Master-Bilt PRS-2 Installation Manual

Refrigeration

Systems

Installation

Manual

7/16 Rev. A 57-02510

Table of Contents

Tools Required 3 General Information 4-7

Unpacking & Inspection for Ceiling Mount 4 Unpacking & Inspection for Remote 5 Latch and Diffuser Installation 6-7

General Installation Instructions 8-11

Ceiling Mount Refrigeration Systems 8-9 Wall Mount Refrigeration Systems 10 Freezer Models 100 & 150 or Cooler Model 075 11

Remote Refrigeration Systems 12-13

With Electric Vaporizer 12 With Optional Electric Condensate Vaporizer 13 Instructions for Pre-Charged Lines 14-15 Instructions for Wire Harness 16

Outdoor Systems 17-18

Membrane Roofing Material 17-18

Operation 19-21

Standard Temperature (Cooler) Systems 19 Low Temperature (Freezer) Systems 20-21

Maintenance 22 Maintenance Analysis 23

Tools Required fof Uncrating and Installation of the Refrigeration System

Tools Required

•

Safety Glasses

•

Metal Snips

•

Pry bar

•

Hammer

•

Adjustable open end wrench (2)

•

Drill driver

•

Pencil

Refrigeration Systems-General Information

CEILING MOUNTED REFRIGERATION SYSTEM

GENERAL INFORMATION

This Refrigeration System was produced utilizing the latest in manufacturing technology, the highest quality materials available, along with innovations that make it a distinctive product in its field. Despite rigid controls in the production of the product, there is no substitute for thoroughly reading and UNDERSTANDING the instructions that follow. The result will be an orderly and efficient installation. Please take the time to follow the steps explicitly!

UNPACKING & INSPECTION--CEILING MOUNT SYSTEM

Check the Delivery Receipt for the number of pieces that made up the shipment and make sure that the number of pallets, boxes or crates agrees with that number. Each piece should be clearly marked with the same five-digit order number that appears on the Delivery Receipt as the shipper's number.

Examine the general condition of the shipment and, as soon as unpacking is completed, carefully inspect all parts for possible shipping damage. If damaged parts are discovered, contact the supplier immediately.

Delivery Receipt

Refrigeration Systems-General Information

UNPACKING & INSPECTION--REMOTE REFRIGERATION SYSTEMS

It is recommended the condensing unit be elevated from the deck a minimium of 12"-18" to ensure the condenser fan is not drawing or pulling heat reflected off the building roof or pavement in a grade level installation in which the summer heat may exceed 120°°°°F.

Refrigeration Systems-General Information

CAPSULE PAK™ LATCH AND DIFFUSER INSTALLATION INSTRUCTIONS

CAUTION: REMOVE DIFFUSER PRIOR TO CEILING PANEL INSTALLATION!

1. Remove diffuser from ceiling panel before installing ceiling panel.

Figure 1

2. Lift Capsule Pak™ into position on top of walk-in. Note: Do not slide Capsule Pak™ into position as cowl gasket damage will occur. If the Capsule Pak™ must be slid into position, place Capsule Pak™ on a piece of cardboard prior to moving to prevent gasket damage.

Figure 2

3. Inspect cowl gasket to ensure proper placement.

Figure 3

Refrigeration Systems-General Information

4. Secure interior latches.

Figure 4

5. Seal cowl to ceiling at gasket seam above diffuser panel using provided silicone.

Figure 6

Figure 5

6. Replace diffuser panel removed in step 1.

General Installation Instructions

GENERAL INSTALLATION INSTRUCTIONS

This section has the general instructions for installing the ceiling mounted Refrigeration System. Before proceeding, also see the following section on mounting "Remote Systems with Electric Vaporizer", if applicable.

Note: Proper "temporary" interior support must be added during the installation of the refrigeration.

Note: Due to the weight of these systems, it is highly recommended that proper lifting equipment, such as a fork lift or scissor lift, be utilized during installation. Also, be sure to allow for sufficient airflow around the condenser. Model numbers ending with the letter "A" require a minimum clearance of two feet for proper unit operation. Model numbers ending with the letter "B" require a minimum of five inches behind the unit and open to the front for proper operation. If multiple units are located in the same area, be sure they do not exhaust hot air into one another. In addition to allowing for proper airflow, consideration should be given to the final mounting location of the refrigeration system relative to the customer location to avoid any possible risk of noise impacting the customer experience.

Position the insulated evaporator section of the Refrigeration System over the hole in the walk-in ceiling section.

Align the tabs on the side of the insulated evaporator section with the predrilled holes in the ceiling section. Fasten latches and seal perimeter as described in the Latch and Diffuser Installation Instructions found on pages 6 and 7. When reinstalling the diffuser panel, make sure the ceiling section divider on the panel seals against the black gasket. Some adjustment may be required by simply bending the ceiling section divider slightly forward or backward. This will prevent any short cycling of discharge and return air.

Fasten the insulated evaporator section down to the ceiling using the provided drive screws, which can be found attached to the side of the refrigeration system. CAUTION! This must be done to prevent the entire refrigeration system from moving during operation.

Note: On smaller refrigeration systems, you may elect to install the system on the ceiling section while the section

is still on the floor. CAUTION! Make sure to fasten down the system to the ceiling panel. The ceiling section and the refrigeration system may then be erected together in the normal sequence of assembly as shown in the Kold Locker™ Walk-in Installation Instructions. This method is not practical and should not be used with larger systems of 100 series or above, such as a 100, 150 or 151 model.

General Installation Instructions

Note: The process above is the same when locating/installing the insulated evaporator section of a Remote Refrigeration System.

After the system is in place, make sure that the bolts fastening the condensing unit section to the evaporator section are loose enough so that the two sections can adjust to the ceiling surfaces. Note: On large systems, 100 series and above, the units are placed on a rack assembly and do not have these bolts connecting the two sections together. No adjustment is necessary.

Note: Some motor compressors are openly spring mounted to absorb vibration. Be sure that these bolts are loosened to permit the compressor to float freely on the springs. A reminder label

is applied to systems where this procedure applies.

Some systems require a permanent connection to an electrical service and a connection at the junction box located within the condensing unit housing. Refer to the serial tag for all pertinent electrical data. These systems must be connected to a power supply disconnect switch and wired according to local and national electric codes. No plumbing drain is required, under normal conditions, since the condensate moisture is dissipated automatically by a built-in hot gas vaporizer.

General Installation Instructions

WALL MOUNTED REFRIGERATION SYSTEMS

INSTALLATION INSTRUCTIONS

Note: If the system to be wall mounted is a freezer model 100 or 150 or cooler model 075, please see the next section with special instructions on mounting these units.

Carefully raise the entire refrigeration system and insert the projecting sleeve of the evaporator section into the opening of the walk-in wall. While supporting the system, lock it into position by turning the locks exactly as you did when locking the walk-in sections together. Make sure that the locks are positively engaged and insert the plug buttons into the lock access holes when finished. Refer to Figure 1.

Note: Some motor compressors are openly spring mounted to absorb vibration. Be sure that these bolts are loosened to permit the compressor to float freely on the springs. A reminder label is applied to systems where this procedure applies.

connected to a power supply disconnect switch and wired according to local and national electric codes.

Figure 1.

Wall Mounted Refrigeration System

No plumbing drain is required, under normal conditions, for indoor installations. A built-in hot gas vaporizer dissipates the condensate moisture automatically. In outdoor installations, the condensate should be plumbed to the nearest drain. Check local building codes. Outside drain lines must also be wrapped with a suitable heater wire if they are ever subjected to below freezing temperatures. Outdoor installations also require the attachment of the rain hood that will divert rainfall from the upper surface of the evaporator housing. See Figure 1 for an illustration.

Be sure to allow for sufficient airflow around the condenser. A minimum clearance of six inches is required for installation and a minimum of two feet is required for service consideration. Ambient temperature around the system should be less than 90°°°°F and 50% RH. If multiple units are located in the same area, be sure they do not exhaust hot air flows into one another. In addition to allowing for proper airflow, consideration should be given to the final mounting location of the refrigeration system relative to the customer location to avoid any possible risk of noise impacting the customer experience.

Please see the section “Instructions for Pre-Charged Lines” if the installation of this system involves the use of pre-charged lines to connect the evaporator and condenser sections.

General Installation Instructions

Freezer Models 100 and 150 or Cooler Model 075

1. After uncrating, before attempting to attach the refrigeration system to the walk-in, a substantial temporary

support should be built. The support should be approximately 28 inches high and placed directly below the wall opening of the walk-in.

Note: Due to the weight of these systems it is highly recommended that proper lifting equipment, such as a fork truck, be utilized during installation.

2. Lift the refrigeration system onto the temporary support. Determine whether the coil section sleeve is positioned properly so that it can be inserted into the opening without being bent or damaged. Shim the system appropriately so that this can be accomplished.

3. Carefully slide the entire system so that the coil section sleeve enters the opening without disturbing the temporary support below the refrigeration system. Continue until the gasket around the coil section contacts and seals around the entire perimeter of the coil section. Shim the system and adjust it accordingly so that the gasket seal will be uniform on all four sides.

4. Using the section-latching wrench provided for the erection of the walk-in, insert the wrench into the latch access holes of the coil section. Turn each of the locks clockwise until the latches engage the strikes in the walk-in. Turn the lock until a full stop is encountered. DO NOT REMOVE THE TEMPORARY SUPPORT!

5. Remove the louver assembly and drill four 9/16” diameter holes through the two upright angles of the condensing unit section. Drill completely through the walk-in wall and insert the 1/2" threaded nylon rods. Secure with the flat washers and nuts provided. Refer to Figure 2.

6. With the leveling screws threaded completely into the leg support, insert the leg support into the leg retainers at the outer corners of the condensing unit section. Unscrew the leg leveling screws until they contact the floor or other supporting surface. Note: If the supporting surface is extremely uneven, suitable shimming material must be provided under one or both of the leg supports.

7. Attach the diagonal leg support braces using the threaded fasteners provided. Make the final adjustments to the leg leveling screws so that they serve as supporting devices to the outer edge of the refrigeration system.

8. Insert plug buttons into each of the latch access holes.

9. Remove the temporary support assembly that was

provided in Step 1.

Remote Refrigeration Systems

REMOTE SYSTEMS WITH ELECTRIC VAPORIZER

Set the Refrigeration System evaporator section over the hole in the ceiling section. Align the tabs on the side of the insulated evaporator section with the pre-drilled holes in the ceiling section. Remove the Diffuser Panel from the ceiling inside the walk-in to gain access to four latches located along the perimeter of the cowl. Refer to the Latch and Diffuser Installation Instructions found on pages 6 and 7. Seal the seam as described in the instructions. When reinstalling the Diffuser Panel, make sure that the ceiling section divider located on the panel seals against the black gasket. Some adjustment may be required by simply bending the ceiling section divider slightly forward or backward. This will prevent any short cycling of discharge and return air.

Fasten the evaporator section down to the ceiling using the provided drive screws, which can be found taped to the side of the insulated evaporator section.

CAUTION! This must be done to prevent the entire refrigeration system from moving during operation.

Remote Refrigeration Systems

OPTIONAL FEATURE - ELECTRIC CONDENSATE VAPORIZER

Note the location of the condensate drain line coming from the evaporator. Locate the electric vaporizer so the condensate will run into it. If the vaporizer cannot be located at the drain line, use the supplied plastic tubing, copper elbow, and hose clamp(s) as required to extend the drain line. Cut the plastic tubing to length as required.

Provide power to the electric vaporizer per local and national electric codes.

Remote Refrigeration Systems

INSTRUCTIONS FOR PRE-CHARGED LINES - REMOTE SYSTEMS

By employing self-sealing refrigeration couplings, the condensing unit section, evaporator section, and the connecting tubing are separately pre-charged with refrigerant and leak tested at the factory before shipment. Follow steps 1-8 below to install the connecting tubing at both the condensing unit and the evaporator section.

1. Carefully uncoil the suction line. This is the line covered with a continuous length of sponge rubber insulation.

2. Carefully uncoil the liquid line. The liquid line is the smaller diameter, bare copper tube.

3. Before making any connections, determine the routing of both lines and carefully hand bend them to suit the situation. Keep any bend radius rather large to prevent kinking the tubing. It is a general practice to route the suction and liquid line parallel and close together in the installation.

4. Remove the dust caps and plugs from the couplings and inspect them to see if the synthetic seals are intact.

5. Using a clean cloth, wipe the coupling seals and threaded surfaces to prevent the inclusion of any dirt or foreign material in the system.

6. LUBRICATE the synthetic seal in the male half of the couplings with refrigeration oil and thread the two coupling halves together BY HAND to ensure proper mating of the threads. Note: Make certain that the insulated suction line is connected to the coupling half marked "Suction Line" and that the bare tube liquid line is connected to the coupling half marked "Liquid Line".

Note: Always use two wrenches on the coupling body hex nut and on the union to prevent twisting of the tube while tightening the connections as described in the next step.

7. Using the proper size wrench on the union nut, tighten until the coupling bodies bottom, or until a definite resistance is felt. Tighten an additional 1/6 to 1/4 turn. This final turn is necessary to ensure the knife edge metal seal bites into the brass seat of the coupling halves, forming a leak proof joint.

Note: legs shown in photos are not standard but instead, an optional item.

Connecting to the Condensing Unit Side

Remote Refrigeration Systems

8. Once the suction line is connected, the sponge insulation must be pulled up to cover the quick connects. Tie or tape off the insulation to prevent air infiltration and reduce water/ice formation on the suction line.

All valves are open and the system is ready for operation. Remember, the refrigeration couplings on this system are self sealing and, if the need ever arises, the couplings may be disconnected without any loss of refrigerant.

IMPORTANT: Since this system is equipped with pre-charged refrigerant lines, it is the installing contractor’s responsibility to ensure that the quick connect refrigerant couplings are properly mated and are leak free. It is also their responsibility upon start-up to check the system for proper operation and make any necessary temperature control or thermal expansion valve adjustments.

Note: A drain line is required to be run by the contractor for this type of installation.

CAUTION: Line set must not exceed 3 feet longer than required length to complete connection or improper oil return may result in compressor failure. Contact the Service Department with model and serial number for further assistance.This information is also included on a tag attached to the line set.

Connecting to the Evaporator Section Side

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