilt recommends black polyethylene sheeting, which keeps sunlight out and eliminates the "greenhouse" condition which occurs when clear plastic is used. In heavy traffic areas, it is advisable to place protective rails around stacks of panels to guard them from any possible damage. 8

9 ASSEMBLY INSTRUCTIONS Cam Fasteners NOTE: Position the panels so that when you are facing the interior of the panel the vertical latch access holes are on the left side of the panel. Before attempting to assemble the walk-in, you need to know how Master-Bilt cam-locks operate. On some panels you may not be able to position the cam-wrench exactly as shown below, but the locking procedure will be the same. Make sure all cam-lock locking arms are in the "open" position before attempting to lock panels together. Push panels together and turn cam-wrench 1/4 turn clockwise. This will engage the locking arm over the locking pin. Continue to turn cam-wrench for 1/2 turn or until panels are fastened together securely. NOTICE Do not over-tighten cam fasteners. When the rotation of the cam-wrench stops due to normal tightening, the fastener has gone as far as it should. Over-tightening will break the cam fastener and the panels will not latch properly. If locking arm fails to hook locking pin, turn cam-lock counter-clockwise 3/4 of a turn and repeat the procedure above. Figure #3 Figure #4 Figure #5 9

10 ASSEMBLY INSTRUCTIONS Ceiling And Wall Clearances Please keep the following points in mind when determining space requirements for your walk-in. When a ceiling mounted refrigeration system is used, the distance between the top of the walkin and the building ceiling should be at least the height of the condensing unit or housing plus an additional two inches to allow proper air circulation. For easier maintenance and service access, allow two feet from the top of the refrigeration system housing to the building ceiling. A minimum space of two inches must be allowed between the ceiling of the walk-in and the building ceiling to permit installation of the walk-in ceiling. A minimum of two inches should be allowed between walk-in walls and building walls. The extra space compensates for irregularities in building construction and provides an air space which increases the walk-in's operation efficiency. 10

11 Leveling the Floor NOTICE The surface where the walk-in is to be installed must be level. The existing surface must be level before the walk-in is installed. If it is not, leveling must be performed to insure proper installation. If shims are used, they should be rot-resistant wood, strips of galvanized metal, or other sturdy material which will not deteriorate due to weather conditions. Leveling Walk-ins with Floors If the existing surface is not level, the floor panels must be leveled either by using a leveling bed or by placing shims between the existing surface and the floor panels. Shims under floor panels must be on 18-inch centers or less, across both length and width of the panels, to provide adequate support for the walk-in and its contents. Shimming just the outer edges or corners will cause panels to break. Leveling Walk-ins without Floors Floorless walk-ins will be attached either directly to the existing floor or to screeds. Screeds are 4" high panels placed under the wall panels of a floorless walk-in to raise the wall height. If the existing surface is not level, shims MUST be placed under the screeds or wall panels every eight inches or less. The shims used must be 4 or 5 inches wide to match the thickness of the wall panels or screeds. Flooring Installation Walk-Ins with Floors Lay out all floor panels in sequence as shown on assembly drawings and make sure they are level. Fasten these panels as evenly as possible to each other to provide a square and level base for the wall panels. Tighten the cam fasteners all the way so that the panels are evenly aligned and fit snugly. Walk-Ins without Floors On floorless-type walk-ins you are provided with 1-1/2" x 1-1/2" floor angles with which to attach the bottom of all wall sections or screeds to the existing floor. Follow the leveling procedures previously described if the existing floor is not level. Attach the floor angles to the existing floor before the wall panels or screeds are installed. Make sure that the angles are fastened to the floor straight and square, and that they are spaced so that the wall panels or screeds can be placed on top of the angle flange attached to the floor. 11

12 Wall and Ceiling Assembly Usually, you should begin by assembling the front of the walk-in first. However, if the walk-in is to be installed inside an existing building or if space is restricted, assembly may be easier if you begin at the rear (opposite the door wall). NOTICE Position the panels so that when you are facing the interior of the panel the vertical latch access holes are on the left side of the panel. Lay out wall panels or screeds as shown in the assembly drawings. As wall panels are assembled, make sure that the cam fasteners are completely tightened and that the panels are straight. If the wall panels have a stair-step appearance at the top as they are being assembled, the floor is not level. In that case, stop immediately and follow the instructions under Leveling the Floor on the previous page. Assemble the wall panels of the front portion until you get to both corners. Then start to assemble ceiling sections to secure wall panels that are already in place. Each walk-in will vary slightly in the number of wall panels you can assemble prior to assembly of ceiling panels. On small walk-ins, all walls and corners can be assembled prior to the installation of the ceiling. On larger walk-ins, you must support the wall panels already in place as you go with ceiling panels. As ceiling panels are assembled, each one should be properly aligned to the adjoining ceiling and wall panels and locked into position securely. Door and Frame Installation After all the wall and ceiling panels are in place and aligned straight and square, you are ready to install the door and frame. Loosen the cam fasteners on the ceiling panel above the door frame and on the wall panels on each side of the door so that there is enough room for movement to set door frame in place. Place a carpenter's level against the door frame leg (inside door opening) to ensure that it is correctly aligned vertically, and latch the door frame to the adjoining wall panel. Place a carpenter's level against the face of the door frame to ensure correct vertical alignment and latch the door frame to the ceiling panel while holding level in place. Retighten the cam fasteners on the adjoining ceiling and wall panels. Attach the threshold plate. Adjust the bottom wiper gasket of the door so that it sweeps when the door is closed. Do not adjust the wiper gasket so far down that it prevents the door from closing properly. 12

13 Caulking Caulk where necessary with a high-grade caulking (see Figures #6, #7, #8 and #9) to help make the walk-in as airtight as possible. The type of caulking required may vary according to building code standards and other appropriate regulations. Use the correct type of caulking for your application. One 10 oz. tube of caulking is required for approximately every 60 square feet of panel surface. NOTICE On walk-ins located outside, the caulking of ceiling joints will not seal the ceiling against water penetration. A weather-protective roof must be installed on top of the insulated ceiling panels. Figure #6 Ceiling to Wall Caulking Detail Figure #7 Floor to Wall Caulking Detail Figure #8 Like Panel to Like Panel Caulking Detail Figure #9 Flat-bottom Wall Caulking Detail 13

14 SERVICING PROCEDURES Adjusting Door and Replacing Hinges Note: If adjustment is necessary, all Master-Bilt swing doors have adjustable back-up plates in the door for hinge adjustment (see Figure #11) Place shims under door (see Figure #10). If adjusting the door, loosen but do not remove the screws that attach the hinge blade to the door (see figure #11 for location of screws). If replacing hinges, remove the hinge blade screws. Shim under door as necessary to provide a 1/4" space between top of door and the door frame to ensure square fit (see Figure #10). Tighten or reinstall screws attaching the hinge blade to the door. After adjusting or replacing the hinges, remove shims and check the space at the top of the door periodically for proper alignment. Figure #10 14 Figure #11

15 Door Frame Heater Replacement WARNING To avoid electrical shock, disconnect main power supply to door of walk-in before beginning this procedure. While performing this procedure, refer to Figures #12 and #13 on the following pages. Remove threshold plate from door frame. Remove stainless steel raceways from around door opening. Put the raceways away from the walk-in to allow them to warm to room temperature. This will aid in tape adhesion described below. Disconnect the heater cable lead wires from the power supply inside the light switch J-box and discard heater cable. Feed new heater cable lead wires through the opening in the inner frame and secure grommet in the opening in the back of the light switch J-box. Do not connect heater to power supply at this time. Route heater cable along inside corner of raceway and secure with foil tape. Fasten raceways to door frame when heater cable is secured in place. Route heater cable along inside bed of sill plate, securing with foil tape as you go. Be careful not to "kink" the heater cable, which could result in improper operation and shortened life of heater. After routing cable through sill plate, position and fasten threshold plate into place. Fasten heater cable lead wires to power supply in light switch J-box and connect main power supply to door frame. Freezer Door Heater Repair (Optional E-Series Heavy-Duty Doors Only) WARNING To avoid electrical shock, disconnect main power supply to door of walk-in before beginning this procedure. Master-Bilt heavy-duty freezer doors are provided with two heater cables around exterior perimeter of door. One is a working heater and the other is a backup heater. If the first heater burns out, the backup heater should be connected as follows. 15

16 Remove door power cord from hole in upper corner of door (see Figure #12). Pull wire caps from inside door and locate two orange wires with taped ends. Remove wire caps from burned out heater cable and disconnect them from door power cord. Connect door power cord to new heater wires and snap power cord back in place. Reconnect main power supply to door frame. Figure #12 Optional Heavy-Duty Cooler/Freezer Door and Frame Heater Detail 16

17 Figure #13 Master-Bilt Infitting Door Wiring Diagram 17

18 CLEANING PROCEDURES CAUTION The floor surface of your walk-in cooler or freezer can become slippery and present a potential safety hazard if the surface is not kept cleaned and maintained. You should constantly monitor and inspect your walk-in to insure that proper maintenance and cleaning are being performed. Freezer Cleaning Move all items to one side of the freezer and sweep interior thoroughly with a broom. Replace stock properly. Repeat process on opposite side. CAUTION Do not use water for cleaning the inside of the freezer. The water will freeze and form ice on the floor which could cause someone to slip and fall. Cooler Cleaning Fill clean mop bucket with a sanitizing solution consisting of 1 part bleach and 32 parts water (4 oz. bleach to 1 gal. water). Spread solution on ceiling and walls with scrub brush, applying baking soda to the wall with the scrub brush as you clean. Rinse ceiling and wall thoroughly with clean, cold water. Spread remaining sanitizing solution on the floor, sprinkle baking soda and scrub with brush. Rinse floor of the cooler with clean, cold water. Wipe ceiling and walls with towels to avoid mildew and bacteria growth. Clean all water off the floor using a squeegee, directing the water to a drain outside the cooler. 18

19 SALE AND DISPOSAL If you sell or give away your Master-Bilt walk-in cooler or freezer, you must make sure that all safety labels and the Installation and Operations Manual are included with the walk-in. If you need replacement labels or manuals, contact the parts and technical service department at Master-Bilt at The parts and technical service department at Master-Bilt should be contacted at the time of sale or disposal of your walk-in so records may be kept of its new location. If you sell or give away your Master-Bilt walk-in cooler or freezer and evacuate the refrigerant charge before shipment, you must evacuate the refrigerant into an approved recovery and reclaim system in order to satisfy all applicable federal and state regulations regarding release of chlorofluorocarbons to the atmosphere. The release of chlorofluorocarbons to the atmosphere is a source of ozone depletion and regulated by federal and state law. 19

20 PANEL DESIGNATION LEGEND PANEL TYPE PANEL WIDTH (inches) PANEL STYLE PANEL HT./LTH. (inches) LINER FINISH CASING FINISH R 3 5 S G G PANEL TYPE VALUES C = CORNER F = FLOOR R = ROOF S = SCREED T = ROOF (CASING ACCESS) W = WALL METAL FINISH DESIGNATIONS A =.080" TEXTURED NATURAL ALUMINUM B = 24 GA. BROWN GALVANIZED STEEL C = 20 GA. 304 STAINLESS STEEL D =.040" SMOOTH NATURAL ALUMINUM E = 26 GA. STUCCO WHITE GALVANIZED F = 22 GA. GALVANIZED STEEL G = 24 GA. GALVANIZED STEEL H = 20 GA. GALVANIZED STEEL I =.040" STUCCO NATURAL ALUMINUM J =.032" STUCCO WHITE ALUMINUM K =.032" STUCCO ALUMINUM L = 24 GA. STUCCO GALVANIZED M = 24 GA. WHITE GALVANIZED STEEL P = 22 GA. PAINT-LOK STEEL Q =.063" SMOOTH ALUMINUM S = 22 GA. STUCCO STAINLESS STEEL T = 24 GA. TAN GALVANIZED STEEL U = 26 GA. STUCCO GALVANIZED V = 24 GA. SMOOTH GRAY GALVANIZED W =.032" SMOOTH WHITE ALUMINUM Y = 16 GA. 304 STAINLESS STEEL Z = 22 GA. 304 STAINLESS STEEL # = 16 GA. TEXTURED GALVANIZED $ = 16 GA. TEXTURED 304 STAINLESS STEEL * = SEE PARTS LIST / = STOCK BOX METAL PANEL STYLE VALUES (" " USED IF NO VALUE IS REQUIRED) (POS. #1) A = "A" SECTION B = "B" SECTION C = "C" SECTION D = DOOR HEADER E = END F = FLAT BOTTOM G = GLASS FRONT H = PARTITION HEADER I = PARTITION J = FLAT BOTTOM PARTITION K = FLOORLESS PARTITION L = FLOORLESS M = TOP OF STACK N = CENTER OF STACK P = FLAT BOTTOM RELIEF PORT Q = FLOORLESS RELIEF PORT R = RELIEF PORT S = STARTER T = TRANSITION U = UNIT V = FLAT BOTTOM UNIT W = FLOORLESS UNIT X = SEE WALK-IN PARTS LIST Y = SEE WALK-IN PARTS LIST Z = SEE WALK-IN PARTS LIST (POS. #2) A = "A" SECTION B = "B" SECTION C = "C" SECTION D = SINGLE NOTCHED "A" TRANSITION E = SINGLE NOTCHED "B" TRANSITION F = FLAT BOTTOM "A" G = FLAT BOTTOM "B" H = TOP OF STACK "A" I = TOP OF STACK "B" J = CENTER OF STACK "A" K = CENTER OF STACK "B" L = LINTEL M = FLOORLESS "A" (WALL TEE) N = FLOORLESS "B" (WALL TEE) P = DOUBLE NOTCHED "A" TRANSITION Q = DOUBLE NOTCHED "B" TRANSITION R = RELIEF PORT S = SILL T = FLAT BOTTOM SILL U = SEE WALK-IN PARTS LIST V = SEE WALK-IN PARTS LIST W = SEE WALK-IN PARTS LIST X = SEE WALK-IN PARTS LIST Y = SEE WALK-IN PARTS LIST Z = SEE WALK-IN PARTS LIST 20

21 DOOR AND FRAME DESIGNATION LEGEND PANEL TYPE E DOOR SIZE & FRAME WIDTH (inches) DOOR SWING TEMP. PANEL HT./LTH. (inches) LINER FINISH CASING FINISH 3 9 R C X X PANEL TYPE V = Standard V-Series door X = Inswinging V-Series door E = Heavy-duty door I = Inswinging heavy-duty door DOOR SIZE, STYLE, FRAME WIDTH & TYPE 34 = 34" x 76" FT or FL (46" Frame) 35 = 34" x 76" FB (46" Frame) 36 = 34" x 76" FT or FL (69" Frame) 37 = 34" x 76" FB (69" Frame) 38 = 36" x 76" FT or FL (46" Frame) 38 = 36" x 78" FT or FL (46" Frame, Type "E", "V" or "I") 39 = 36" x 76" FB (46" Frame) 39 = 36" x 78" FB (46" Frame, Type "E", "V" or "I") 40 = 36" x 76" FT or FL (69" Frame) 40 = 36" x 78" FT or FL (69" Frame, Type "E" or "I") 41 = 36" x 76" FB (69" Frame) 41 = 36" x 78" FB (69" Frame, Type "E" or "I") 42 = 42" x 76" FT or FL 42 = 42" x 78" FT or FL (Type "E" or "I") 43 = 42" x 76" FB 43 = 42" x 78" FB (Type "E" or "I") 48 = 48" x 76" FT or FL 48 = 48" x 78" FT or FL (Type "E" or "I") 49 = 48" x 76" FB 49 = 48" x 78" FB (Type "E" or "I") 50 = 48" x 84" FT or FL 51 = 48" x 84" FB 52 = 48" x 92" FT or FL 53 = 48" x 92" FB 54 = 54" x 76" FT or FL 54 = 54" x 78" FT or FL (Type "E" or "I") 55 = 54" x 76" FB 55 = 54" x 78" FB (Type "E" or "I") 56 = 54" x 84" FT or FL 57 = 54" x 84" FB 58 = 54" x 92" FT or FL 59 = 54" x 92" FB 60 = 60" x 76" FT or FL 60 = 60" x 78" FT or FL (Type "E" or "I") 61 = 60" x 76" FB 61 = 60" x 78" FB (Type "E" or "I") 62 = 60" x 84" FT or FL 63 = 60" x 84" FB 64 = 60" x 92" FT or FL 65 = 60" x 92" FB NOTES: Door Style "FT" = Floortype (Walk-In With Floor) Door Style "FL" = Floorless (Walk-In Less Floor) Door Style "FB" = Flat Bottom (Less Floor & Screed) All doors with openings more than 36" in width are provided in 69" wide frames. Right hinged doors have the hinges mounted on your right when facing the hardware side of the frame. Left hinged doors have the hinges mounted on your left when facing the hardware side of the frame. DOOR SWING R = Right L = Left TEMP C = Cooler F = Freezer LINER (inside) & CASING (outside) METAL FINISHES A =.080" TEXTURED ALUMINUM (Floor Liner Only) B = 24 GA. SMOOTH BROWN GALVANIZED STEEL C = 20 GA. #304 STAINLESS STEEL D =.040" SMOOTH NATURAL ALUMINUM E = 24 GA. STUCCO WHITE GALAVNIZED STEEL F = 22 GA. SMOOTH GALVANIZED STEEL G = 24 GA. SMOOTH GALVANIZED STEEL H = 20 GA. SMOOTH GALVANIZED STEEL I =.040" STUCCO NATURAL ALUMINUM J =.032" STUCCO WHITE ALUMINUM K =.032" STUCCO NATURAL ALUMINUM L = 24 GA. STUCCO GALVANIZED STEEL M = 24 GA. SMOOTH WHITE GALVANIZED STEEL N =.032" SMOOTH ANODIZED ALUMINUM P = 22 GA. PAINT-LOCK STEEL Q =.063" SMOOTH NATURAL ALUMINUM (Floor Liner Only) S = 22 GA. #304 STUCCO STAINLESS STEEL T = 24 GA. SMOOTH TAN GALVANIZED STEEL U = 26 GA. STUCCO GALVANIZED STEEL V = 24 GA. SMOOTH GRAY GALVANIZED STEEL W =.032" SMOOTH WHITE ALUMINUM X = 26 GA. STUCCO GALVALUME ALLOY Y = 16 GA. #304 STAINLESS STEEL (Floor Liner Only) Z = 22 GA. #304 STAINLESS STEEL # = 16 GA. TEXTURED GALVANIZED STEEL (Floor Liner Only) $ = 16 GA. #304 TEXTURED STAINLESS STEEL (Floor Liner Only) 21

22 Condensing Unit and Refrigeration System Installation & Operations Manual 908 Highway 15 North New Albany, MS Phone: Fax: _LN

23 TABLE OF CONTENTS INTRODUCTION...3 WARNING LABELS AND SAFETY INSTRUCTIONS...4 B-SERIES CONDENSING UNIT FEATURES...5 M-SERIES CONDENSING UNIT FEATURES...6 MASTER-BILT REFRIGERATION NOMENCLATURE...7 PRE-INSTALLATION...7 INSTRUCTIONS...8 General Information...8 Delivery Inspection...8 INSTALLATION INSTRUCTIONS...8 Handling and Placement of Condensing Unit...8 Handling and Placement of Evaporator Coil in Walk-In...9 Evaporator installation Instructions 9 Electrical...9 Refrigerant Piping...10 Leak Check...10 Evacuation, Dehydration and Start-Up...10 Evacuation Procedure...11 Finish Charging Procedures...11 Preliminary...11 Remote "M-Series" Built-Up Remote "B-Series" Condensing Units...12 Pre-Charged Remote Refrigeration Systems...12 Final Check List for All Models...14 R-404A SUCTION AND LIQUID LINE SIZES...15 EQUIVALENT LENGTH ALLOWANCE FOR FITTINGS...17 LOW AMBIENT OPERATION CHARGE...18 CONDENSING UNIT SPECIFICATIONS UNIT BASE SPECIFICATIONS SALE AND DISPOSAL...41 INSTALLATION DATA

24 INTRODUCTION Thank you for purchasing Master-Bilt refrigeration equipment. This manual contains important instructions for installation, use and service. Read all of this manual carefully before installing or servicing your Master-Bilt refrigeration equipment. NOTICE Installation and service of the refrigeration and electrical components must be performed by a refrigeration mechanic or licensed electrician. The portions of this manual covering refrigeration and electrical components contain technical instructions intended only for persons qualified to perform refrigeration and electrical work. DANGER Equipment MUST be properly grounded. Improper or faulty hook-up of electrical components of the refrigeration units can result in severe injury or death. All electrical wiring hook-ups must be done in accordance with all applicable local, regional or national standards. NOTICE Read this manual before installing your refrigeration. Keep the manual and refer to it before doing any service. Failure to do so could result in personal injury or equipment damage. This manual cannot cover every installation, use or service situation. If you need additional information, contact us at: Parts and Technical Service Department Master-Bilt Products 908 highway 15 North New Albany, MS Phone: Fax: service@master-bilt.com 3

25 WARNING LABELS AND SAFETY INSTRUCTIONS This is the safety-alert symbol. When you see this symbol, be alert to the potential for personal injury or damage to your equipment. Be sure you understand all safety messages and always follow recommended precautions and safe operating practices. NOTICE TO EMPLOYERS You must make sure that everyone who installs, uses or services your refrigeration is thoroughly familiar with all safety information and procedures. Important safety information is presented in this section and throughout the manual. The following signal words are used in the warnings and safety messages. DANGER: Severe injury or death WILL occur if you ignore the message. WARNING: Severe injury or death CAN occur if you ignore the message. CAUTION: Minor injury or damage to your refrigeration can occur if you ignore the message. NOTICE: This is important installation, operation or service information. If you ignore the message, you may damage your refrigeration. The warning and safety labels shown throughout this manual are placed on your Master-Bilt refrigeration at the factory. Follow all warning label instructions. If any warning or safety labels become lost or damaged, call our parts and technical service department at for replacements. This label is located on the condensing unit. 4

26 B-SERIES CONDENSING UNIT FEATURES STANDARD COMPONENTS The B-Series units offer the most complete set of standard features (pre-wired and mounted except as noted)* These include: Liquid line and suction line vibration absorbers (eliminators) for semi-hermetic units only. Adjustable dual pressure control Head pressure control (flooding valve) Corrosion-resistant hinged weather hood with lockable snap-down hood latch for easy installation and service access Suction line filter Heavy-duty 12 gauge galvanized steel legs Pre-wired electrical control panel with timer and circuit breaker or fuse block Crankcase heater Liquid line filter/drier Sight glass Liquid and suction line kit with service valve Liquid line solenoid valve (shipped loose) Timer Generously-sized condenser (for 105 to 110 ambient) Large liquid receiver (good for maximum 250 ft. line run) Defrost heater contactor when required Compressor contactor used in 1 1 /2 HP units and up PSC fan motors One year limited compressor warranty *Components may vary depending on horsepower and application. Consult our factory for verification of standard and optional components. OPTIONALLY AVAILABLE Water-cooled units Special voltages Oil separator Condensing units above 40 H.P. Insulated and heated receiver (thermostatically controlled) Suction accumulator (shipped loose) Coated condenser coils Phase loss/low voltage monitor Factory pre-assembled evaporator coil (includes factory pre-mounting of thermostatic air control and expansion valve) Pre-mounted solenoid at evaporator Extended four years limited compressor warranty Master Controller electronic control system Reverse cycle defrost 5

27 M-SERIES CONDENSING UNIT FEATURES STANDARD COMPONENTS The M-Series set of standard features (pre-wired and mounted except as noted)* include: Liquid line and suction line vibration absorbers (eliminators) for semi-hermetic units only Preset non-adjustable high pressure control and preset non-adjustable low pressure control** Crankcase heater Head pressure control (flooding valve) Heavy gauge, galvanized steel mechanically-fastened weather hood Suction service valve Heavy-duty angle leg base Liquid line filter/drier Pre-wired electrical control panel Sight glass Liquid and suction line kit with service valve Timer (standard on low temp units only) Compressor contactor Defrost heater contactor (when required) Generously-sized condenser (rated up to 120 ambient) Rifled tubes in condenser for greater efficiency Liquid line shut-off valve for easy change of filter PSC condenser fan motors Large liquid receiver (good for maximum 100 ft. line run) One year limited compressor warranty *Components may vary depending on horsepower and application. Consult our factory for verification of standard and optional components. **Preset high pressure control and preset low pressure control are non-adjustable in medium temp M-Series units. The low pressure control is adjustable in low temp units. OPTIONALLY AVAILABLE Special voltages Insulated and heated receiver (thermostatically controlled) Suction accumulator Coated condenser coils Oil separator Phase loss/low voltage monitor Factory pre-assembled evaporator coil (includes factory pre-mounting of thermostatic air control and expansion valve) Factory pre-charged system with quick connect liquid and suction line sets up to 40 ft. (specify length when ordering) Adjustable low pressure control for medium and high temp units Dual pressure control Circuit breaker Suction filter Fan cycling switch Pre-mounted solenoid at evaporator Liquid line solenoid valve (shipped loose) Timer for medium temp units Extended four years limited compressor warranty Master Controller electronic control system Reverse cycle defrost 6

28 MASTER-BILT REFRIGERATION NOMENCLATURE MODEL NUMBER EXPLANATION (CONVENTIONAL = ACCESSIBLE HERMETIC) BC = Built-up Remote Conventional Condensing Unit MH = Hermetic Condensing Unit BH = Built-up Remote Hermetic Condensing Unit MS = Scroll Condensing Unit BS = Built-up Remote Scroll Condensing Unit MD = Discus Condensing Unit MC = Conventional Condensing Unit ROOM TEMPERATURE EXPLANATION H = +35 Thru +70 F. Room Temperature M = +25 Thru +34 F. Room Temperature L = 0 F. Thru -20 F. Room Temperature HORSEPOWER RATING EXPLANATION (NOTE: APPLIES TO B-SERIES ONLY) 005 = ½ H.P. 017 = 1¾ H.P. 030 = 3 H.P. 075 = 7½ H.P. 150 = 15 H.P. 270 = 27 H.P. 007 = ¾ H.P. 020 = 2 H.P. 040 = 4 H.P. 090 = 9 H.P. 200 = 20 H.P. 300 = 30 H.P. 010 = 1 H.P. 025 = 2½ H.P. 050 = 5 H.P. 100 = 10 H.P. 220 = 22 H.P. 350 = 35 H.P. 015 = 1½ H.P. 028 = 3 H.P. 060 = 6 H.P. 120 = 12 H.P. 250 = 25 H.P. 400 = 40 H.P. BTU/HR RATING EXPLANATION (NOTE: APPLIES TO M-SERIES ONLY) Room temp H = Nominal BTUH +30 suction, 90 ambient (1000 multiplier) Room temp M = Nominal BTUH +20 suction, 90 ambient (1000 multiplier) Room temp L = Nominal BTUH suction, 90 ambient (1000 multiplier) EQUIPMENT VARIATION EXPLANATION 0 = Standard W = Water Cooled A = Plasma Units X = Special Applications D = Demand Cooling Y = Special Applications L = Large Condenser VOLTAGE EXPLANATION A = 115/60/1 F = /50/3 B = 230/60/1 or /60/1 (As Applicable) G = /50/3 C = /60/3 H = 208/60/1 D = 460/60/1 J = 380/50/1 E = 460/60/3 K = /50/1 or 220/50/1 OPTIONS EXPLANATION (NOTE: APPLIES TO B-SERIES ONLY) C = Coated Condenser Coil D = Coated Condenser Coil, Heated and Insulated Receiver L = Large Condenser 7

29 PRE-INSTALLATION INSTRUCTIONS I. General Information Please read this manual prior to installing your Master-Bilt equipment. This information is based on good refrigeration practice and should be used as a guide for installation and operation. To complete the installation, please records the data requested on the Installation Data form on page 35 of the manual and return this manual to the owner. II. Delivery Inspection You are responsible for filing all freight claims with the delivering truck line. Inspect all cartons and crates for damage as soon as they arrive. If damage is noted to shipping crates, cartons or if a shortage is found; note this on the bill of lading (all copies) prior to signing. If damage is discovered when the cabinet is uncrated, immediately call the delivering truck line and follow up the call with a written report indicating concealed damage to your shipment. Ask for an immediate inspection of your concealed damage item. Crating material MUST be retained to show the inspector from the truck line. INSTALLATION INSTRUCTIONS I. Handling and Placement of Condensing Unit To minimize damage to the unit housing, it is recommended that the crate not be removed until the unit is moved to its final location. The following should be considered when placing the unit: A. The condenser coil (air inlet) should not be located so as to restrict air flow into the coil. A minimum of 12" is required (18" is preferred) between the face of the coil and a wall or other vertical obstruction. B. A minimum of 6" is required on the sides to allow access to the housing clamps. C. A minimum of 24" is required on the louvered end ( air outlet) for clearance when opening housing and for ease of maintenance. D. Do not position multiple units so that the air discharge of one is into the condenser air intake of another. Holes are provided in the base supports for mounting bolts and for bridle lift rods. For indoor mounting, motor rooms should be provided with fans designed to move 1000 cfm of air per ton of refrigeration. 8

30 II. Handling and Placement of Evaporator Coil in Walk-In To minimize damage to the evaporator coil, it is recommended that the carton (or crate) not be removed until the evaporator coil is moved close to its final location. When the container is removed from the evaporator coil, extreme care must be used when lifting and mounting to the ceiling, to prevent sheet metal damage. EVAPORATOR INSTALLATION INSTRUCTIONS A. Do not install the evaporator too close to door openings to prevent icing problems. B. Minimum clearance between evaporator and the walls is equal to or greater than the coil height for proper air flow and service access. C. Refer to the evaporator coil drawing dimension for mounting holes location. D. Install washers and secure with nuts. Tighten until the coil is firm against the ceiling. The evaporator coil must be level. DANGER Installation of the refrigeration and electrical components must be performed only by a refrigeration mechanic or licensed electrician. Improper or faulty hook-up of electrical components can result in death. III. Electrical Electric power supply must match the condensing unit power requirements indicated on the unit data plate. A WIRING DIAGRAM IS LOCATED ON THE INSIDE OF THE ELECTRICAL BOX COVER. All field wiring may enter the holes provided in left side, back and bottom of the electrical box. All field wiring should be done in a professional manner, in accordance with all governing codes. Double check all wiring connections, including factory terminals, before start-up of condensing unit. 9

31 IV. Refrigerant Piping The condensing unit must remain sealed and pressurized from the manufacturer until piping is complete and final connections are ready to be made. Use only refrigeration grade copper tubing, (ACR), type "L", bright annealed, dehydrated, and properly sealed against contamination. Soft temper tubing may not be used for field interconnection of refrigeration components (condensing unit to evaporator assembly). Take extreme care to keep refrigeration tubing clean and dry prior to installation. Use an appropriate size tube cutter (DO NOT CUT TUBING WITH A SAW). Refrigerant lines must be sized as dictated by the charts on pages Suction lines should slope down 1/2 inch for each 10 feet of horizontal run towards the compressor. If any portion of the suction line rises above the exit elevation of the evaporator, P-type oil traps should be located at the base of each suction riser for proper oil return to the compressor. When brazing, dry nitrogen MUST be passed through the lines at low pressure to prevent scaling and oxidation inside the tubing and fittings. All flux must be removed from the joints after brazing. MINIMIZE the amount of flux used to prevent internal contamination of the refrigeration system. Silver brazing wire is to be utilized (high temperature alloy of 15% silver content on all copper to copper connections, and high temperature alloy of 45% silver content on all dissimilar metal connections). NOTICE Be sure solenoid valves are open before beginning evacuation and leak check. v. Leak Check When all refrigeration line connections have been made, the complete system, including factory connections, should be leak checked. Add the proper refrigerant to 60 psig, then boost to 175 psig with dry nitrogen. Leak check all joints with an electronic leak detector or a halide torch. If leaks are found, relieve the pressure and make repairs as necessary and recheck. VI. Evacuation, Dehydration and Start-Up A vacuum of 500 microns or less must be pulled to properly dehydrate the system. This requires a two-stage vacuum pump with an electronic vacuum indicator. DO NOT USE THE SYSTEM COMPRESSOR AS A VACUUM PUMP. DO NOT OPERATE COMPRESSOR WHILE SYSTEM IS IN A VACUUM. 10

32 EVACUATION PROCEDURE A. Open all condensing unit service valves and relieve system pressure. Also, open any line valves installed in the system and energize all solenoid valves to facilitate evacuation. B. Connect the vacuum pump to the high and low sides of the system using 1/4" or larger cop per lines or 1/4" ID hoses with high vacuum designation. C. Leaks or moisture will be indicated if the system pressure rises when the vacuum line is closed off. D. Pull a vacuum of 1500 microns, close vacuum line and break vacuum to 3 psig, maximum, with refrigerant to be used in the system. E. Repeat step D. F. A final vacuum of 250 microns should be pulled before charging. When 250 microns is reached, close vacuum line and charge through high side, with proper refrigerant to the level of 2-1/2 lbs. per ton of refrigeration. FINISH CHARGING PROCEDURES A. Preliminary 1. Be sure all service valves are open. 2. Loose the compressor hold-down bolts and remove shipping clips to allow compressor to float freely on the springs. 3. Check evaporator fan motors after start-up. Medium temperature, air defrosts fans run continuously. Low temperature fans and coolers provided with electric defrost will be delayed by the fan control. 4. Start the system by flipping on the circuit breaker in the unit electric box. 5. Start charging per (B), (C), (D) or (E) on the following pages. CAUTION: Never add liquid refrigerant to the suction side of the compressor. 6. Check operating pressures while charging and on initial pull down to prevent damage if a problem occurs. If system floods back to the compressor, adjust the thermostatic expansion valve as required for proper operation. There should be at least +30 F superheat entering the compressor. 7. Observe compressor amperage draw and compare to compressor nameplate to prevent damage due to high amperage. The oil sight glass should be between 1/2 and 3/4 full during normal operation 11

33 B. Remote "M-Series" Condensing Units 1. For models without head pressure control valve: With the system operating, add refrigerant until the sight glass indicates a full charge, then add one pound for each 2 rated horsepower of the condensing unit when charging above +75 F. If ambient is below +75 F, add 1/2 to the above. 2. For models with head pressure control valve: Add additional charge per the procedure. C. Built-Up Remote "B-Series" Condensing Units These units are equipped with a head pressure control valve for low ambient operation. This valve will flood the condenser when ambient temperatures are low, requiring additional refrigerant to provide correct operation under various ambient conditions. See attached Charts B and C (pages 19 and 20) for the additional charge data, and finish charging as follows. 1. Add the proper refrigerant for a full sight glass. 2. Add additional charge per the procedure on page 19. DANGER Charging of the refrigeration system must be performed only by a certified refrigeration mechanic. Improper or faulty hook-up of refrigeration electrical components can result in injury or death. Technical installation instructions for Pre-Charged Remote Refrigeration are given on the following pages. Installation requirements for other remote refrigeration systems may vary. If additional information is needed, your certified refrigeration mechanic or electrician can call Master-Bilt at Quick-Couples are pre-charged with the proper refrigerant at the factory. D. Pre-Charged Remote Refrigeration Systems. Place a steel or treated-wood spreader on the top of the walk-in to distribute the load of the coil. The spreader must be at least twice the width of the coil. The coil must be mounted away from the edge of the roof a distance equal to the height of the coil (See Figure #1). Uncrate the coil and through-bolt it to the ceiling of the walkin with suitable fasteners. 12 Figure #1 Quick-Couple Remote Refrigeration Uncrate the condensing unit and locate near coil. Be sure air movement around the unit is not restricted so the condensing unit will have a sufficient supply of air to function properly. NOTE: Install evaporator coil in accordance with the manufacturer's recommendations from inside wall or obstructions to rear of evaporator.

34 Drill holes through the walk-in wall large enough to pass refrigeration lines, electrical line and drain line. Connect liquid and suction lines to the coil and the condensing unit. Lubricate rubber seal in male half of coupling with refrigeration oil. Thread coupling halves together by hand to ensure proper mating of threads. Tighten with wrenches until coupling bodies bottom or a definite resistance is felt (See Figure #2.) Figure #2 Quick-Couple Coupling Detail Using a scribe or ink pen, mark a line lengthwise from the coupling hex to the bulkhead. Then tighten an additional 1/6 to 1/4 turn. The misalignment of the mark will show the degree of tightening for future reference. This final turn is necessary to ensure that the knife edge metal seal bites into the brass seat of the coupling halves, forming a leak-proof joint. When routing refrigeration lines, special care should be taken not to kink the lines and restrict the flow of refrigerant. NOTE: Wiring diagrams are located inside the pre-wired electrical panel on the condensing unit. CAUTION Be sure the electrical supply is sufficient for all electrical loads of the quick-couple Remote Refrigeration system. Connect correctly rated over current protection device in the service line to the service line J- box on the condensing unit. After routing condensate line from drain pan of evaporator coil, seal around all refrigeration, electrical and drain lines with silicone or butyl caulking. Start compressor and allow to run at least 24 hours before placing product into the walk-in. During the testing period you should: Check the temperature holding range against the control setting. On low temperature units, check the defrost control system to see that all ice is removed from the coil during each defrosts cycle. Perform checks of door operation and all other component operations. These particular systems are pre-charged at the factory with proper refrigerant, but should be operationally checked as per page 11, A.6 and A.7. 13

35 VII. Final Check List for All Models A. Check high-low pressure control settings. B. Check setting of defrost timer: 1. Medium temperature 2 to 4 defrosts/24 hours, with 35 minutes fail safe. 2. Low temperature 3 to 4 defrosts/24 hours, with 44 minutes fail safe. C. Check operating pressure. D. Check electrical requirements of unit to power supply voltage. E. Set temperature control for desired temperature range. F. Check setting of thermostatic expansion valve for proper operation. G. Check sight glass for proper refrigerant charge. H. Check compressor oil level. I. Check system for proper defrost settings and operation. J. Check condensing unit for vibrating or rubbing tubing. Dampen or clamp as required. K. Open all valves completely counter clockwise. L. Check packing nuts on all service valves. M. Replace all service valve caps and latch unit covers. 14

36 NOTE: Sizes specified are for Type "L" copper tubing.

37 NOTE: Sizes specified are for Type "L" copper tubing. 16

38 EQUIVALENT LENGTH ALLOWANCE FOR FITTINGS EQUIVALENT LENGTH IN FEET FITTING Tee Tee SIZE Ell Ell (Line) (Branch) Chart A 1/2" /8" /8" /8" /8" /8" /8" GENERAL: 1. Suction lines should be pitched down in direction of flow, 1/2" per 10 feet of line. 2. Refrigerant lines should be supported and fastened properly to prevent leaks and for professional looking installation. Supports should be every 5 feet for lines to 7/8" OD, 7 feet for 1-1/8" to 1-3/8" OD lines, and 10 feet for 1-5/8" and 2-1/8" OD lines. 3. Where condensation dripping would be objectionable, insulate suction lines, and where the sun could adversely affect performance, insulate both the liquid and suction lines. Insulation thickness of 1/2" will usually be adequate. 4. A P trap must be installed at the bottom of the riser in all vertical suction lines rising 4" or more. To insure proper oil return to the condensing unit, the trap should be the same size as the horizontal line and the riser should be sized per the line sizing charts on pages In installations where condensate can accumulate on the vibrasorber, a covering of heat shrink PVC tubing or waterproof tape may be used to prevent freezing under the ferrule, causing a rupture.