GEL Series Gelato & Ice Cream Merchandiser Installation
Contents
1. 44 1 2 INSTALLATION INSTRUCTIONS GENERAL INSTRUCTIONS 1 Be sure the equipment is properly installed by competent service people 2 Keep the equipment clean and sanitary so it will meet your local sanitation codes Clean the cabinet with a mild detergent and water then rinse 3 Rotate your stock so that older stock does not accumulate This is especially important for ice cream First In First Out rotation practice will keep the products in good salable condition 4 Do not place product in the case when it is soft or partially thawed Also product should not be put in the case for at least 4 hours after it is started 5 Stock cases as quickly as possible exposing only small quantities to store temperatures for short periods of time 6 When replacing burned out fluorescent tubes be sure that the electrical power to the lighting circuit is turned off MBMASTER BILT i Refrigeration Solutions NOTICE STORE OWNERS MANAGERS WARNING Moisture or liquid around or under the cabinet is a potential slip fall hazard for persons walking by or working in the general area of the cabinet Any cabinet malfunction or housekeeping problem that creates a slip fall hazard around or under the cabinet should be corrected immediately If moisture or liquid is observed around or under a Master Bilt cabinet an immediate investigation should be made by qualified personnel to determine the source of the moisture or liquid2. x x DRAIN TROUGH DEFROST HEATER J DRAIN LINE q DRAIN LINE HEATER a HEATER R R 5 gt I J gt EVAP FAN ae 5 6 E ZONE SENSOR 12 P EvAP SENSOR E 60 l ey BK 4 2 3 RS X 3 2 lt 5 a 1 Q 8 oil gt om o z 53 lt LS 120V 28 9 N w BK af W z S R J f z R ab compressor CUTOFF SWITCH NORVALLY 5 8 WAS SOLENOID Cas DETAIL NORMALLY CLOSED 3 8 So BK SOLENOID B CONTACTOR SEE COMPRESSOR TERMINAL COVER FOR CONNECTIONS Gi 09 05 06 Refrigeration Solutions 16 I Refrigeration Solutions FRONT GLASS S GEL 9 12 FRONT LIP HEATER w D R BL 5 7 O 7 d A D 0 Q Q gt m SIDE GLASS ee 2 w REAR DECK HEATER R lac D LIGHT SWITCH x h DRAIN TROUGH DEFROST HEATER 1 J DRAIN LINE DRAIN LINE HEATER R 8 2 lle A
3. After the cabinet starts a defrost cycle wait about 15 minutes then disconnect the power supply to the cabinet and let the cabinet stand for this prolonged period This will ensure that all ice has been defrosted and drained from the evaporator and storage area MECHANICAL Remove front and rear grille and check refrigeration lines to see that they are free not touching each other or compressor Spin condenser fan blade to see that it is free Check that all service valves 2 are open The springs are secured for shipping by either tightening bolts Loosen the hold down bolts so that the compressor floats freely Check all refrigeration lines and electrical conduit for rubbing or chaffing paying particular attention to area where lines enter the cabinet Remove cabinet from crate base and slide into location Cabinet must be level from side to side and front to back for correct draining of coil pan and for self closing doors to operate correctly MV RMASTER BILT Refrigeration Solutions WARNING Before servicing electrical components in the case or the doors or door frames make sure all power to case is off Always use a qualified technician Check voltage and amps drawn on the data label to determine proper line and fuse or circuit breaker size Check power supply for low voltage If voltage reads 230 with no load and it drops below 207 when the compressor tries to start it is an indication
4. 13 FINAL CHECK 14 SENSOR PROBE aa qaqa awa kaha adet EONA ATENE 14 MASTER BILT PART NUMBERS i 2 cccc ccecccesesccceeeeecercteedeceeecescuesenveascaveereecdctecesencedeerceeeensec eae 14 ACCESSORIES uu aa 14 SALE AND DISPOSA k 2 ceed saq S 15 WIRING DIAGRAMS aea aai aaa 16 17 M BMASTER BILT INTRODUCTION Thank you for purchasing a Master Bilt cabinet This manual contains important instructions for installing using and servicing a Master Bilt GEL case A parts list is included with this manual Read all these documents carefully before installing or servicing your equipment STORE CONDITIONS The Master Bilt GEL cases are designed to operate in the controlled environment of an air conditioned store The store temperature should be at or below 75 F and a relative humidity of 55 or less At higher temperature or humidity conditions the performance of these cases may be affected and the capacity diminished It is not uncommon in a newly constructed store for the temperature and humidity to be above design conditions These excessive conditions may produce sweating in the case until the store is operational and the ambient environment is more desirable The Master Bilt
5. GEL should not be positioned where it is directly exposed to rays of the sun or near a direct source of radiant heat or air flow No HVAC return or supply air ducts may be located near case openings This will adversely affect the case air flow and will result in poor performance Do not open windows or doors that will affect the case air flow The maximum air velocity near the case is 30 FPM This case is designed to be open to the front customer side of the case and open at the rear server side of the case This case should not be placed against a wall that closes off the front or the rear of the case To comply with sanitation requirements the cabinet must be sealed to the building floor with NSF Listed Silicone Sealant or mounted on 6 Minimum legs or casters NOTICE Read this manual before installing your cabinet Keep the manual and refer to it before doing any service on the equipment Failure to do so could result in personal injury or damage to the cabinet A DANGER Improper or faulty hook up of electrical components on 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 A NOTICE Installation and service of the refrigeration and electrical components of the cabinet must be performed by a refrigeration mechanic and or a licensed electrician The portions of this manual covering refrigeration and
6. R a 5 J NO WY ZONE w SENSOR 12 j el 10 11 m 5 SENSOR 10 wr BK w 5 BK W x RJ 5 2 D x TRANSF a M gt fod gt amp 120 gt gt al BK w w OR Y Se Rheostot a Jimmer w 9 BK BK A COMP COMP CUTOFF CUTOFF us N NORMALLY SWITCH SWITCH NORMALLY a 5 83 SOLENOID SOLENOID de Me oe 5 w NORMALLY BK N TIME NORMALLY 5 87 CONTA BK 8 RELAY SOLENO tian CONTACTOR CONTACTOR BK 16 SEC 3 8 SEE COMPRESSOR 7 TERMINAL COVER E FOR CONNECTIONS Tan SEE COMPRESSOR NY FOR CONNEC HONS 09 05 06 Refrigeration Solutions
7. 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 MRMASTER BILT Refrigeration Solutions WARNING LABELS AND SAFETY INSTRUCTIONS This symbol is the safety alert symbol When you see this symbol on your cabinet or in this manual be alert to the potential for personal injury or damage to your equipment Be sure you understand all safety messages and always follow recommended precautions and safe operating practices A NOTICE TO EMPLOYERS You must make sure that everyone who installs uses or services your cabinet is thoroughly familiar with all safety information and procedures Important safety information is presented in this section and throughout the manual The following signal words are used in the warnings and safety messages DANGER Severe injury or death will occur if you ignore the message WARNING Severe injury or death can occur if you ignore the message CAUTION Minor injury or damage to your cabinet can occur if you ignore the message NOTICE This is important installation operation or service information If you ignore the message you may damage your cabinet The warnin
8. of too small supply wiring or too long to run It is recommended that a separate circuit be run for each cabinet to prevent another appliance blowing the fuse or breaker causing loss of product A IMPORTANT This cabinet is pre wired internally for separate 115 and 230 volt circuits Tapping or feeding the 115 volt circuit from 230 volt supply may result in overloaded circuit breakers or blown fuses and damage to electrical system thereby voiding the warranty The cabinet should be grounded A IMPORTANT This cabinet will require a separate 115V circuit for the condensate drain pan unless the drain will be piped to a floor drain MV RMASTER BILT Refrigeration Solutions HOT GAS REFRIGERANT PIPING The Master Bilt GEL series of cabinets is equipped with a hot gas defrost This involves some extra piping from an electrical or air defrost system The diagrams here show only one condensing unit and one set of connection points at the evaporator It should be noted however that the GEL 9 and GEL 12 have two condensing units each unit having evaporator connection points at each end of the evaporator There are two solenoid valves The 3 8 solenoid valve is normally closed and the 5 8 solenoid valve is normally open During a normal refrigeration cycle the 3 8 valve is closed the 5 8 valve is open and refrigerant is allowed to flow through the condenser coil and the expansion valve before fl
9. some seconds after the fault in the related probe they automatically stop some seconds after the probe restarts normal operation Check connections before replacing the probe Temperature alarms HA and LA automatically stop as soon as the thermostat temperature returns to normal values and when defrost starts MASTER BILT ie Refrigeration Solutions SERVICE INSTRUCTIONS 1 High head pressure and high back pressure A Condenser coil clogged or restricted B Condenser fan motor defective C Air discharge in front of cabinet restricted Low back pressure and low head pressure A Restriction in system B Refrigerant undercharged C Leak in system Pressure normal cabinet warm A Coil blocked with frost see 4 B Refrigerant undercharged C Control set too warm Cabinet not cycling coil blocked with frost A Defective temperature controller Refrigerant overcharged Evaporator Fan Motor defective Condenser clogged Condenser fan motor defective Hot gas solenoid valve defective Copressor starts and runs but cycles on overload A Low voltage B Relay defective C Overload defective MASTER BILT Refrigeration Solutions Hot gas defrost duration not long enough or too few defrosts CHECK LIST A Check operating pressures B Check electrical requirements of unit to supply voltage C Set temperature control for desired temperature range D Check sight
10. 3199 09 09645 09 09826 09 09453 23 50793 09 01162 19 13934 2 19 13707 23 01693 23 01577 2 23 50562 4 25 01274 2 17 09437 03 14985 2 17 09434 17 09434 07 13076 2 15 13093 13 01283 19 13918 19 13932 09 00992 09 09171 07 13315 13 13199 09 09645 09 09826 09 09453 23 50793 09 01162 19 13934 2 19 13707 MRMASTER BILT Refrigeration Solutions SALE AND DISPOSAL OWNER RESPONSIBILITY If you sell or give away your Master Bilt cabinet you must make sure that all safety labels and the Installation Service Manual are included with it If you need replacement labels or manuals Master Bilt will provide them free Contact the customer service department at Master Bilt at 800 684 8988 The customer service department at Master Bilt should be contacted at the time of sale or disposal of your cabinet so records may be kept of its new location Refrigeration Solutions GEL 6 FRONT GLASS az a FRONT LIP HEATER w 5 BL Dg SIDE GLASS C 7 5 BR w REAR DECK HEATER R D LIGHT SWITCH m
11. RMASTER BILT Refrigeration Solutions GEL Series Gelato amp Ice Cream Merchandiser Installation amp Operations Manual Master Bilt Products 908 Highway 15 North New Albany MS 38652 Phone 800 684 8988 PN 018 90000 Rev 12 12 06 TABLE CONTENTS INTRODUCTION 3 STORE CONDITIONS ban u u u un ents 3 WARNING LABELS AND SAFETY INSTRUCTIONS 4 PRE INSTALLATION INSTRUCTIONS J 5 Inspection for Shipping r 5 INSTALLATION INSTRUCTIONS u Il ec eed sasa sassa sk 5 General 5 Mechanical 7 ls a aa is Ws veg 8 Leg and Condensate Pan 1 51 8 6 mien L azas Za 8 CABINET CLEANING PROCEDURES 6 TEMPERATURE SENSOR DEFROST HEATER AND FAN MOTOR REPLACEMENT 7 DIXELL XR60C REFRIGERATION CONTROL 11 SERVICE INSTRUCTIONS gt 2 25
12. The investigation should determine if the cabinet is malfunctioning or if there is a drainpipe leaking CABINET CLEANING PROCEDURES WARNING To avoid electrical shock disconnect main power supplies to the merchandiser before beginning this procedure May have more than one disconnect switch The exterior of the cabinet should simply be wiped clean with a Warm damp cloth daily This will be sufficient to keep the merchandiser looking its finest Do not use a brush scouring pad or any abrasive material on the painted surfaces To clean the interior of the cabinet the condensing unit and power to the merchandiser fans lights and heaters should be shut off Disconnect all power before cleaning All product in the cabinet should be removed and stored in an appropriate facility All shelving trays Pans etc should be removed and cleaned separately For cleaning the air discharge honey comb in the back wall Romove the honey comb retainer that s hold the honey comb in place by unscrewing all the thrump scews Gently pull out all the honey combs Wash with hot warm water only and carefully replace it back Be sure the honey combs is dry before putting it back inplace to provent from ice build up blocking the air flow The interior as well as the exterior of the cabinet may be cleaned with a germicidal detergent at the manufacturer s recommended concentration Do not use any ammonia based products as this may damage the electrical components
13. WN Y lt keys for 3 seconds LEDs under DEF and COMP start blinking Select the required parameter by pushing the UP A or DOWNY arrows Press the SET key to display its value now only the COMP LED is blinking Use UP or DOWN to change its value To exit Press SET or wait 15s without pressing a key N NOTE 1 The set value is stored even when the procedure is exited by waiting the time out to expire NOTE 2 Master Bilt s SETPOINT is set at a recommended 10 F at the factory for low temperature LT and 35 F for medium temperature MT application NOTE 3 To scroll down the parameters without changing them press the DOWN button LIST OF PARAMETERS Here is a list of the parameters the value of which can be changed in the programming mode as well as their ranges Parameter Display Description Range Master Bilt s Symbol Setting Minimum When this temperature is temperature alarm ALL reached the alarm is enabled 58 to 230 F 40 limit after a delay Maximum When this temperature is temperature alarm ALU reached the alarm is enabled 58 to 230 F 15 limit after a delay ALARM SIGNALS Message Cause pe ee probe failure Compressor output according to par Con and COF probe failure Defrost end is timed temperature alarm Outputs unchanged LA Minimum temperature alarm Outputs unchanged NOTE Probe alarms P1 and P2 start
14. d the 2 minute drip time has passed There is 4 minutes delay after a defrost before the fan comes on The difference of the evaporator and room temperature of more than 9 F will override the fan delay FAN LED indicator is on while FAN relay is energized Defrost The control uses a hot gas defrost every two hours During defrost the display will show dEF and the LED indicator under DEF in on MANUAL DEFROST 1 Push this key for more than 2 seconds and a manual defrost will start 2 While in defrost Push and hold the ea key for more than 5 seconds and the controller will end the defrost cycle The controller will then enter drip mode for 2 minutes The DEF led is flashing in drip mode HOW TO SEE THE SETPOINT Box temperature cut out SET 1 s Push and immediately release the SET key the display will show the Set point value 2 Push and immediately release the SET key or wait for 5 seconds to display the probe value actual box temperature again HOW TO CHANGE THE SETPOINT 1 Push the SET key for more than 2 seconds to change the Set point value 2 The value of the set point will be displayed and the LED under COMP starts blinking 3 To change the Set value push the UP A or DOWNY arrows within 10s To memorize the new set point value push the SET key again or wait 10s MBMASTER BILT Refrigeration Solutions HOW CHANGE a parameter value a SET 1 Enter the Programming mode by pressing the SET and DO
15. g and safety labels shown throughout this manual are placed on your Master Bilt Products cabinet at the factory Follow all warning label instructions If any warning or safety labels become lost or damaged call your customer service department at 800 684 8988 for replacements vancer CAUTION High Voltage Turn power off GROUND REQUIRED before servicing May have more FOR SAFE OPERATION than one disconnect switch This label is located on top of the electrical control This label is attached to the cabinet power cord label and on the wiring channel on models with a power cord MV RMASTER BILT i Refrigeration Solutions PRE INSTALLATION INSTRUCTIONS INSPECTION FOR SHIPPING DAMAGE You are responsible for filing all freight claims with the delivering truck line Inspect all cartons and crates for damage as soon as they arrive If damage is noted to shipping crates or cartons or if a shortage is found note this on the bill of lading all copies prior to signing If damage is discovered when the cabinet is uncrated immediately call the delivering truck line and follow up the call with a written report indicating concealed damage to your shipment Ask for an immediate inspection of your concealed damage item Crating material must be retained to show the inspector from the truck line
16. glass for proper refrigerant charge if provided MASTER BILT PART LIST Check packing nuts on all service valves Check system for proper defrost settings and operation All valves should be completely opened counter clockwise Replace all service valve caps and latch unit covers Check condensing unit for vibrating or rubbing tubing Dampen and clamp as required The table below gives Master Bilt part numbers Use this chart when ordering replacement parts for your GEL cabinets Always Advise Cabinet Serial Number When Ordering Parts Ballast 96 Bulb Lamp F25T8 24 Bulb Lamp F32T8 Bulb Holder Bulb Shield Drain Trough Heater Compressor Anti Sweat Heater Front Anti Sweat Heater Rear Deck Condenser Coil Condenser Fan Blade Condenser Fan Motor Electronic Controller 20 Sensor Assembly CRO Valve Drier Evaporator Coil Evaporator Motor Blade Assy 3 8 Solenoid Valve 5 8 Hot Gas Solenoid Valve Expansion Valve Lamp Switch Receiver Tank Contactor Time Delay Relay 23 01693 23 01577 23 50562 2 25 01274 17 09435 03 14985 17 09432 17 09432 07 13076 15 13093 13 01283 19 13918 19 13932 09 00992 09 09171 07 13313 13 13199 09 09645 09 09826 09 09453 23 50793 09 01162 19 13934 23 01693 23 01576 2 23 50562 4 25 01274 2 17 09436 03 14985 2 17 09433 17 09433 07 13076 2 15 13093 13 01283 19 13918 19 13932 09 00992 09 09171 07 13314 13 1
17. in the cabinet Again do not use a brush scouring pad or any abrasive material on the painted surfaces Use a soft brush or cleaner pad for built up dirt stains or spills Remove only the necessary mechanical parts to access the evaporator coil and fan housing Care should be taken not to unnecessarily soak fan motors electrical connections controls or any wire raceway Wipe all surfaces with a damp cloth A sanitizer should then be thoroughly sprayed onto the surfaces and again wiped with a damp cloth Remove only the necessary mechanical parts to access the condenser coil and compressor housing Care should again be taken not to unnessarily soak fan motors electrical connections time clock ballasts or any wire raceway Check the condenser coil to insure that it is not clogged with dirt dust or lint A dirty or clogged condenser coil will result in diminished performance of the cabinet The condenser should be brushed with a plastic bristled brush For dust or dirt that has accumulated deep inside the condenser use compressed air to blow the dirt through the coil Do not let dust or dirt accumulate on the fan blades If dust or dirt is noticeable simply wipe the fan blades with a damp cloth as with other surfaces After cleaning replace any equipment that was previously removed and started the condensing unit and return power to the lights fans and heaters CLEANING As a regular maintenance routine the condenser coil should be cleaned a
18. owing through the evaporator coil See the figure on the next page During a defrost cycle both valves are energized 3 8 valve opens the 9 8 valve closes the condenser coil and the expansion valve are bypassed and hot gas is introduced to the evaporator coil for defrosting See the figure on the next page Refrigeration Solutions CONDENSER COIL 7 2 7 MM fz A 0 Y sa l SO Ee Zi 2 Go 5 CX SE XPANS ALLY 50 ECIEVER x CAI DULL Refrigeration Solutions MASTER BILT ELECTRONIC REFRIGERATION CONTROL OPERATION Compressor When power is first turned on to the control the LED indicator under COMP on the display starts blinking After one minute delay the compressor comes on The COMP LED indicator stays on while compressor relay is energized Display will show actual box temperature Figure 4 is the display layout The compressor will be cycled off when the actual box temperature reaches its set point The COMP indicator will be off FAN DEF Fig 4 Display Lay out Fan The fans will run constantly except when a defrost is initiated or when the evaporator temp is above the 30 F When in defrost mode the fan is off until the end of the defrost an
19. pprox every 6 to 12 months depending on store conditions Keep the equipment clean and sanitary so it will meet your local sanitation codes Wipe up all spills clean with water and a mild detergent then rinse with clean water Wipe the exterior and gasket area as needed MRMASTER BILT Refrigeration Solutions Cabinet Monthly Checklist 1 Check condenser coil clean if necessary 4 Check for excessive noise 2 Check service valve packing for leaks evident by oil traces 5 Check for proper temperature adjust if necessary 3 Check for obstruction restricting air flow over the evaporator coil and the condenser 7 Check for proper operation sequence in coil Insure that the air intake is not normal refrigeration cycle and defrost cycle when obstructed applicable EXTERNAL CLEANING Clean the front and side glass panels and the end panels and serving surfaces with warm water and a mild detergent Never use steel wool abrasives glass paper or similar products Never use acids chlorines ammonia etc as it could damage the cabinet surface WEEKLY DEFROSTING For enhanced performance and efficiency the Master Bilt GEL series should be defrosted weekly for an extended period at least twelve hours To achieve this defrost the cabinet should have a manual defrost first Press and hold the button labeled MAN DEF for ten seconds on the control See the section of this manual labeled ELECTRONIC REFRIGERATION CONTROL
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