Blood Plasma Walk-In Manual - Master-Bilt
Contents
1. NI X1VM 3416110 103 3110 41 092 43 00018 43 FIOJLNOO 157 20 Refrigeration Solutions MBMASTER BILT le TYPICAL WIRING DIAGRAM FOR ANTE ROOM FIGURE 6 10109 Saud 109 WA TIA le H LINN 9NISN3QNOO 305535905 10 9 ARMES 1031409 lt 353005 YIMOd 93199934 09 MOLOVLNOO 305534905 480 09 91 uoee MOO 9611 t L 09 SLL 21004 5584 86 1000 1929214 970 V 09 SLL jog 91 55914 sduy jueuoduio5 8868 89 008 311 15 15015 41 71430 3048935 19 3 TIVO 35 1 AYOLOVA AHL LV YSTIONLNOD OL Q3193NNOO A33 8 2005 81 3Nnss3Nd SMJOSN3S 11 3LON ANOLOWS imei ea 071313 HOLIMS AL3JVS SH 3NWA NOISNVdX3 51319313 33 H3onasNvHl 33055349 14 AINO N3lSVW NOSN3S WOON 51 MOSN3S 33nlvH3dW3l 12. de E ge MOSN3S dW3l dWO2 304 SYOLONGNOD OML i arty 38055344 303 5 33NHL 9721 303 IVISOWH3HL 540 1 gor OL NOIOVMINOO 10313 B3TIVISNI A8 ILIS gor Es zx N3TIOHINOO Ol Q3103NNOO A33 5 3NhSS3Nd SNOSN3S Tv 4 E 73 PM 7 491 7 MIONGSNVYL 1110 SYOLONGNOD vo 81 305534409 rr m niu Wg eg eee yo eee ena pe ene En ees ated aad Uu PNE Urin hri B re enl an 3 NOSN3S NOILONS 303 SMOIOnONOO vo 30078 SOIOVINOO mE 193NNOOSIO AIVA 003705 ama ef 93513 001 NUNL3Y 10 1 8 3 ame i 903105 1009815 1 pam 7118 2 NOUVOINDWAOS 1 ain m gt Bie e 999 yg WH3L 1505339 Ars 305435 1 ist rund 1 Zed 184 it LO 1 1 i Ls si 1 1 1 I5 T 2 74 7 mU TIPS o aw B 96071 6 1 Fe x 23 ag 1 a5 Q SNvJ 1504430
3. 16 17 Charging the Master Controller Refrigeration 18 Technical Notes 2 222 22 222 21222224208212 202 4222292211422 42 0 210 0 n eo kos Ded seus ial etos upon teca 18 Electrical Wiring 19 TYPICAL WIRING DIAGRAMS x Sune RN YE EK HERMES 20 Line Sizing and 22 Start Up 22 REVERSE CYCLE DEFROST 23 General Information 23 PROS IMAG SS AN m 23 Factory lnstalled a a 23 Eliminated 24 CRUCE PEE 24 Charging a Master Controller System Equipped with Reverse Cycle Defrost 24 TROUBLESHOOTING GUIDE 25 Troubleshooting Electric Expansion 26 MAS TER BILT PART NUMBER cc caer 26 3 Refrigeration Solutions 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 A DANGER Improper or faulty hook up of electrical components of the refrigeration units can result in severe injury or death All electrical wiring hoo
4. MASTER BILT Refrigeration Solutions Blood Plasma Freezer With Master Controller For Model BCLZR10AC Installation amp 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 Refrigeration Solutions INTRODUCTION sisieun a 4 WARNING LABELS
5. TET NN NOLLdO AYI3 ES gs Z Avida 1 jo e MEXICO curias Ce d AN es G G 8 1 E S 27 V 1 as 1 i f zs zi z z 8 280 uoee moot 561 su F 3 i eb 1 09 91 1 400q 5594 e 1 950 ae i se WO9 SLL 2000 1929914 We 01 1 a aaa o ES 2 970 09 61 4919H ainssalg oz 1 sduy 1 l E S EA EEEE S EEIE OX 50500 65 3404 31 423 9 na I 26 11 359105 asn YDYM saosse4duo 52 puojado3 suooa 10 eseu 1604430 31049 3SNH3A3M 09 1 0 2 807 WALSAS 31000W 1831 ONVI3dOO Vd2 012 4 07315 HOLIMS AL34VS 1504330 SH 24091 61 14091 61 NOISNVdX3 21519313 SG6 1 61 YSONGSNVYL 34055344 NOLLONS 260 1 61 H30nOSNVHL 3HhSS3Hd 3ONVHOSIO 40 1 6 NOSN3S dW3l 1205 dWOO 51 640 1 6 HOSN3S 3MhivH3dW3l WOON lt 51 40v1 61 HOSN3S 3univH3dW3L NI LNO 131100 ZSL L0v1 61 MOSN3S 3HniVH3dWil NOLVNIWH31 1504439 I3INI 151 QN39431
6. Temp C ohms 1k Temp F Temp C ohms 1k 50 45 6 43 45 15 9 4 7 579 40 40 0 32 31 20 6 7 6 731 35 37 2 27 96 25 3 9 5 993 30 34 4 24 27 30 11 5 349 25 31 7 21 13 32 0 5 123 20 28 9 18 43 35 1 7 4 781 15 26 1 16 12 40 4 4 4 281 10 23 3 14 13 50 10 0 3 454 5 20 6 12 42 60 15 6 2 805 0 17 8 10 94 70 21 1 2 294 5 15 0 9 651 80 26 7 1 888 10 12 2 8 544 NOTE Use resistance at 32 F for sensor checking Suction Pressure Transducer The green lead is connected to terminal 1 on the board The white lead is connected to terminal 1S on the board The black lead is connected to terminal 1 on the board The black wire gets 5 VDC the white wire is the signal and the green wire is the ground TABLE 2 shows the characteristics of the pressure transducer NOTE The pressure transducer cannot be repaired but replaced only TABLE 2 Pressure Sensor Simulation Values 0 to 150 PSIA PSIG White to Bar PSIA Green 0 0 14 6 0 509 0 69 10 4 6 0 784 1 379 20 5 4 1 058 2 069 30 15 4 1 332 2 758 40 25 4 1 587 3 448 50 35 4 1 862 4 137 60 45 4 2 136 4 827 70 55 4 2 391 5 516 80 65 4 2 665 6 206 90 75 4 2 920 6 895 100 85 4 3 194 7 585 110 95 4 3 469 8 274 120 105 4 3 724 Refrigeration Solutions Charging Master Controller Refrigeration System Note If you are a first time
7. F Default 50 AL DIF2 If in alternating mode number of deg above air set point to override and both controllers to go into cool mode 0 25 deg 5 F Note 1 When power is lost the backup power is to drive the EEV completely close Note 2 Compressor CPR valve setting 10 to 15 PSIG Refrigeration Solutions ALARM DISPLAY Any alarm will cause relay 3 to switch All alarms have a distinct display shown on the two digit display on the controller The green LED will be on and the red LED will blink Multiple alarms can exist There is a priority as to which alarm will be displayed before another Onboard Optional 2 Digit Panel Display Display Description PRIORITY NOAL Displays when there are no alarms The onboard 2 digit display will display status and temperature readings SP PRSR pressure transducer 1 So SCSR evaporator outlet temperature sensor TS2 alarm 2 SA RMSR room temperature sensor TS3 alarm 3 LS LOSH low superheat alarm 4 rH HIRM high room temperature alarm 5 rL LORM low room temperature alarm 6 Sd DFSR defrost termination sensor TS1 alarm 7 CS CMSR Compressor Suction Temperature Sensor Alarm 8 dA DPSR high press transducer alarm 9 LP LPAL Low pressure alarm 10 CA CMAL communication alarm 11 Setting Parameters By On Board Pushbuttons When the two digit display is a displaying a temperature or status the green LED is always on The red LED is the negative sign When the red LED i
8. Low Room Temperature Alarm rL The low room temperature alarm occurs when the room temperature is below the preprogrammed LOW TEMPERATURE ALARM for a preprogrammed number of minutes The alarm is cleared when the room temperature is above the LOW TEMPERATURE ALARM set point Defrost term temp sensor alarm Sd o Defrost mode Open valve until alarm goes away or defrost terminates alarm and outlet temp sensor alarm defrost will last only three minutes Use outlet sensor for defrost temperature termination Refrigeration Solutions Definition of On Board Symbols STATUS DEFAULT AND READING DISPLAY When the on board green light is on the controller is in normal operation When the green light is blinking a set point is being displayed or ready for change When the red light is blinking there is an alarm The status and the digital data are displayed on the onboard two digit LED display Below is a list of the parameters of the operational status Onboard Optional Two Digit Panel Display Display Description SU STUP Indicates the status of Start Up Mode CF CKFN Check fan working status CP CKP1 Check pressure transducer oP OKP1 Indicates the pressure transducer is working as it should C1 CKT1 Check sensor TS1 the inlet defrost termination temperature sensor 01 OKT1 Indicates the TS1 is working as it should C2 CKT2 Check sensor TS2 the outlet fan cut in temperature sensor 0
9. Refrigeration Solutions 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 53 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 factory tested A technician should check all the settings for proper 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 tw
10. MASTER BILT PART NUMBERS Use the chart below when ordering replacement parts for your Master Bilt Master Controller refrigeration system item Description Part Number Notes High Pressure Transducer for Blood Plasma Room 19 14092 Evaporator Inlet Outlet Sensor Surface Sensor 6 Pin 25 ft Data Cable 19 13780 For use with remote panel display Controller Mounting Cover Assembly 900 18151 For Ante Room Only Remote Panel Display 19 13778 Standard Feature effective 05 08 For condensing unit installation and wiring please consult the Master Bilt Condensing Unit System Installation and Operation Manual If any discrepancy is found in this manual please contact Master Bilt Technical Service Department immediately 26 MBMASTER BILT Refrigeration Solutions MBMASTER BILT Refrigeration Solutions 908 Highway 15 North New Albany MS 38652 Service Dept phone 800 684 8988 Fax 866 882 7629 Email service master bilt com REV 07 Aug 2008 TBC 27 Refrigeration Solutions
11. AND SAFETY INSTRUCTIONS sese 5 APPPIGATIONS beendet ncc Pbi foro Dore P Ro iD S 5 MASTER CONTROL ER caver coepi ede 6 c oot eR UE ERI IRI DM m D Le DM DS LM 6 Factory Mobuhted Parte ucro ore LH E asl du du 9 et na DU 9 Sequences of Operation conia cop ket doom roD He Tan diat cU 10 STARTUP epu RT DE 10 MODE ee dco dio Doi Diem eed eB 10 COO MODE decori LE NU MI UM LIMEN NIA A IE A D Ede 10 DEFROST MODE Lbs i Lien 11 Scheduled 11 Manual nennen nne 11 E 11 PTD SONDA 12 SAEETY MODE T 12 Definition of On Board Symbols cris repe 13 STATUS DEFAULT AND READING nnne nnne 13 Typical Set Points for Blood Plasma Control 14 Alarm DISplay rao a cto ies 15 Setting Parameters by On Board 15 56 16 SENSOR SERVICE INSTRUCTIONS 00 6
12. The hardware and input output descriptions and connections of a Master controller are shown below on Figure 1 20 A 240 VAC N 0 DEFROST RELAY BATTERY BACKUP 9 VDC POWER INPUT 24 VAC 40 VA OFF MODE SWITCH 10 A 240 VAC N C FAN RELAY 5 A 240 VAC N O N C ALARM RELAY m SUCTION PRESSURE TRANSDUCER HIGH PRESSURE ELECTRONIC EXPANSION TRANSDUCER VALVE TERMINALS EXTERNAL RELAY Tum EN CONTROL 752 COMPRESSOR SUCTION TEMPERATURE 751 SENSOR TS4 SET POINT BUTTONS ROOM TEMPERATURE SENSOR TS3 PANEL JACK DISPLAY GREEN STATUS LED 2 DIGIT LED DISPLAY RED STATUS LED 5 485 PORT Figure 1 Master Controller MBMASTER BILT Refrigeration Solutions SEI SER Terminals Sporlan SEI and SER type electric expansion valves are currently 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 saturat
13. installer of a Master Controller system please call Master Bilt for on phone training Since the system is built with high compressor EER the head pressure control valve is not installed in this type of system During initial pull down after primary charge while the system is running a large evaporator superheat is built up The electric expansion valve is then open all the way If the system is charged full sight glass during this period the system is already overcharged The recommended charging procedures are 1 Charge the system by weighing exact amount of refrigerant specified by Master Bilt for the unit TABLE 3 below give the proper refrigerant charges needed for each Blood Plasma sytem The refrigerant charge greatly depends on the length of the liquid line Measure the line set carefully and use the table provided accordingly TABLE 3 REQUIRED REFRIGERANT FOR RESPECTIVE SYSTEMS Condenser BCLZR10AC Compressor 9TH2 101E TFC Evaporator EXLRS330B Liquid Line Length ft Refrigerant Ibs of R 404 A 5 13 25 10 14 31 15 15 37 20 16 43 25 17 49 30 18 55 50 22 79 65 25 97 75 28 09 100 33 39 150 43 99 Liquid Line Size 7 8 Technical Notes e With the optional alarm relay the external temperature and alarm indicator should be connected to common and NC normal close terminals The alarm does not indicate what causes the alarm To find out
14. 00 ONY 137100 ZSL 05 35 3B3nlVN3dW3l NOILVNINYSL 1504330 L3 NI 151 WW 3 Tis quss 651 id Le AINO NO NOOS b T ma 3NHOJSNYML w T 3 1504430 V LAVISS NOLVNOQVA3 T T 4 303 L n WW A M31v3H Nvd 9 T 2 M18 21 Refrigeration Solutions MBMASTER BILT Line Sizing and Insulation Table 4 below depicts proper line sizing for each Blood Plasma system offerd by Master Bilt There is no room for error when making line size selections and this guideline must be followed The suction line must be insulated with 1 minimum Armoflex or equivalent insulation The insulation must fit the piping properly and all joints and bends be properly glued and sealed TABLE 4 LINE SIZING FOR BCLZR10AC Condensing Unit Model Suction Line Sizes Liquid Line Sizes Equivalent Length P Length 50 75 100 150 200 50 100 150 200 BCLZR10AC 1 3 8 13 8 13 8 13 8 13 8 7 8 a 7 8 7 8 7 8 Start Up Check List for Bloo
15. 2 OKT2 Indicates the TS2 is working C3 Check sensor TS3 the room temperature sensor 03 OKT3 Indicates the TS3 is working FH CKFH Indicates all sensors are OK Fd FNDL Indicates FAN DELAY MODE FP FDTP Actual TS2 value in FAN DELAY CL COOL Indicates COOL MODE oF OFF Indicates OFF MODE dF DEFR Indicates DEFROST MODE Cd DRIP Indicates COIL DRAIN MODE dn DFTP Inlet sensor TS1 value in DEFROST MODE Refrigeration Solutions list of the parameters that can be displayed and or changed is shown below when access to the default settings is needed This access is usually done by a trained technician The following are outputs only and may not be changed ro RMTP room temperature from 60 F to 93 F EO POSN percentage the valve is open 0 to 9996 SH SUPH actual superheat in COOL MODE TS2 in CS COSH actual superheat measured at the compressor suction TS4 in in TSAT evaporator saturated temperature calculated from suction pressure Pr oU TOUT evaporator suction outlet temperature from TS2 dE DFTP temperature read from the evaporator defrost termination sensor TS1 Ct CMTP temperature read from compressor suction TS4 Pr PRES suction pressure read from the pressure transducer 14 6 to 138 4PSIG dp DPRS head pressure during Cool Mode suction pressure during Defrost Mode in Hexadecimal Digits Use remote display to read head pressure The following are adjustable parameters Cn CM
16. MD The Standalone Alternating Mode Standalone Ao nS MSGP The address group for communication 15 0 reserved for future use SS SHSP superheat set point 5 to 30 F SS 10 rs RMSP room temperature set point or cut out 50 F to 30 F Default 45F dU DFTM maximum defrost duration 0 to 60 minutes dU 20 95 DFSP defrost termination temperature 35 to 90 F dS 50 dr DRTM drip time duration 0 to 15 minutes dr 5 nd NMDF number of defrosts per day 1 to 12 nd 3 HA HIAL high temperature alarm set point 40 to 35 F Default 30F Ad ALDL temperature alarm delay 0 to 59 minutes Ad 30 LA LOAL low temperature alarm set point 60 F not adjustable oC OFTM minimum time the valve is close 0 to 15 minutes oC 2 2 rn RNTM minimum time the valve is open 0 to 15 minutes rn 2 rP RNTP cut in temperature differential 0 to 25 F rP 05 PS MPSP Maximum pressure set point 4 6 to 55 PSIG Default is PSI Pn NPSP Minimum pressure set point 14 6 to 3 PSIG Default is 14 6 PSI HS DPSP Suction Pressure Set Point during defrost 10 to 80 PSIG Default 30 Ar LGAD Address of controller for remote data logging Ar 00 not used here DGCF Temps measured in Degrees C or Degrees Default FA FS FDSP Fan delay temperature set point 55 to 30 deg 20 F FN FDTM Maximum time to delay fans 0 10 Minutes 5 min SC CMSP Superheat setpoint at compressor suction 15 to 80
17. an alarm will show on the controller display Four temperature sensors are used in the Master Controller refrigeration system They are the room temperature return air sensor the evaporator defrost termination temperature surface sensor the evaporator outlet suction line temperature surface sensor and a Compressor Suction Return Gas Temperature sensor All sensors are solid state devices with the same characteristics that change electrical resistance in response to a change in temperature The room temperature sensor is factory mounted on the lower back of the evaporator at the drain pan This placement avoids heat from defrost heaters and lights and still allows a good air stream over the sensor Figure 3 shows a typical mounting of the room temperature sensor The defrost termination sensor is mounted on one of the distributor tubes close the coil end plate The outlet sensor is mounted on the suction line at the outlet of the evaporator as shown in Figure 4 These sensors are interchangeable Figure 3 SENSOR SERVICE INSTRUCTIONS Care must be taken when brazing the suction line at the SENSOR evaporator The outlet sensor must be taken out before brazing N After brazing fasten the sensor with the metal strap provided Make sure the sensor is tight and has good contact with the suction line 58 The temperature sensor cannot be repaired Using the BD measurements in Chart A below you can determine
18. ature Sensor TS4 is mounted at the suction line just prior 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 When power is applied to the controller the green LED will be on constantly during normal operation The red LED is the negative sign for temperatures showing less than 0 F on the two digit LED display If the red LED is off the two digit display reading is between 0 to 99 F If it is on the 2 digit display reading is between 55 to 1 F 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 functions 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 amp 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
19. cle Defrost Note If you are a first time installer of a Master Controller system please call Master Bilt for on phone training Since the system is built with high compressor EER the head pressure control valve is not installed in this type of system During initial pull down after primary charge while the system is running a large evaporator superheat is built up The electric expansion valve is then open all the way If the system is charged full sight glass during this period the system is already overcharged The recommended charging procedure In a reverse cycle defrost system there may not be a liquid receiver Charge the system at three lbs per ton of rated cooling capacity to start with Let the system run through the pull down period until room temperature is closely reached Then gradually add refrigerant until actual superheat SH on board is approaching superheat setpoint SS Bubbles may be left in the sight glass How to diagnose an overcharged system An overcharged system will not operate properly e First be sure that system is not leaking e Compressor be short cycling e Frost building up on compressor suction section suction filter or service valve Low superheat alarm appears on the controller display constantly Solution Taking some refrigerant out of the system until on board actual superheat SH is observed approaching superheat setpoint SS Due to the reversing of the refrigerant flow it is reco
20. d Plasma Refrigeration Equipment 1 All refrigerant piping should be complete and in accordance with Master Bilt sizing selections Please contact our facility if you are unsure of proper line sizing Good refrigeration piping practices must be followed 2 All refrigeration equipment should have reached proper vacuum levels prior to Master Bilt Engineers arriving on job site Micron gauges should be left on systems so that Master Bilt personnel may observe that proper vacuum levels have been reached 3 40 F rooms the Master Controller Board should be mounted outside Walk In box and all electrical conduits and circuits should be complete Please reference supplied system drawings for proper conduit schedule 4 All electrical connections should be made This shall include all EEVs Pressure Transducers Temperature Sensors and all respective power supplies for each refrigeration system 5 All drain lines should be complete with insulation and drain line heaters wired Electricity to drain line heaters should be left off until start up All lighting door heaters and pressure relief ports should be wired and ready to activate upon start up Walk In Boxes should be clear of debris that may have collected during installation process 22 Refrigeration Solutions REVERSE CYCLE DEFROST General Information Master Bilt s patented U S patent no 7 073 344 reverse cycle defrost is an option provid
21. ed suction pressure in absolute value but displayed 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 measure defrost termination temperature during defrost cylce Figure 2 on the next page shows the sensor locations of the evaporator and the controller Outlet Fan Cut In Temperature Sensor TS2 is mounted on the suction line about 6 to 8 away from the evaporator to measure outlet temperature during cooling cycle and to serve as evaporator fan cut in temperature sensor The sensor is at a 2 or 10 o clock position on the suction line The default value of the fan cut in temperature FS or FDSP is pre set at 20 F for Blood Plasma Storage 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 flow across it If necessary it may be relocated to a spot with better representation of the cold room temperature Compressor Suction Temper
22. ed on Master Controller equipped refrigeration systems only If your Master Controller refrigeration system is equipped with reverse cycle defrost a reverse cycle valve is already factory installed on the condensing unit The valve s primary function is to reverse the direction of the refrigerant flow during defrost Under the normal refrigeration cycle the refrigerant flow is the same as traditional refrigeration modes During the defrost mode the refrigerant flow is reversed back through the evaporator coil heating it from the inside out along its entire length and completely eliminating frost buildup see figure 5 below REFRIGERATING CYCLE DEFROST CYCLE Reversing Reversing Valve Valve Compressor Compressor Electric Electric Walk in Expansion Valve reezer Valve COLD LOW PRESSURE HOT HIGH PRESSURE REFRIGERANT REFRIGERANT Figure 5 Advantages Reverse cycle technology offers several significant advantages An 80 reduction in defrost energy usage This savings coupled with that from the demand defrost feature dramatically reduces electrical consumption Eliminates many mechanical parts Reduces cost of evaporator installation and wiring Reduces defrost time No noticeable increase in freezer room temperature Product temperature rise significantly less Factory Installed Parts A 4 way reversing valve is installed in a reverse cycle defrost unit The 4 way reversing valve operates a
23. if they are Ec functioning correctly If the sensors are found out of tolerance FAN DELAY they should be replaced ls ui As mentioned above the temperature sensor changes cm U electrical resistance in response to temperature changes ERN Disconnect the sensor from the controller check the temperature m at the sensor location then check and record the resistance 6 TO 10 Figure 4 through the temperature sensor Procedures to check temperature sensor tolerance with ice water 1 Useacup of water with well stirred ice The water temperature should be an even 32 F Submerge the room temperature sensor TS3 into the water while the Master Controller is normally operating Check the display for the value If the sensor shows 32 F it is working properly 3 Push PB1 and PB2 simultaneously until the green LED is blinking scroll down the display to in the defrost termination sensor TS1 value Submerge the sensor into the water Check the display for the value If the sensor shows 32 F it is working properly 4 Scroll down the display to oU the outlet sensor TS2 value 5 Submerge the outlet sensor into the water Check the display for the value Again if the sensor shows 32 F itis working properly Compare the temperature and resistance to TABLE 1 MBMASTER BILT Refrigeration Solutions TABLE 1 Temperature Resistance Characteristics 50 to 80 F Temp
24. ill be turned off It will resume normal operation when the pressure is above the Minimum pressure set point While in COOL MODE the two digit display on Master will show CL for three seconds ro for two seconds and the numerical display of the room temperature for five seconds DEFROST MODE dF The defrost mode of this controller is somewhat similar to a conventional defrost timer with one exception This control will termintate the defrost if one of two things happens If the defrost termination temperature ds is reached the controller will terminate the defrost However if the maximum defrost duration dU is reached before the termination temperature is achieved the controller will terminate the defrost After the defrost has been terminated the system will go into the coil drip mode Coil drip mode is another adjustable parameter featured on the Master Controller This set point dr is factor set at 5 minutes During drip mode the reversing valve will remain energized with 24 VAC Scheduled Defrost The following is the description of the scheduled defrost The time of day is really an elapsed counter that counts the number of minutes that have passed An elapsed count of 0 1 12 00 AM The count goes up to 1439 which corresponds to 11 59 PM The counter will then reset to 0 The time of day will be kept as long as the 24 VAC power is connected If the 24 VAC is turned off then back on the time of day will be reset to 0 which c
25. k ups must be done in accordance with all applicable local regional or national standards A 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 BMASTER BILT Refrigeration Solutions 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 gt You must make sure 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 occur if you ignore
26. l show oF for three seconds ro for two seconds and the numerical display of the room temperature for five seconds COOL MODE CL The controller starts COOL mode by opening the valve The condensing unit will start by a suction line low pressure control cut in The electric expansion valve is modulated by the controller so that a preprogrammed superheat set point SS is maintained during the refrigeration process Actual superheat is the temperature difference of the evaporator outlet and the evaporating temperature converted from the reading of the presssure transducer or The controller will keep modulating the valve so the superheat will equal the superheat set point Meanwhile the controller reads also the room air temperature TS3 When the room temperature is below the room temperature set point pre set to 40 F for ultra low temp it goes back to OFF mode If the suction pressure is above the maximum operating pressure set point PS the valve will modulate to control the pressure at or below the maximum operating pressure set point PS When the operating suction pressure is lower than PS it will go back to superheat control Suction pressure is used to calculate saturated temperature Tat via the Pressure Transducer 10 Refrigeration Solutions If the suction pressure is below the Minimum pressure point Pn the valve will close and the control signal to the external relay w
27. lity range This range allows the controller to 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 8096 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 Refrigeration Solutions Sequences of Operation START UP When power is applied to the board the controller closes the valve The controller will display SU on its two digit display for five seconds It will then display CF on the two digit display for 10 seconds The evaporator fans will be on for the first 15 seconds allowing a service technician time to check them The controller will then turn the fans off and check each sensor The controller will check the pressure transducer for a short or open It will display CP on the two digi
28. mmended that the refrigeration liquid line piping also be insulated to prevent condensation drips between the condensing unit and the evaporator coil 24 Refrigeration Solutions TROUBLESHOOTING GUIDE Use the alarm display together with the chart below to check the causes of each error message Trouble Alarm Codes Causes Corrective Actions Pressure transducer alarm SP PRSR dA DPSR Bad transducer e Fitting leak Loose wire e Wrong hook up NOTE for DA or DPSR high side pressure transduce may be out of range 0 500 psig Replace the pressure transducer Repair leak Wire correctly NOTE for DA or DPSR HS may need to be raised Outlet sensor TS2 fails So SCSR Mechanical damage Connection wire loose Overheated Out of range Tighten the connection wires on the controller terminal When brazing suction line take out the sensor Install the sensor after brazing Room sensor TS3 fails SA RMSR Mechanical damage Connection wire loose Overheated Out of range Tighten the connection wires on the controller terminal The room sensor can be replaced by surface sensor Low superheat LS LOSH Superheat setting too low Wrong locations of 51 TS2 e Sensors may be loose e Uneven feeding of coil circuits Overcharge of refrigerant Defective electric expansion valve EEV Compressor stops Change to c
29. o 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 10 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 30 F and left for 12 hours after which the box temperature may be taken to 45 F 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 adjustabi
30. onds SAFETY MODE When an alarm occurs such as a sensor failure or a communication alarm the controller will go into SAFETY MODE SAFETY MODE provides minimum refrigeration to the refrigerated room before the corrective action is taken and the alarm is cleared Pressure transducer alarm SP o Cool mode Valve open for the minimum compressor run time Valve closed for the minimum compressor off time Keep doing above cycle until alarm goes away Ignores maximum pressure control mode e Outlet sensor alarm So o Cool mode Valve open for the minimum compressor run time Close valve for the minimum compressor off time Keep doing above cycle until alarm goes away Fan delay mode ets fan delay time out five minutes o Defrost Mode this alarm and defrost term temp sensor alarm reverse defrost will last only three minutes with valve open Boxtemp sensor alarm SA o Cool Mode Run superheat control for the minimum compressor run time Close valve for the minimum compressor off time Keep doing above cycle until alarm goes away e Low superheat alarm LS o Closes valve and wait for alarm to go away e High Room Temperature Alarm rH The high room temperature alarm occurs when the room temperature is above the preprogrammed HIGH TEMPERATURE ALARM for preprogrammed number of minutes The alarm is cleared when the room temperature is less than the HIGH TEMPERATURE ALARM set point
31. orrect set point Make sure the distributor is feeding each circuit evenly Insulate the sensors with foam tape Use correct refrigerant charge Check EEV wiring Replace defective EEV Check compressor High room temperature rH HIRM Insufficient refrigeration e Heat load too large Compressor fails or high pressure cuts out e Evaporator fans may not run e Door open for too long Coil iced up Check system design to select a sufficient system Replace failed compressor Fix the evaporator fans Keep the cold room door closed during refrigeration Check possible air leak through the walls of cold room Low room temperature rL LORM Inproper low temp setpoint e Over designed system e Change low temp set point Re select the system Defrost termination sensor TS1 fails Sd INSR e Mechanical damage e Loose connection wire e Overheated Out of range Tighten the connection wires on the controller terminal Let the sensor cool down to application temperature range 50 F to 103 F Replace failed sensor Low pressure alarm Refrigerant leak e Fix leak LP PAL e Bad transducer e Replace pressure transducer Communication e Loose RS 485 coonection e Tighten the terminals CA CMAL Failed communication Change a new controller board 25 IM RMASTER BILT Refrigeration Solutions Troubleshooting the Electric Expansion Valve If the valve
32. orresponds to 12 00 AM The first defrost start time is an elapsed time of 0 12 00 AM The subsequent defrost start times are determined by adding the number of minutes between each defrost to the previous start time until there is a defrost start time for each defrost per day The number of minutes between each defrost is determined by taking 1440 number of defrosts per day as set up by the NUMBER OF DEFROSTS set point When starting a reverse cycle defrost the K2 relay is energized to turn off the fans while at the same time terminals B and W of the controller are de energized to turn off the compressor There is a 10 second delay before the K1 relay is energized to switch the four way reverse valve Then there is a 30 second waiting period for pressure equalizing Afterward terminals B and W are energized to turn the compressor on Hot gas will be reversed to flow to the evaporator while the electric expansion valve is modulated to start a defrost The controllers use the inlet sensor TS1 as the defrost termination sensor When this temperature gets above the preprogrammed DEFROST TERMINATION TEMPERATURE SET POINT dS before the preprogrammed MAXIMUM DEFROST TIME 90 the defrost will terminate Otherwise it will be terminated when the MAXIMUM DEFROST TIME elapses as metioned above While in DEFROST MODE the two digit display will be dF for three seconds for three seconds and the numerical display of the
33. rature The red LED will be off if the set point is positive or on if the set point is negative To scroll down the parameters without changing them press PB2 To increase the set point by one increment press PB1 When that set point gets to its maximum value pressing PB1 will rotate it to its minimum value CLEAR ALARM Pressing PB1 three times within five seconds will cause the controller to clear LS rH and rL alarms and restart timer MANUAL DEFROST If the controller is in OFF or COOL MODE pressing and holding pushbutton PB1 for over five seconds will cause the controller to go into defrost cycle If the controller is in 15 Refrigeration Solutions PUMP DOWN MODE pressing and holding pushbutton PB1 for over five seconds will cause the controller to go into DEFROST MODE If the controller is in DEFROST MODE pressing and holding pushbutton PB1 for over five seconds will cause the controller to go into COIL DRAIN MODE If the controller is in COIL DRAIN MODE pressing and holding pushbutton PB1 for over five seconds will cause the controller to go into FAN DELAY MODE If the controller is in FAN DELAY MODE pressing and holding pushbutton PB1 for over five seconds will cause the controller to go into COOL MODE Temperature Sensors The application range of the temperature sensors used for this controller is 50 F to 103 F If the sensor detects a temperature out of the range
34. s on it indicates the temperature is below zero When the green light is blinking a set point is being displayed or ready for change When the red light is blinking it indicates an alarm There are two levels for programming the controllers with the two digit display and two pushbuttons The first level User s Level will enable the USER to set the room temperature set point rS the second level Technician s Level allows access to the other parameters as described above USER s Level Press and hold PB2 until the display shows rS about five seconds The green LED will start blinking The display will toggle between rS and the numerical value of the room temperature set point The red LED will be off if the set point is positive or on if the set point is negative Press PB1 to increase the room temperature set point by 1 F Press PB2 to decrease the room temperature set point by 1 F The set point can be changed between 40 F to 80 F If no button is pushed for 20 seconds the controller will go back to normal operation The green LED will be on constantly and the mode will be displayed as described above TECHNICIAN s Level To enter the second level of programming able to see all temperatures and change all Set points press and hold PB1 and PB2 simultaneously until the display shows ro about five seconds The green LED will start blinking The display will toggle between ro and the numerical value of the room tempe
35. stops moving depending upon how far open it is one or more alarms may be displayed These alarms include a low superheat alarm a low temperature alarm and or a high temperature alarm Use the following steps to troubleshoot the valve 1 Disconnect the valve from the controller 2 The resistance between the black and white leads should be approx 90 ohms The resistance between the black and red leads should be an open 3 The resistance between the red and green leads should be approx 90 ohms The resistance between the white and green leads should be an open 4 The resistance between each lead and the brass housing of the valve should be an open 5 Read the AC not DC voltage across the black and white leads while the valve is moving The AC voltage should be 11 to 18 VAC The voltage will be close to 0 VAC when the valve is not moving 6 Repeat step 5 across the red and green leads If any voltage is out of tolerance replace the controller If the above steps pass inspect for contamination in the valve or nicks on the seat of the valve CAUTION If the valve was taken apart and was left running while taken apart the piston may have come too far out of the motor assembly If you reassemble the valve with the piston in this position the threads in the piston will be stripped when the piston is forced into the seat while tightening the lock nut Make sure the piston is drawn up far enough into the motor assembly before reassembling
36. t 24 VAC A transformer is installed in the master evaporaratpr to supply 24VAC to the 4 way reversing valve 23 Refrigeration Solutions Eliminated Parts The Master Bilt Reverse cycle s unique technology coupled with the bi flow electric expansion valve eliminates the need for Defrost heaters please note some evaporators will have heater they are not wired e Head pressure control valves Check valves and expansion valves at the condenser that are normally necessary in traditional hot gas defrost systems Ante Room only By pass valves Liquid line solenoid valves Receiver tanks Ante Room Only Sight glasses on Ante Room Only Removing these components reduces the cost of the evaporator itself and saves on installation and wiring Defrost Time Defrost time is greatly lessened with the reverse cycle option The average time using traditional defrost heaters is 20 30 minutes but reverse cycle performs a completely clean defrost in 5 8 minutes on average Because the defrost is so rapid there is no noticeable increase in freezer room temperature and the product temperature rise is also significantly less Reverse cycle defrost combined with demand defrost assures the evaporator receives the number of complete defrosts needed at the necessary times to prevent iced evaporators while assuring the protection of the valued product being stored Charging a Master Controller System Equipped with Reverse Cy
37. t display for three seconds If the sensor fails the controller will display an alarm and go to safety mode for a failed sensor If the sensor passes it will display oP on the two digit display for three seconds The controller will check the sensor connected to TS1 for a short or an open It will display C1 on the two digit display for three seconds If the sensor fails the controller will display the alarm Si on the two digit display and go to safety mode for a failed inlet sensor If the sensor passes it will display 01 on the two digit display for three seconds The controller will check the sensor connected to TS2 for a short or an open It will display C2 on the two digit display for three seconds If the sensor fails the controller will display the alarm So on the two digit display and go to safety mode for a failed outlet sensor If the sensor passes it will display 02 on the two digit display for three seconds The controller will check the sensor connected to TS3 for a short or an open It will display C3 on the two digit display for three seconds If the sensor fails it will display the alarm SA on the two digit display and go to safety mode for a failed room temperature sensor If the sensor passes it will display 03 on the two digit display for three seconds If all sensors pass the controller will display on the two digit display for six seconds When sensor fails the alarm relay
38. temperature reading from sensor 51 for three seconds Manual Defrost The controller allows manually initiated defrost when needed The manual defrost will be disabled if the evaporator inlet sensor detects the temperature higher than the defrost termination temperature Operation of the manual defrost will be discussed in a later section COIL DRAIN MODE Cd The controller automatically goes into COIL DRAIN whenever a defrost is terminated The controller stays in this mode for the preprogrammed DRIP TIME dr When this time is completed the controller opens the expansion valve and goes into FAN DELAY mode While in COIL DRAIN MODE the two digit display on the controller will show Cd for five seconds ro for three seconds and the numerical display of the room temperature for three seconds Refrigeration Solutions The controller will pull down the temperature of the evaporator without the fans on until one of the following occurs The fan delay time FN of 0 59 minutes times out or the fan cut in sensor s temperature TS2 goes below the fan delay temperature FS of 20 F Please note this parameter FS has a range of 55 F to 83 F The controller will then go into COOL mode While in FAN DELAY MODE the two digit display will be Fd for three seconds for three seconds and the numerical display of the temperature reading from sensor TS2 for three sec
39. the message WARNING Severe injury or death can occur if you ignore the message 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 DANGER High Voltage Turn power off before servicing May have more than one disconnect switch 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 Refrigeration Solutions 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
40. voltage is different from control voltage Refrigeration Solutions One 5 Amp 240 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 example 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 remote 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 40 The Master Controller power input requirment is 24VAC A factory mounted 40VA step down transformer is provided at the evaporator Secondary voltage 24VAC must be connected to the control board by the refrigeration technician Defrost Term Temp Sensor Evaporator Liquid Line Electric Expansion BO Valve Distributor Evap out Fan Delay Temp Sensor Suction xe um Pressure _ Transducer D Room Temp Sensor 2 Optional Off QBs 1 Mode Switch ST essure Q 5 Transducer 35 485 J 669 MASTER CONTROLLER Figure 2 MBMASTER BILT
41. what has caused the alarm check the onboard two digit display for alarm codes and refer to the diagnosis chart for corrective action No electric current goes through the alarm output circuit Thermostat wiring can be used for connection Defrost termination set point Ds can be also set as 50 70 or 80 F When setting the defrost termination temperature make sure that the frost is free after each defrost Also make adjustments to the maximum defrost duration when necessary 18 Refrigeration Solutions superheat of each application can be set by the customer Superheat 10 15 F is recommended for winter operation superheat 5 10 F for summer Always clear the LS rH and rL alarms after corrective action is taken The sensor and communication alarms cannot be cleared unless they are corrected Follow the instructions in the Master Bilt Condensing Unit and Refrigeration System Installation amp Operation Manual to perform the final check up before charging and starting up the system Always refer to this service manual make sure all steps are understood Don t hesitate to call Master Bilt Customer Service Department at 800 684 8988 for technical assistance Electrical Wiring A WARNING Please make sure to turn all power off before servicing electrical equipment Always use a qualified and trained technician If you are the technician and a first time installer of a Master Controller s
42. will be de energized The controller will not go into defrost during the preceding start up procedure It will check the number of defrosts per day nd and time of day TIME If it is time for the controller to be in defrost it will start in DEFROST Df mode If not the controller will start in COOL CL mode after fan delay The set points are stored in EEPROM Electrically Erasable Programmable Read Only Memory Batteries are not required to store the new set points If 24 VAC power is lost the set points which were in the controller at that time will be used when power is restored OFF MODE oF The controller starts in OFF mode by fully closing the valve The controller will keep the valve closed for the minimum OFF Time in order to keep the compressor in pumpdown or off for a minimum amount of time When the room temperature reaches the cut in set point room temperature set point rS plus the temperature difference set point rP the controller goes to COOL mode CL While the controller is in OFF mode it is constantly checking the number of defrosts per day and the time of day and calculating the time for defrost When the time of day is right for a defrost it will immediately go into DEFROST mode right after the current OFF mode After the Minimum OFF Time has elapsed and the room temperature reaches the Cut In temperature the controller will go into COOL mode CL While in OFF MODE the two digit display on Master wil
43. ystem call our service department at 800 684 8988 for free training and support The field wiring for the Master Controller in the Blood Plasma Room is somewhat different from the wiring assosicated for the Ante Room Since the Blood Plasma Control Board is mounted outside the Walk in Box the control wiring will need to be done by the electrical contractor and the refrigeration technician Please see the wiring diagrams given below for conduit and wiring detail A large Drawing for each of these is included with your equiipment Please note that the control wiring between the condenser and the evaporator may be low voltage thermostat wire All other high voltage wiring must be in compliance with local and national codes Figures 5 and 6 illustrate the wiring details for the Blood Plasma and Ante Rooms respectivelly Refrigeration Solutions TYPICAL WIRING DIAGRAM FOR BLOOD PLASMA ROOM FIGURE 5 09 0 7 807 rl o 1 58 53 1 AINO MOSS3NdWOO 9NINOLINOW MOSN3S dW3l 393NVHOSIQ pim 5 N3MOd WOX LINGNOD 5 38
Download Pdf Manuals
Related Search