Master-Bilt MCR-33-102PT Installation Manual

Blast Chiller

Installation & Operation Instructions

MCR/MCF – 33101

MCR/MCF – 33102

MCR/MCF – 33101PT

MCR/MCF – 33102PT

Master-Bilt Products

908 Highway 15 North

New Albany, MS 38652

Phone: (800) 684-8988

Printed in U.S.A.

5/16 Rev. A 57-02064

TABLE OF CONTENTS

INTRODUCTION…………………………………………………………………………………….4 ABOUT THIS MANUAL…………………………………………………………………………….5 WARNING LABELS AND SAFETY INSTRUCTIONS……………………………………………6

UNDERSTAND SIGNAL WORDS AVOID HIGH VOLTAGE ELECTRICAL SHOCK……………………………………………………………. PREPARE FOR EMERGENCIES FOLLOW SAFETY INSTRUCTIONS………………………………………………………………………….. ELECTRICAL CONNECTIONS………………………………………………………………………………...

………………………………………………………………...6

………………………………………………………………….7

8 INSTALLATION……………………………………………………………………………………..9 PACKING LIST……………………………………………………………………………………..10 VAN SHIPMENT……………………………………………………………………………………11 FREIGHT CLAIMS…………………………………………………………………………………12 PRE-ASSEMBLY PROCEDURES…………………………………………………………………13

HANDLING AND SET-UP PRCAUTIONS…………………………………………………………………... STORAGE………………………………………………………………………………………………………

13 SITE CHECKLIST…………………………………………………………………………………..14 BLAST CHILLER BOX INSTALLATION………………………………………………………...15

WALK-INS WITHOUT FLOORS……………………………………………………………………………... WALK-INS WITH FLOORS PAN…………………………………………………………………………….. WALK-INS WITH FLOORS…………………………………………………………………………………... INSTALL INSULATED WALL PANELS…………………………………………………………………

15 16 17

17-18

INSTALL EVAPORATOR AND FAN ASSEMBLYS………………………………………....19-20

INSTALL CEILING PANELS………………………………………………………………………21 INSTALLATION OF DOOR PANEL…………………………………………………………...22-23 INSTALL INTERIOR TRIM………………………………………………………………………..23 INSTALL EXTERIOR TRIMS……………………………………………………………………...26 MOUNT CONTROL PANEL……………………………………………………………………….23 ROUTE TEMPERATURE SENSOR & MOUNT CONTROL PANEL……………………………24 CONTROL WIRING………………………………………………………………………………...25 CHECK DRAIN FOR LEAKS………………………………………………………………………27 CHECK DOOR SWING……………………………………………………………………………..27 DELIVERY INSPECTION………………………………………………………………………….28 INSTALLATION DATA……………………………………………………………………………28 BLAST CHILLER CONTROL OPERATION & PROGRAMING……………………………..29-51 FOOD AND PANS INTRUCTIONS………………………………………………………………..52 BLAST CHILLER CHILLING RATES…………………………………………………………….53 START UP & OPERATION CHECK………………………………………………………………54

PERFORM THE FINAL CHECKLIST

…………………………………………………………….54 CLEANING………………………………………………………………………………………….55 FINAL INSTALLATION DATA SHEETS……………………………………………………...56-58 WIRING DIAGRAM………………………………………………………………………………...59

Blast Chiller installation or operation. Failure to

INTRODUCTION

THANK YOU for purchasing a Master-Bilt® Blast Chiller. The Master-Bilt® Blast Chiller is designed for accurate and rapid field assembly.

NOTICE Read this manual carefully before you begin

do so could result in personal injury or damage to your Blast Chiller.

NOTICE This manual is a necessary and permanent part of your Blast Chiller. Always keep this manual accessible for installation and operation procedures.

This manual cannot cover every installation, use or operation situation. If you need additional information, call or write our customer service department for assistance.

MASTER-BILT Products 908 Highway 15 North New Albany, MS 38652 Phone: 1-800-684-8988

If this manual or any of the warning labels on your Master-Bilt destroyed, contact Master-Bilt to replace them.

Locate the serial number plate on the Blast Chiller. Write the 10-digit serial number below. Your

Master-Bilt dealer needs this number when you order parts.

Serial Number ________________________

Blast Chiller are marred or

ABOUT THIS MANUAL

Please read this entire installation manual before you install your Master-Bilt Chiller. It provides information on installation and operation of the Blast Chiller. It is very important that you complete each step of installation in the order that the steps appear in the installation sections of this manual. Otherwise, you may find yourself unnecessarily disassembling and re-assembling parts.

The information and graphics in this manual are common to installation of all Master-

Blast Chillers. A customized print is provided specific to your order. Your print

Bilt

provides information specific to your design and installation. This manual indicates when you should refer to your site-specific drawings.

BLAST CHILLER MODELS

-All Blast Chiller electrical connections should be made per the wiring diagrams found in this manual for the electrical box and control panel.

-All Blast Chiller refrigeration connections should be made per the attached refrigeration diagrams and charts found in this manual according to the correct model. Refer to the correct air or water-cooled schematic per the condensing unit markings and labels.

-All Blast Chillers accept the same size rack.

Blast

WARNING LABELS AND SAFETY INSTRUCTIONS

RECOGNIZE SAFETY INFORMATION

This is the safety alert symbol. When you see this symbol on your equipment or in this manual be alert to the potential for personal injury or damage

to your Master-Bilt

Be sure you understand all safety messages and always follow recommended precautions and safe operating practices.

UNDERSTAND SIGNAL WORDS

Important safety information is presented in this section and throughout the manual. These signal words are used in the warnings and safety messages.

Blast Chiller.

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 Master-Bilt Blast Chiller can occur if you ignore the message. CAUTION also calls attention to

NOTICE This is important installation, operation, or maintenance information that you should pay special attention to. If you ignore this information, you may damage your Master-

Bilt® Blast Chiller.

Never allow small children inside or around your

blast chiller. They can become trapped inside and

be injured or killed.

AVOID INJURY FROM HIGH VOLTAGE ELECTRICAL SHOCK

Disconnect power before cleaning or servicing the Blast Chiller. Do not spray with water or steam. Use a damp cloth to remove dirt.

Be sure Blast Chiller is grounded. Check ground connection. Do not use if unit is not grounded.

PREPARE FOR EMERGENCIES

Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone.

WARNING TO EMPLOYERS

and/or licensed electrician.

e all persons around this equipment know

FOLLOW SAFETY INSTRUCTIONS

Carefully read all safety messages in this manual and safety signs on your equipment. Keep safety signs in good condition. Replace any missing or damaged safety signs.

Learn how to operate the equipment and how to use controls properly. Do not let anyone operate without instruction and proper training.

NOTICE TO EMPLOYERS

It is the employers’ responsibility to make sur where the inside latch is and how it works.

Keep your equipment in proper working condition. Unauthorized modifications to the equipment may impair the functions and/or safety and reduce equipment life.

OBSERVE SAFETY SIGNS

Your Master-Bilt the blast chiller box, fan, controls, etc., and an electrical supply for the condensing unit.

ELECTRICAL CONNECTIONS

The wiring will be performed by a qualified and certified electrician.

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

Installation of the refrigeration and electrical components of the walk-in must be performed only by a refrigeration mechanic or licensed electrician.

Blast Chiller requires two electrical supplies: an electrical supply for

NOTICE Electrical connections must be done in accordance with all applicable local, regional, or national standards as well as the National Electrical Code.

NOTICE

Installation and service of blast chiller must be preformed by licensed refrigeration mechanic

INSTALLATION

PRE-INSTALLATION

Read and comply with the following information:

-Packing List

-Van Shipment (if applicable)

-Freight Claims

-Site Checklist

INSTALLATION

Special equipment needed for installation includes:

-Fork lift or hoist

Your envelope contains:

-Your Master-Bilt® Blast Chiller Installation and Operations Manual

-Customized drawings and diagrams for your specific order: Installation diagram Panel numbering diagram Wiring diagram*

*2 identical wiring diagrams are provided: One is included in the envelope for use at the installation site. One is a permanent part of your manual.

NOTICE

Master-Bilt recommends you practice safe

lifting and safe moving techniques.

AFTER INSTALLATION

Complete the Installation Data on pages 44 to 46. Retain one copy. Return one copy to Master-Bilt. Leave one copy at the installation site.

PACKING LIST

Assure that all components on this packing list are included when unit arrives:

Quantity Description

______ Insulated Wall Panels

______ Insulated Ceiling Panels Assembly

______ Control Box

______ Top Trim Panels

______ Top Trim Panel Mounting Strips

______ Evaporator Coil Assembly

______ Evaporator Fan Assembly

______ Interior Top Trim Panels

______ Interior Side Trim Panels

______ Optional Stainless Steel Floor Pan

______ Box of Hardware: Screws, Bolts, Light Globe, Wall Panel, Plug Buttons,

______ Blast Chiller Rack

______ Compressor/Condenser Unit

Locking Wrench, Installation Manual

VAN SHIPMENT

If your Blast Chiller is shipped by van, it is not crated. Components are blanket wrapped and secured carefully in the van. Be sure to check your packing list (page 8) to be sure all parts are received.

If parts are missing or damaged:

-Make a notation to that effect on the driver's Bill of Lading

-Notify the van company at once

Since van shipped parts are not crated, handle and store them carefully before you begin installation.

FREIGHT CLAIMS

IMPORTANT

FREIGHT CLAIMS INSPECTION:

You are responsible for all claims. It is vitally important that upon arrival, all cartons and crates are inspected for visible damage. If at all possible, cartons and crates should be opened immediately to check for concealed damage within. All cartons and crates must be saved until the unit is completely removed from the carton so concealed damaged claims can be filed.

You, as the consignee, must file freight claims with the delivering truck line. If there is any question whatsoever regarding the condition of the equipment, this question should be noted on the bill of lading, which you sign as a delivery receipt.

All shortages must be noted on the bill of lading as the shipment is received. If a bill of lading is signed as complete for the delivering truck driver, there is virtually no way to secure a claim for shortages which are found later.

MASTER-BILT Products

908 Highway 15 North

New Albany, MS 38652

Phone: 1-800-684-8988

PRE-ASSEMBLY PROCEDURES

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 the unit or accessories, contact 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 blast chiller.

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 Below). Forklifts must have the capacity to support panels weighing two pounds per square foot each.

STORAGE

When the unit must be stored at the job site prior to set-up, it is very important that it be stored 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 the unit 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.

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

SITE CHECKLIST

-Inspect the area where your Master-Bilt

1. Check to make sure the floor is level. a. The entire floor under the Blast Chiller must be level, clean, and smooth.

NOTICE

The existing surface must be level before the blast chiller is installed. If it is not, leveling must be performed to insure proper installation If the floor area under the Blast Chiller is not level and smooth, have the area grouted.

2. Check the ceiling height above the Blast Chiller area: a. Refer to the enclosed print specific to this project. b. The top area of the Blast Chiller must be accessible for servicing. c. Make sure proper clearance is allowed.

3. Assure a drain is located near the Blast Chiller. a. Make sure the drain is located relative to the enclosed Blast Chiller print. b. Measure and locate where the drain will exit the Blast Chiller box.

4. Assure electrical supply is near the Blast Chiller. a. Review the enclosed Blast Chiller print to determine the best location for

the (customer supplied) electrical disconnects for the two electrical supplies required.

ii. At condensing unit. b. Measure and locate where the electrical supply will be located. c. Review the enclosed Blast Chiller prints for voltage, amperage, and phase

and location.

5. Assure adequate clearance is allowed for the door to the Blast Chiller to swing

open.

Blast Chiller will be installed.

i. On an adjacent wall for blast chiller.

Inside Wal

BLAST CHILLER BOX INSTALLATION

STEP 1

In this step you will prepare the floor and install either the wall angles, or optional floor pan or

optional floor.

WALK-INS WITHOUT FLOORS

-Locate the Blast Chiller print sent with the unit.

-Mark the floor with the inside dimensions.

-Check the marked area for:

1. Level surface a. Floor must be completely level around wall parameter. b. Add grout as needed

2. Surface condition a. Surface must be smooth. b. Add grout as needed

3. Cleanliness a. Sweep and clean area to assure surface is free of dirt, debris, water, oil, and grease.

4. Adequate space.

a. Allow for insulated panel thickness if the Blast Chiller location is against a wall or partition.

b. Measure between the inside flange and the wall to assure adequate space is allowed.

c. Refer to the Blast Chiller print (the standard Master-bilt

-Correct any of the above problems with the floor BEFORE proceeding with Blast Chiller installation

-On floorless-type walk-ins you may use 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.

-Attach the floor angles to the existing floor before the wall panels 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 can be placed on top of the angle flange attached to the floor.

-Seal with NSF approved sealant as shown.

If you are not sure about any of the above conditions, STOP. Call Master-bilt at 1-800-647-1284.

panel is 4" thick)

Optional Cove Molding

WALKINS WITH FLOOR PAN

-Locate the Blast Chiller floor pan.

-Move the floor pan into position (wear heavy gloves).

-Scribe the floor pan location.

-Move the floor pan aside.

-Check the scribed area for:

1. Level surface: a. Floor must be completely level. b. Add grout as needed.

2. Surface condition: a. Surface must be smooth (capable of having vinyl tile/carpet laid) b. Add grout as needed.

3. Cleanliness a. Sweep and clean area to assure surface is free of dirt, debris, water, oil, and grease.

4. Adequate space a. Allow for insulated panel thickness if the Blast Chiller location is against a wall or

partition.

b. Measure between the inside flange and the wall to assure adequate space is allowed.

c. Refer to the Blast Chiller print (the standard Master-bilt

-Correct any of the above problems with the floor BEFORE proceeding with Blast Chiller

installation

If you are not sure about any of the above conditions, STOP.

Call Master-bilt at 1-800-984-

8988.

- Carefully stand the floor pan up on one end against a stable wall.

-Apply NSF approved clear silicone to the floor pan.

1. Around the perimeter of the floor pan. a. Locate the bead about 4" in from the floor pan

edge.

b. Use a uniform bead of about 3/8".

2. To the center of the floor pan (surfaces that contact the

floor).

a. Crisscross the floor pan center until the floor

pan is completely covered with silicone. This prevents any air trapped under the installed floor pan from creating an "oil canning" effect and also any condensation that may appear on the other side of the floor pan.

-With the aid of helpers, carefully lower the floor pan into position for installation.

-Carefully walk on the floor pan to remove trapped air.

-Check to make sure the silicone properly coats the floor pan perimeter.

panel is 4" thick)

WARNING Install Blast Chiller floor pans on concrete floors only.

WALK-INS WITH FLOORS

-Locate the Blast Chiller floor panels.

-Lay out all floor panels in sequence as shown on assembly drawings.

-Scribe floor around floor panels.

-Move floor panels out of scribed area.

-Check the scribed area for:

1. Level surface: a. Floor must be completely level. b. Add grout as needed.

2. Surface condition: a. Surface must be smooth. b. Add grout as needed.

3. Cleanliness a. Sweep and clean area to assure surface is free of dirt, debris, water, oil, and

grease.

-Correct any of the above problems with the floor BEFORE proceeding with Blast Chiller installation.

If you are not sure about any of the above conditions, STOP. Call Master-bilt at 1-800-684-8988.

-Caulk panels as shown with NSF approved caulking.

-Fasten these panels as evenly as possible to each other to provide a square and level base for the wall panels.

-Using wrench provided tighten the cam fasteners all the way so that the panels are evenly aligned and fit snugly.

-Caulk around outer perimeter with NSF approved caulking.

1. This prevents condensation that may appear on the other side of the floor panel.

In this step you install the insulated wall panels

INSTALL INSULATED WALL PANELS

-Refer to the enclosed panel print customized for your order.

-Locate and arrange panels according to the panel print.

-Hold the first panel in place.

1. Position the panel to cause it to seat with the floor, floor pan, or

floor angle.

2. Apply NSF approved clear silicone to the bottom of the panel.

3. Refer to the print to position the panel and cause it to seat with

the floor, floor pan, or floor angle.

STEP 3

-Hold the first panel in place

-Place the second panel in place.

1. Position the panel to cause it to seat with the floor, floor pan, or

floor angle.

2. Apply NSF approved clear silicone to the outside of the V joint

of the side panel and to the bottom.

-Lock these panels together using internal cam locks.

1. Locate cam lock wrench provided.

2. Insert wrench onto the hex head pin in the cam lock opening.

3. Rotate the cam lock clockwise until the lock hooks with the

adjoining panel.

4. Continue rotating until the lock pulls the panel together snugly as

shown above.

NOTICE Occasionally, a cam fastener will not operate because an operating hex pin is broken or rounded off during assembly. If one cam on a panel fails to fasten, the remaining cam fasteners provide adequate support and alignment for assembly of the chiller.

NOTICE The stainless steel panels are covered with a protective sheet of plastic. Remove the protective plastic covering from the wall panels as each area is completed.

-Continue to erect the sides and back of the chiller box.

1. Insure the panels are even at the top.

WARNING Perform the following installation steps now. The area is not accessible after the evaporator and fan assemblies are installed.

-Apply a small bead of silicone at the joint of the floor pan flange and the chiller wall.

-Check all remaining cam locks.

1. Tighten or re-tighten as needed.

-Press the cam lock covers (plug covers) into the holes with your hands.

NOTICE DO NOT INSTALL THE DOOR PANEL AT THIS POINT. The door panel is installed after the coil assembly is installed. All panels except the door panel and ceiling panels must be complete before the evaporator coil assembly is installed.

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