Master-Bilt BCLZR10AC Installation Manual
Blood Plasma Freezer
With Master Controller
For Model BCLZR10AC
Installation & Operations Manual
An Electronic Microprocessor-Based
Electric Expansion Valve Refrigeration Control System
Featuring Reverse Cycle Defrost
IMPORTANT NOTICES
• Read this manual before installing your Master Controller system. Keep the
manual and refer to it before doing any service on the equipment. Failure to do
so may result in personal injury or waive warranty of damaged equipment.
• Modifications to existing equipment are subject to approval by Master-Bilt and
must be explicitly written. There are no implied flexibilities designed into this
product.
• The following points apply unless overwritten and approved by the Master-Bilt
engineering department:
o Maximum distance of wires between the evaporator and the Master
Controller MUST not exceed 40 FT.
o The Master Controller MUST be mounted in close proximity to the
vestibule entrance door.
o All control wiring (i.e. sensor wires, pressure transducer wires, and
Electronic Expansion Valve) must be in separate conduit from the power
supply. Blood Plasma Room Only.
• Due to continuous product enhancements, Master-Bilt reserves the right to
make engineering changes and change specifications for product
improvement without notice.
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INTRODUCTION ..................................................................................................................4
WARNING LABELS AND SAFETY INSTRUCT IONS ..........................................................5
APPLICATIONS....................................................................................................................5
MASTER CONTROLLER .....................................................................................................6
Description.................................................................................................................6
Factory-Mounted Parts...............................................................................................9
Features.....................................................................................................................9
Sequences of Operation..........................................................................................10
START UP.........................................................................................................10
OFF MODE ........................................................................................................10
COOL MODE......................................................................................................10
DEFROST MODE.................................................................................................11
Scheduled Defrost .....................................................................................11
Manual Defrost .........................................................................................11
COIL DRAIN MODE ..............................................................................................11
FAN DELAY MODE...............................................................................................12
SAFETY MODE...................................................................................................12
Definition of On-Board Symbols...............................................................................13
STATUS, DEFAULT AND READING DISPLAY...............................................................13
Typical Set Points for Blood Plasma Control Board.................................................14
Alarm Display...........................................................................................................15
Setting Parameters by On-Board Pushbuttons........................................................15
Temperature Sensors ..............................................................................................16
SENSOR SERVICE INSTRUCTIONS ........................................................................16
Pressure Transducer ..............................................................................................17
Charging the Master Controller Refrigeration System..............................................18
Technical Notes.......................................................................................................18
Electrical Wiring ................................................19
TYPICAL WIRING DIAGRAMS .................................................................................20
Line Sizing and Insulation…………………………………………………………………22
Start-Up Checklist………………………………………………………………………….22
REVERSE CYCLE DEFROST ...........................................................................................23
General Information .................................................................................................23
Advantages..............................................................................................................23
Factory-Installed Parts.............................................................................................23
Eliminated Parts.......................................................................................................24
Defrost Time ............................................................................................................24
Charging a Master Controller System Equipped with Reverse Cycle Defrost..........24
TROUBLESHOOTING GUIDE ...........................................................................................25
Troubleshooting Electric Expansion Valve
..............................................................26
MASTER-BILT PART NUMBERS.......................................................................................26
3
INTRODUCTION
Thank you for purchasing a Master-Bilt Master Controller electric expansion valve refrigeration system. This
manual contains important instructions for installing, using and servicing the system as well as a parts list.
Read this manual carefully before installing or servicing your equipment.
DANGER
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
Installation and service of the refrigeration and electrical components must be performed by a
refrigeration mechanic and/or a 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
write us:
Customer Service Department
Master-Bilt Products
Highway 15 North
New Albany, MS 38652
Phone: 800-684-8988
Fax: 800- 684-8988
Email: service@master-bilt.com
4
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
WARNING: Severe injury or death can
CAUTION: Minor injury or damage to your refrigeration system 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 system.
The warning and safety labels shown throughout this manual are placed on your Master-Bilt
refrigeration system at the factory. Follow all warning label instructions. If any warning or safety labels
become lost or damaged, call our customer service department at 800-684-8988 for replacements.
occur if you ignore the message.
occur if you ignore the message.
This label is located on the cover of a Master Controller.
APPLICATIONS
Master Controller electric expansion valve systems are designed to control Master-Bilt made condensing units
and evaporators for freezer and cooler applications. Each system contains a condensing unit, evaporator(s)
with Master Controller board(s), electric expansion valve(s), pressure transducers, temperature sensors and
operational controls.
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MASTER CONTROLLER
Description
The Master Controller is a custom-designed microprocessor-based electronic controller for Master-Bilt
refrigeration products to control an electric expansion valve in response to evaporator superheat and return air
temperature. The hardware and input/output descriptions and connections of a Master controller are shown
below on Figure 1.
Figure 1 . Master Controller
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• SEI or SER Terminals. Sporlan SEI and SER type electric expansion valves are curr ently used for all
applications. There are 1596 nominal steps for entire valve stroke.
• Off Mode Switch is a digital input ‘DI2’. Shorting of pins tells controller to shut everything off for 45
minutes. The defrost heaters, evaporator fans, and output to control the relay for the compressor are
turned off. The valve is also shut. An open between the pins of ‘DI2’ tells the controller to run in normal
operation. “FF” will appear on the two digeit LED display when the Off Mode is initiated.
• Suction Pressure Transducer is mounted at the evaporator suction header to measure saturated
suction pressure in absolute value but dis played in gauge pressure in PSIG. The suction pressure is
converted to evaporating temperature. The difference between outlet temperature and evaporating
temperature is the superheat displayed as “SH”.
• High Pressure Transducer is mounted on the condenser and used to monitor both high pressure
during cool mode and suction pressure during defrost.
• Defrost Termination Temperature Sensor TS1 is mounted downstream of the distributor tube after
the valve and close enough to the evaporator coil to m easure defrost term ination temperature during
defrost cylce. Figure 2 on the next page shows the sensor locations of the evaporator and the
controller.
• Outlet/Fan Cut-In T emperature Sensor TS2 is m ounted on the s uction line about 6” to 8” away from
the evaporator to m easure outlet temper ature during c ooling cycle and to serve as evaporator fan c utin temperature s ensor . The sensor is at a 2 or 10 o’cloc k position on the suction line. The default value
of the fan cut-in temper ature (FS or FDSP) is pre-set at -20
o
F for Blood Plasma Stor age Applications.
This value may be adjusted depending on respective situations.
• Room Temperature Sensor TS3 is mounted at the drain pan on the air intake side of the evaporator.
It is located around the center of the evaporator to allow even air f low across it. If nec essar y, it may be
relocated to a spot with better representation of the cold room temperature.
• Compressor Suction Temperatu re Sensor TS4 is mounted at the suction line just pr ior to entering
the compressor. It is used to measure compressor return gas superheat.
• Two Digit LED Display is used to show status of the controller, set point values and temperatures.
• Green and Red LED Status Indicators. W hen power is applied to the controller, the green LED will
be on constantly during normal operation. The red LED is the negative sign for tem peratures showing
less than 0
0 to 99
o
F on the two digit LED display. If the red LED is off, the two digit display reading is between
o
F. If it is on, the 2 digit display reading is between –55 to –1oF. A blinking red LED indicates an
alarm has occurred.
• Two Push Buttons are used to display set points and status as well as to reset operational
parameters like room temperature, defrost mode, number of defrosts per day, etc. Once an operational
parameter has been changed for a given setpoint, no confirmation inputs are required, the Master
Controller will recognized these changes immediately. Their f unctions can also be viewed/changed by
an optional remote display panel.
• Two 20 Amp, 240 VAC NC/NO Relays. Relay ‘K1’ is used for the drain pan heater when the heater
load is less than 20 am p. It will be wired to defrost heater contactor coil when heater load is over 20
amp or three phase heaters. Relay ‘K2’ is used to switch evaporator fans ON and OFF. A fan contactor
will be used if the fan motor is lager than 10 amps or three phase or the voltage is different from control
voltage.
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• One 5 Amp, 240 VAC NC/NO Relay is an option for an external alarm system. The customer will
decide what type of a physical alarm is used. This relay is energized when the controller is powered on.
Whenever the controller gives an alarm, the relay will be de-energized. For exam ple, a technician can
connect a phone alarm system to this relay. When there is an alarm, the alarm system can dial in his
pager or cellular phone.
• Panel Display Jack. When a rem ote display panel is used for a standalone Master Controller system,
this jack is used to connect the remote panel display with a communication cable supplied by the
factory.
• Power Input 24 VAC 40 VA. The Master Controller power input requirment is 24VAC. A factory
mounted 40VA step down transform er is pr ovided at the evaporator. Secondary voltage (24VAC) must
be connected to the control board by the refrigeration technician.
Defrost Term.
Room Temp
Sensor
Temp. Sensor
Liquid Line
Distributor
Electric
Expansion
Valve
Evap out / Fan Delay
Temp Sensor
Suction Line
Evaporator
Pressure
Transducer
MASTER CONTROLLER
Figure 2.
Optional Off
Mode Switch
Pressure
Transducer
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Factory-Mounted Parts
• The Electronic Expansion Valve (EEV), pressure transducer, and 2 ea. 40VA transformers will be
mounted at the factory. Three temperature sensors (TS1, TS2, and TS3) are mounted but not
connected to the Master Controller.The EEV, pressure transducer, and 24 VAC supply power must
also be connected once the controller is mounted.
This should be done by the refrigeration technician.
• An external relay (12VDC Coil) is mounted at the condensing unit. When in the cooling or defrost
mode, this relay will be energized. This relay will then energize the compressor contactor.
• All components are fac tory tested. A technician should c heck all the s ettings for pr oper operation after
installation.
Features
• Free floating head pressure saves energy. The Head pressure control is not installed on Master-Bilt
Master Controller systems. Without this control, compressors work at the highest efficiency at the
lowest possible condensing pressure rather than at the limited pressure level typically found in
conventional systems using a head pressure control valve for low ambient environments
• The electric expansion valve replaces a thermal expansion valve. The refrigerant flow of the electric
expansion valve is modulated by the true superheat, or the difference of evaporator outlet and
evaporating temperatures.
• The room temperature sensor replaces the conventional temperature control. The temperature is set
with the two pushbuttons on the Master Controller board. The default temperature must be checked
during the first startup of the machine against actual application temperature. Default must be re-set to
actual application temperature if there is a discrepancy. NOTE: This is an extremely low temp
application which requires staging the pull down upon the initial start-up. This Blood Plasma
refrigeration system should be set to -10º and be left alone for 24 hours. If the high alarm setpoint (HA)
has not been reset to accommodate this higher room temp setting, a High Temp Alarm will occur (HA).
This can be cleared easily by pressing PB1 on the control board three times consecutively.
After the initial pull down, the room temperature set point may then be taken down to -30ºF and left for
12 hours after which the box temperature may be taken to -45ºF. This staging helps prevent freezer
panels from delamination.
• The on-board timer is used for run time control and scheduling defrosts. No mechanical defrost timer is
necessary for this system. Number of defrost per day may be set on the Master Controller via the
number of defrost per day (nD) parameter.
• The operational status of modes, room temperature and alarms is displayed on the two-digit on-board
display.
• Manual defrost is available on both the Ante Room and the Blood Plasma Room. A manual defrost
may be accomplished by holding PB2 down for more than 5 seconds.
• The superheat set point has a wide 2° to 20
meet different customers’ needs, and requires less refrigerant charge for winter operation than
conventional refrigeration unit when no head pressure valve is installed in the condensing unit.
• The unique, patented reverse cycle defrost option (United States Patent 7,073,344) reduces defrost
energy usage by 80% and reduces defrost time from 20-45 minutes to 5-10 minutes with a completely
clean defrost.
• Maximum operating suction pressure can be controlled by the electric expansion valve eliminating the
crankcase pressure regulator for some applications.
• Minimum operating suction pressure provides additional compressor protection.
• The off mode switch turns off the evaporator fans during loading or unloading of refrigerated items.
If the off mode swith is left closed for 45 minutes, it will then go back into its normal operating mode.
o
F adjustability range. This range allows the controller to
.
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