Master-Bilt DD-66, DD-26, DD-46, DD-88LCG Manual

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Page 1

11/22 Rev. G 57-02680

Installation and Operations Manual

For

R290

ICE CREAM DIPPING-DISPLAY MERCHANDISERS

DD-xx – Standard Models

DD-xxL – Low Glass Models

DD-xxLCG – Low Curved Glass Models

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11/22 Rev. G 57-02680

TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................................................ 3

STORE CONDITIONS ................................................................................................................................................ 3

WARNING LABELS AND SAFETY INSTRUCTIONS ............................................................................................... 4

PRE-INSTALLATION INSTRUCTIONS ..................................................................................................................... 5

Inspection for Shipping Damage ........................................................................................................................... 5

INSTALLATION INSTRUCTIONS ............................................................................................................................. 6

General Instructions ............................................................................................................................................... 6

Electrical ................................................................................................................................................................ 6

Mechanical ............................................................................................................................................................. 7

Startup ................................................................................................................................................................... 7

TEMPERATURE CONTROL .................................................................................................................................. 8-9

CLEANING INSTRUCTIONS ................................................................................................................................... 10

Can Holder Cleaning ........................................................................................................................................... 11

Frost Shield Cleaning .......................................................................................................................................... 11

Lid Locking Kit ..................................................................................................................................................... 12

OPERATION CONDITIONS AND PRESSURES ..................................................................................................... 13

SERVICE INSTRUCTIONS (Trouble Shooting Guide ........................................................................................... 13

CONTROLLER SENSER PROBE LOCATION ....................................................................................................... 14

AIR FILTER CLEANING INSTRUCTION ................................................................................................................. 15

DIPPING-DISPLAY CABINET PART NUMBERS ................................................................................................... 16

OPTIONS .................................................................................................................................................................. 17

SALE AND DISPOSAL ............................................................................................................................................ 17

WIRING DIAGRAMS ........................................................................................................................................... 18-20

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11/22 Rev. G 57-02680

INTRODUCTION

This manual contains important instructions for installing, using and servicing the Ice Cream Dipping-Display case. A part list is included in this manual. Read all these documents carefully before installing or servicing your equipment.

CAUTION This unit uses a flammable refrigerant. Use care when handling and operating to avoid damaging the refrigerant tubing or increasing the risk of a leak.

All service should be performed by factory authorized personnel. All component parts shall be replaced with like components to minimize the risk of possible ignition due to incorrect parts or improper service.

STORE CONDITIONS

The cases are designed to operate in the controlled environment of an air-conditioned store. The store temperature should be at or below 75°F and a relative humidity of 55% or less. At higher temperature or humidity conditions, the

performance of these cases may be affected and the capacity diminished. It is not uncommon in a newly constructed store for the temperature and humidity to be above design conditions. These excessive conditions may produce sweating in the case until the store is operational and the ambient environment is more desirable.

These cases should not be positioned where it is directly exposed to rays of sun or near a direct source of radiant heat or airflow. This will adversely affect the case and will result in poor performance.

NOTICE

Read this manual before installing your cabinet. Keep the manual and refer to it before doing any service on the equipment. Failure to do so could result in personal injury or damage to the cabinet.

DANGER

Improper or faulty hook-up of electrical components of the refrigeration units can result in severe injury or death.

NEVER use an extension cord to power this unit. 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 of the cabinet 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 have the serial number at hand and call or write us:

Refrigerated Solutions Group

891 County Road U Hudson, WI 54016 800-388-5253

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11/22 Rev. G 57-02680

WARNING LABELS AND SAFETY INSTRUCTIONS

This symbol is used to alert user that there is risk of fire or explosion since flammable refrigerant is

used. This symbol can be observed on back or sides of cabinet.

This symbol is the safety-alert symbol. When you see this symbol on your cabinet or in this manual, 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 cabinet is thoroughly familiar with all safety information and procedures.

Important safety information is presented in this section and throughout 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 cabinet 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 cabinet.

The warning and safety labels shown throughout this manual are placed on your cabinet at the factory. Follow all warning label instructions. If any warning or safety labels become lost or damaged, call your customer service department at 800-388-5253 for replacements.

This label is located on top of the electrical control This label is attached to the cabinet power cord

label and on the wiring channel. on models with a power cord.

CAUTION!

GROUND REQUIRED

FOR SAFE OPERATION

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11/22 Rev. G 57-02680

PRE-INSTALLATION INSTRUCTIONS

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 landing (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.

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11/22 Rev. G 57-02680

INSTALLATION INSTRUCTIONS

GENERAL INSTRUCTIONS

1. Be sure the equipment is properly installed by competent service people.

2. Keep the equipment clean and sanitary so it will meet your local sanitation codes.

3. Rotate your stock so that older stock does not accumulate. This is especially important for ice cream. A "First-In, First-Out" rotation practice will keep the products in good salable condition.

4. Do not place product in the case when it is soft or partially thawed. Also, product should not be put in the case for at least 6 hours after it is started.

5. Stock cases as quickly as possible, exposing only small quantities to store temperatures for short periods of time.

6. When replacing burned out LED, be sure that the electrical power to the lighting circuit is turned off.

NOTICE TO STORE OWNERS / MANAGERS

Moisture or liquid around or under the cabinet is a potential slip/fall hazard for persons walking by or working in the general area of the cabinet. Any cabinet malfunction or housekeeping problem that creates a slip/fall hazard around or under the cabinet should be corrected immediately.

If moisture or liquid is observed around or under a cabinet, an immediate investigation should be made by qualified personnel to determine the source of the moisture or liquid. The investigation should determine if the cabinet is malfunctioning or if there is a drainpipe leaking.

ELECTRICAL

WARNING

Before servicing electrical components in the case, make sure all power to case is off. Always use a qualified technician.

NOTICE

For replacement ballast, use only ballast that complies with UL and recommended in part list.

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11/22 Rev. G 57-02680

MECHANICAL

Remove grille and check refrigeration lines to see that they are free (not touching each other or compressor). Spin condenser fan blade to see that it is free.

Check that all service valves are open.The picture below is standard DD series condensing unit. The compressor is hermetic, it is internally spring mounted and ready to run.

Hermetic Compressors, Jelly Roll & fin and tube condenser

Remove cabinet from crate base and slide into location. Cabinet must be level from side to side and front to back.

To comply with Sanitation requirements the cabinet must be mounted on legs (6” high min.) or casters or the base must be sealed to the floor with an N.S.F. listed silicone sealant.

STARTUP

Uncoil the lead cord and pass it through the hole provided in the grille. While the cabinet is in operation, check the voltage draw and the amperage draw versus this rating on the nameplate. Voltage should be checked at the compressor terminals while the compressor is initially starting. The unit is designed to operate at +/- 10% of 115 volts, 60 cycle, single phase. This means that the voltage should be between 103 and 126.5 volts. After the cabinet has pulled down in temperature to approximately 0°F at load line, check the thermostatic control by turning it to its warmest position. This should shut the compressor off. A separate 20 amp. fuse circuit for each cabinet is recommended to avoid the possibility of other appliances on a circuit from overloading and causing a malfunction. Make sure that the electrical service is grounded upon installation.

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11/22 Rev. G 57-02680

TEMPERATURE CONTROL

The dipping-display cabinet has a temperature control that is adjustable from #1 (warmest setting) to # 9 (coldest setting). Turn the control knob in line with the punch mark to the desired setting. The temperature control is located near the condensing unit at the front of the cabinet.

Punch Mark

WARMEST SETTING

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11/22 Rev. G 57-02680

Punch Mark

COLDEST SETTING

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11/22 Rev. G 57-02680

CLEANING INSTRUCTIONS

WARNING: DO NOT REMOVE FROST WITH A KNIFE, PICK, OR SHARP OBJECTS. DO NOT USE ABRASIVE CLEANERS OR CAUSTIC CLEANERS OR SCOURING PADS

Every 30 to 60 days (depending on frost accumulation), the cabinet should be emptied, warmed up, and wiped down using a solution of 1 teaspoon of baking soda with 1 quart of water. This solution will help eliminate odors. Do not use strong soaps or detergents as they leave odors that can contaminate your product. Cabinets are equipped with a floor drain that exits out the lower rear. This exit has a convenient garden hose fitting.

If it is not convenient to turn the cabinet power off, lay a piece of plastic sheeting on the floor of the cabinet and scrape the frost off walls using a plastic scraper. Do not use metal scrapers. This will damage the interior paint of the cabinet.

Lid Removal and Cleaning

The lid can be removed by lifting up and out (see picture). The lid is a high-impact plastic. Wash with warm soapy water or non-abrasive detergent to avoid scratching.

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11/22 Rev. G 57-02680

Can Holder Assembly Removal And Cleaning (Optional)

Remove plastic can clamp by screwing knob off the threaded shaft. Wash the can holder and can clamp with a nonabrasive detergent to maintain sanitary gloss. Remove the shaft by loosening the wing nut and unscrewing the shaft from the shelf. Wash the shaft and shelf using a non-metallic brush.

Frost Shield Removal and Cleaning (optional)

When the frost-shields accumulate approximately ½ to 1 inch of frost (about two to three days), remove it by lifting up to disengage from the keyhole slot. Remove the frost by holding under running water until clean. Dry and replace the frost-shield by engaging screws at the big end of the keyhole and push down.

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11/22 Rev. G 57-02680

Lid Locking Kit Installation (Optional)

A simple and easy to install Lid locking kit option is avaialble to restrian from unwanted access to the ice cream stored inside the dipping cabinets.When the option is opted, please follow the below instruction to lock the lid. One kit is needed for each Lid to be locked.

* For disassemble of the Lid Locking Kit, please follow the process in reverse.

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11/22 Rev. G 57-02680

OPERATION CONDITIONS AND PRESSURES

With room ambient temperature of +75 oF and cold cabinet (unit cycling on control):

DD-66 & DD-88 with R-290

Suction pressure – 2 to 4 psig. Head pressure – 130 to 160 psig.

DD-26 & DD-46 with R-290

Suctions pressure 1 to 5 psig Head pressure 130 to 160 psig

SERVICE INSTRUCTIONS (Trouble Shooting Guide)

1. High head pressure and high back pressure: A. Condenser coil clogged or

restricted. B. Condenser fan motor defective. C. Air in the system. D. Refrigeration overcharge.

2. Low back pressure and low head pressure: A. Capillary tube restriction. B. Refrigerant undercharged. C. Leak in system. D. Moisture in system.

3. Pressures normal – cabinet warm: A. Refrigerant undercharged. B. Thermostat set too warm.

4. Compressor starts and runs – but cycles on overload: A. Low voltage. B. Overload protector defective. C. High head pressure (see#1).

5. Compressor will not start – hums, but cycles on overload: A. Low voltage. B. Relay defective. C. Overload defective. D. High head pressure (see #1).

6. Cabinet sweating: A. High ambient humidity.

7. Special service situations

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11/22 Rev. G 57-02680

CONTROLLER SENSOR PROBE LOCATION

In DD-46,DD-66 & DD-88 models, the bulbwell is a straight 3/8” copper tube placed 3” below the dog house as shown below. For the DD-26 model the bulb well is inverted “L” shape as as shown in the picture. Please make sure the bulb well opening is properly insulated with permagum. While replacing the sensor probe please make sure the probe is inserted to the end of the bulb well till it stops. Special care needs to be take during iserting the probe inside the bulb well so that it is will not be damaged. The sensor probe is color coded as shown below.

Make sure the probe is fully inserted into the bulb well till the mark up.

Bulbwell location with sensor probe

(representation only)

Sensor probe with bulbwell foamed

Bulbwell in DD-26

Bulbwell location in DD-46, DD-66

& DD-88

Red: DD-26 Green: DD-46 Yellow: DD-66 Blue: DD-88

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11/22 Rev. G 57-02680

AIR FILTER CLEANING INSTRUCTIONS (Air Filter for DD-66 & DD-88 Fin & Tube Condenser)

The condenser for DD-66 & DD-88 is a 5mm fin and tube condenser. A special removable and reuasable air filter has been provided to protect the condenser and avoid it to be blocked by dust. The filter needs to be removed and cleaned periodically for optimum performance of the unit. Find below the pictorial presentation of filter removal and reinstallation after cleaning.

Draining system

The drain outlet is as shown below in the picture.

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If moisture or liquid is observed around or under a cabinet, an immediate investigation should be made by qualified

Description

DD-26(L)(LCG)

DD-46(L)(LCG)

DD-66(L)(LCG)

DD-88(L)(LCG)

LED Driver

23-01878

LED

23-01947

23-01945

23-01947(2 REQ)

23-01950(2 REQ)

Jumper

23-01951

Bracket/Attachment

23-01948

Capillary Tube

11-01306

11-01306 (2 REQ)

Compressor

03-50992

03-50996

Condenser Coil

07-14190

07-14186

Condenser Fan Blade

15-13093

Condenser Fan Motor

13-00311

13-13453

Condenser Fan Motor Bracket

Compressor grommet

03-50994

Drier

09-09864

Controller

19-14239

Controller Sensor

19-14785

(37-01544)(37-

(37-01545)(37-

(37-01546)(37-

(37-01547)(37-

01536)

01537)

01538)

01539)

FRONT GLASS

(Straight Glass Model)

31-03991

31-03992

31-03993

31-03994

(Low Glass Model)

31-03976

31-03977

31-03978

31-03979

(Low Curved Glass)

31-04011

31-04012

31-04013

31-04014

SIDE GLASS

(Straight Glass Model)

31-03995

(Low Glass Model)

31-03480

(Low Curved Glass)

31-04015

Lid Assembly

A394-14500

A395-14500

A396-14500*

A397-14500*

Light Switch

19-14810

Shelf, Wire

33-01879

Recess Bumper

29-01691

Wire Harness (126” Power Cord)

Condenser Air Filter

44-01140

Distributor

11-02006

personnel to determine the source of moisture or liquid. The investigation made should determine if the cabinet is malfunctioning or if there is a simple housekeeping problem.

Moisture or liquid around or under a cabinet is a potential slip/fall hazard for persons walking by or working in the general area of the cabinet.

Any cabinet malfunction or housekeeping problem that creates a slip/fall hazard around or under a cabinet should be corrected immediately

DIPPING-DISPLAY CABINET PART NUMBERS

Please use the part numbers below when ordering replacement parts for your DD Series Standard, Low Glass and Low Curved Glass Models.

Top Gasket

*Two lid assemblies required for this model.

13-00754 13-00754

21-01741 21-01741 21-01741 21-01741

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OPTIONS

Description

DD-26(L/LCG)

DD-46(L/LCG)

DD-66(L/LCG)

DD-88(L/LCG)

Can Holders –

White Can Covers

Can Covers

White

44-01084

Lid Locking Kit

A390-11129

(2 QTY)

A390-11129

(2 QTY)

Casters

Set (4 or 6), 3” Dia.

A039-11140

A044-11140

Dipper Well w/Installation Kit

Frost Shields

A390-11150 (DD-26),

& DD-26LCG)

A391-11150 (DD-46),

DD-46LCG)

A392-11150 (DD-66),

& DD-66LCG)

A393-11150 (DD-88),

& DD-88LCG)

Legs

6” leg kit

A062-20225

(DD-26 only)

A062-20225

(DD-46 only)

A062-20225

(DD-66 only)

A062-20225

(DD-88 only)

Includes

Clear

(Patented)

Flavor Tags

A394-20301

44-00984

A060-20400 A060-20400 A060-20400 A060-20400

A394-11150 (DD-26L

A039-11170 A039-11170 A044-11140 A044-11140

A395-20301

44-00984

A395-11150 (DD-46L &

A396-20301

44-00984

A396-11150 (DD-66L

A397-11150 (DD-88L

SALE AND DISPOSAL

If you sell or give away your cabinet you must make sure that all safety labels and the Installation - Service Manual are included with it. If you need replacement labels or manuals, we will provide them free. Contact our customer service department at 800-388-5253.

The customer service department should be contacted at the time of sale or disposal of your cabinet so records may be kept of its new location.

If you sell or give away your cabinet and you evacuate the refrigerant charge before shipment, we recommend that the refrigerant charge should be properly recovered in compliance with section 608 of the Clean Air Act effective November 1995 and in accordance with all applicable local, regional, or national standards.

A397-20301

44-00984

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WIRING HARNESS WITH MOLDED JUNCTION ASSEMBLY

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LED CONNECTION

LIGHT WIRING FOR DD-66 & DD-88

LIGHT WIRING FOR DD-26 & DD-46

POWER CORD TO CONNECT CONDENSING UNIT

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MOLDED JUNCTION ASSEMBLY

FOR COMPRESSOR WIRING CONNECTION, PLEASE REFER TO THE COMPRESSOR MANUFACTURER WIRING DIAGRAM