Master-Bilt PS Installation Manual

PS SERIES

PARALLEL RACK SYSTEM

INSTALLATION & OPERATIONS MANUAL

1st Revision (5-11-2010)

TABLE OF CONTENTS

INTRODUCTION……………………………………………………………………………………………..3
WARNING LABES AND SAFETY INSTRUCTIONS…………………………………………………….4
PS SERIES FEATURES…………………………………………..………………………………………...5
PS SYSTEM NOMENCLATURE……………….…………………………………………………………..6
PRE-INSTALLATION INSTRUCTIONS…………………………………………………………….……..7

General Information…………………………………………………………………………………….…………7
Delivery Inspection………………………………………………………………………………………….….…7

INSTALLATION INSTRUCTIONS…………………………………………………………….………...…7

Handling and Placement of Walk-In Evap(s)………………………………………………………………...…7
Electrical Specifications………………………………………………………………………………………. …8
Refrigerant Piping……………………………………………………………………………………………..…..9
Suction and Liquid Line Sizes………………………………………………………………………..…………10
Leak Check…………………………………………………………………………………………………….….11

Evacuation, Dehydration, and Start-Up………………………………………………………………….....….11

Evacuation Procedure……………………………………………………………………………..……11

Finishing Charging Procedure…………………………………………………………………......….12

Low Ambient Charging (Example)……………………………………………………………...….....13

Handling and Placement of Multiple Rack System…………………………………………………………....7

STARTUP………………………………………………………..………………………………..….........15

SALE AND DISPOSAL……………………………………………………………………………..….…17
LABOR WARRANTY……………………………………………………………………………………..17

TYPICAL PIPING SCHEMATIC…………………………………………………………………...........18

PHYSICAL DIMENSIONS………………………..……………………………………………. .......19-22

OTHER SPECIFICATIONS & DIAGRAMS……..…………………….........................................23-27

2

INTRODUCTION

Thank you for purchasing Master-Bilt refrigeration equipment. This manual contains important instructions for
installation, use and service. Read this entire manual carefully before installing or servicing your Master-Bilt equipment.

NOTICE

Installation and service of the refrigeration and electrical components must be performed by a refrigeration
mechanic or licensed electrician.

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 equipment. Keep the manual and refer to it before doing
any service. Failure to do so could result in personal injury or equipment damage.

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:

Parts and Technical Service Department

Master-Bilt Products

908 Highway 15 North

New Albany, MS 38652

Phone [phone]

Email: [e-mail]

3

WARNING LABELS AND SAFETY INSTRUCTIONS

damage to your equipment.

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

You must make sure that everyone who installs, uses, or services your refrigeration equipment 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:
WARNING:
CAUTION:
NOTICE:

damage your refrigeration.

The warning and safety labels shown throughout this manual are placed on your Master-Bilt Products
refrigeration at the factory. Follow all warning label instructions. If any warning or safety labels become lost or
damaged, call your customer service department at [phone] for replacements.

This is the safety-alert symbol. When you see this symbol, be alert to the potential for personal injury or

NOTICE TO EMPLOYERS

Severe injury or death WILL occur if you ignore the message.

Severe injury or death CAN occur if you ignore the message.

Minor injury or damage to your refrigeration can occur if you ignore the message.

This is important installation, operation or service information. If you ignore the message, you may

This Label is located on the condensing unit

4

PS SERIES PARALLEL RACK FEATURES

• Generously sized condenser for high efficiency. Sized to operate efficiently in high ambient conditions.

• Hermetic, semi-hermetic, and Scroll compressors in any combination the customer chooses

• Generously sized receivers with isolation valves and liquid level indicator

• Compressor Suction Service Valves with Access Ports, and Discharge Line Service Valves with Access Ports

• Pre-wired and mounted high and low pressure controls with each compressor

• Units leak tested

• U.L. listed

• Easy accessibility for service

• Pre-wired for easy installation with Single Point Electrical Connection with individual Circuit Breakers for each

Compressor and Through Door Main Disconnect Switch and Circuit Breaker Installed

• Crankcase Heater Installed for each Compressor

• Refrigeration lines pre-piped to edge of unit

• Pre-piped and mounted refrigerant sight glass

• Flooded Head Pressure Controls standard on each system. Other options available

• Galvanized steel housing is standard, Stainless Steel Housing optional

• Engineered Refrigeration Drawing Available for Specified Projects, or with Purchase Order (Contact Factory for

Additional Details)

• Master-Controller Electronic Refrigeration Controls for Maximum Energy Efficiency are available for use with
parallel racks.

• Replaceable core suction and liquid filter driers.

• Oil return system complete with oil separator, oil level controls and oil filter are standard.

• Two tiered frame/cabinet typically contains up to 12 compressors. Compressors are numbered starting from

the upper left. If a split suction system is used, low temperature compressors are typically on the top tier.

• Up to 3 suction groups can be controlled within a single frame/cabinet.

• Hot gas defrost, electric defrost, off cycle defrost

• Heat reclaim available

• Split condenser available

• Floating head pressure control available

• EVI compressors with sub cooled liquid available

• Various alarms available including compressor failure, liquid level, etc are available. Standard alarms include

phase loss and oil failure.

5

-

C = 208-230/3/60

E = 460/3/60

Z = R404A

1 to 3

2 to 8

R = Remote

C = Mounted on Common Frame

A = Air Cooled

W = Water Cooled

Parallel Rack Nomenclature

PS E C 5 2 Z CA

XXXXX

Quote Number

Voltage

Refrigerant

Number of Suction Groups

Number of Compressors

Condenser Location

Condensing Method

Frame

I = Interior
E = Exterior

Parallel Rack

6

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.

II.

DELIVERY INSPECTION

You are responsible for filling 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 a shortage is found, note this on the bill of
lading (all copies) prior to signing.

If damage is discovered when the cabinet arrives, immediately call the delivering truck line and follow up the call with a
written report indicating concealed damaged to your shipment. Ask for an immediate inspection of your concealed item.
Crating material MUST be retained (if applicable) to show the inspector representing the truck line.

INSTALLATION INSTRUCTIONS

I.

HANDLING AND PLACEMENT OF PARALLEL RACK SYSTEM

There should be a minimum of 3 feet around the perimeter of the Rack System that should be unobstructed.
This allows for proper servicing of the equipment. Please refer to local and state codes as well at the NEC for
additional clearance requirements.

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 100 CFM of air per one ton of

refrigeration capacity.

7

II. ELECTRICALSPECIFICATIONS

Electrical power supply must match the rack power
requirements indicated on the unit data plate. A WIRING

DIAGRAM IS LOCATED ON THE INSIDE ON THE
ELECTRICAL BOX COVER. For best results, it is

suggested that power supply for PS Rack systems be
applied as illustrated below in Figure 1. All field wiring
should be done in a professional manner, in accordance
with all governing codes. All wiring (including factory
terminals) should be double checked before start-up

Wiring diagrams specific to each installation will be provided
by Master-Bilt.

Figure 1: Suggested Field Wiring Location for PS Units.

NOTICE!

Systems with scroll compressors must be checked for proper power phasing. Improper power phasing will result in
improper compressor rotation causing compressor to pump incorrectly. A phase monitor is standard on PS systems for
this purpose.

Three phase scroll compressors are directional dependent, i.e., they will only compress in one rotational direction and
will rotate in either direction depending on power phasing. Verification of proper rotational direction is made by
observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse
rotation also results in an elevated sound level over correct rotation, as well as substantially reduced current draw
compared to data tag values.

NOTICE!

Check phase alignment on all incoming power.

8

III.

Fitting

Tee

Tee

Size

90º Ell

45º Ell

(Line)

(Branch)

REFRIGERANT PIPING

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. Take extreme
care to keep refrigeration tubing clean and dry prior to installation. Use an appropriate size tube cutter. Remove any
burring that may occur when cutting the tubing. Use dry nitrogen to purge the system of any foreign objects that may
have come about during any pipe cutting.

All suction lines will be insulated with not less than ¾” Armaflex or acceptable substitute as determined by Master-Bilt
personnel. Armaflex insulation must be properly glued or taped as approved by insulation manufacturer to prevent
refrigeration lines from “sweating”.

Appropriate oil must be added to systems per Compressor manufacturer specifications.
Suction lines should be sloped down ½” for each 10 feet of horizontal run towards the compressor. This will facilitate

good oil return to the compressor.
Refrigeration lines will be sized appropriately to facilitate

proper oil return to the compressor and reduce refrigerant
line pressure drop. Table 1 depicts proper line sizing
options. Use this as a guideline for your selection.
Any fittings used may be accounted for in the Table to the
right.

1/2" 0.9 0.4 0.8 2
5/8" 1 0.5 1 2.5

7/8" 1.5 0.7 1.5 3.5
1-1/8" 1.8 0.9 1.5 4.5
1-3/8" 2.4 1.2 1.8 6
1-5/8" 2.8 1.4 2 7
2-1/8" 3.9 1.8 3.8 10

Equivalent Length Allowances for Pipe Fittings

(length in feet)

9