BLG/TLG Series

Bottom Mount Glass Door Merchandisers

2005 “K” Version with Dixell controller

Installation & Operations Manual

Master-Bilt Products

908 Highway 15 North

New Albany, MS 38652

Service Phone: 800-684-8988

PN 303-91000

Rev:8-20-05

Rev:8-23-06

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TABLE OF CONTENTS

INTRODUCTION………………………………….……………………………………………………………………4

STORE CONDITIONS…………………………….……………….…..…………………………………………….. 4

WARNING LABELS AND SAFETY INSTRUCTIONS………..…..……………………………………………… 5

PRE-INSTALLATION INSTRUCTIONS………………………..…..………………………………….…………… 6

Inspection for Shipping Damage…………………………………………………………….……………... 6

INSTALLATION INSTRUCTIONS………………………………………………………………………………….. 6

Mechanical ..…………………………………………………………………………………………………..6

Electrical…………...…………………………………………………………………………………………..7

Leg and Condensate Pan Installation..……………………………………………………………………. 7

Doors ..…………....………………………………………………………………………………………….. 8

ELECTRONIC REFRIGERATION CONTROL (DIXELL RX60C)…………………………………………….… 9

Programming……………………………………………………………………………………………..…. 9

List of Parameters………………………………………………………………………………………..….10

SENSOR PROBE ………………………………………………………………………………….………………. 11

CABINET COMPONENT AMP DRAW………………………………………………………………………………11

TEMPERATURE SENSOR, DEFROST HEATER AND FAN MOTOR REPLACEMENT…………………… .12

FINAL CHECK LIST…………………………………………………………………………………….………….… 13

SERVICE INSTRUCTIONS ………………………………………………………………………………………... 13

MASTER-BILT PART NUMBERS …………………………………………………………………………………. 14

ACCESSORIES …………………………………………………………………………………………………….15

SALE AND DISPOSAL ……………………………………………………………………………………………..15

WIRING DIAGRAMS BLG/TLG………………………………………….……………………….………… …...16-19

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INTRODUCTION

Thank you for purchasing a Master-Bilt cabinet. This manual contains important instructions for installing, using, and servicing a Master-Bilt BLG/TLG 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 BLG/TLG 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.

The Master-Bilt BLG/TLG should not be positioned where it is directly exposed to rays of sun or near a direct source of radiant heat or airflow. This will adversely affect the case and will result in poor performance.

If this case is to be located against a wall, there should be at least 6” space between the wall and the back of the case. This space will allow for the circulation of air behind the case, which will prevent condensation on the exterior surfaces.

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.

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.

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 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 866-882-7629

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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.

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 warning 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.

CAUTION!

GROUND REQUIRED

FOR SAFE OPERATION

This label is located on top of the electrical control

label and on the wiring channel.

This label is attached to the cabinet power cord

on models with a power cord.

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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.

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. A "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 6 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.

NOTICE TO STORE OWNERS / MANAGERS

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 liquid. The investigation should determine if the cabinet is malfunctioning or if there is a drainpipe leaking.

MECHANICAL

Remove front 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.

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. Allow minimum of 4” between back of cabinet and wall and between top of cabinet and ceiling for proper condensing unit air circulation.

To comply with Sanitation requirements the cabinet must be mounted on legs (6” high min.) or casters or the base must be sealed to the floor (BLG) with an N.S.F. listed silicone sealant.

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ELECTRICAL

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 (Page 17-20) 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 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.

IMPORTANT

Models (2 and 3 door low temp) are pre-wired internally with a 208-230V NEMA L14-20P plug and should only be plugged into a NEMA L14-20P recepticle. See wiring diagrams on page 19-21. The cabinet should be grounded.

LEG AND CONDENSATE PAN INSTALLATION FOR TOP MOUNT CABINETS ONLY

1. Screw legs into existing crate mounting holes.

2. Before moving cabinet into place, remove the condensate pan from the top unit compartment.

3.

Using the two screws supplied with the pan, attach the pan to the back of the cabinet at the two holes near the bottom of the plastic drain line. Be sure pan is NOT located directly under cabinet. When the pan is attached, feeds drain line into the open hole in screen and clamp the heater conduit to the back of the cabinet. Due to this condensate pan, this case must be a minimum of 6” from the wall.

4. If cabinet must be located next to wall, the pan can be located under the cabinet. When this is done, steam will accumulate on the bottom of the cabinet if there is not adequate ventilation, and rusting of the bottom of the cabinet

will occur.

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DOORS

The BLG/TLG cabinets have Anthony glass doors that are equipped with a patented TorqueMaster

™ hinge system. The doors are easily adjusted using a flathead screwdriver (Fig.3).

* The tension needs to be checked and set when

first install.

Torque Adjustment

Leveling Adjustment

Figure 3

To remove the door shipping clamps,

remove the 4 shipping screws from the grill and

remove the screws from the clamps (Fig.4), and replace grill.

Figure 4

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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.

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 o

F. When in defrost mode the fan is off until the end of the defrost and 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 o

F will override the fan delay.

FAN

LED indicator is on while FAN relay is energized.

Defrost

The control uses time defrost with 4 defrost per day. A programmed “HOT-KEY” has to be used to re-set the defrost scheme for special applications. During defrost the display will show dEF and the LED indicator under DEF in on. The control begins timing the defrost when power is turned on. Four defrost per day means it will occur every 6 hours. To have defrost occur at 8am,

2pm, 8pm, and 2am then power up at one of these four times.

MANUAL DEFROST

key for more than 2 seconds and a manual defrost will start.

2. While in defrost, Push and hold the DEFROST

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)

1. point value;

Push and immediately release the SET key: the display will show the Set

2. Push and immediately release the SET key or wait for 5 seconds to display the probe value

(actual box temperature) again.

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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

▲ or DOWN▼ arrows within 10s.

To memorize the new set point value push the SET key again or wait 10s.

HOW TO CHANGE a parameter value

1. Enter the Programming mode by pressing the SET and DOWN

▼

(LEDs under DEF and COMP start blinking).

2. Select the required parameter by pushing the UP

▲ or DOWN▼ arrows

3. Press the “SET” key to display its value (now only the COMP LED is blinking)

keys for 3 seconds

5. To exit: Press SET + UP

▲ or wait 15s without pressing a key.

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 o

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

Symbol

Temperature Set

Point

Temperature

Differential

Maximum

Temperature

Alarm

Minimum

Temperature

Alarm

Temperature

Alarm Delay

Room Probe display

Evaporator

Probe Display

Set

Hy

ALU

ALL

Ald dP1 dP2

When this temperature is reached the compressor LED will be off

Cut-out temperature is Set + Hy

-16 to 5°F

1 to 255°F

230°F

-58°F

0 to 255 min

Setting

BLG

-10°F or -15°F

10

15

-25

30

10

ALARM SIGNALS

Message

“P1”

Cause

Room probe failure

Evaporator probe failure

“P2”

“HA”

“LA”

Maximum temperature alarm

Minimum temperature alarm

Outputs

Compressor output time, 6 min on, 4 min off

Defrost end is timed

Outputs unchanged.

Outputs unchanged.

NOTE:

Probe alarms “P1” and “P2” start 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.

ELECTRICAL CONNECTIONS

The controller is provided with screw terminal block to connect cables with a cross section up to 2,5 mm

2

.

Before connecting cables make sure the power supply complies with the control’s requirements. Separate the probe cables from the power supply cables, from the outputs and the power connections. Do not exceed the maximum current allowed on each relay, in case of heavier loads use a suitable external relay.

PROBE CONNECTIONS

The probes shall be mounted with the bulb upwards to prevent damages due to casual liquid infiltration. It is recommended to place the thermostat probe away from air streams to correctly measure the average room temperature. Place the defrost termination probe among the evaporator fins in the coldest place, where most ice is formed, far from heaters or from the warmest place during defrost, to prevent premature defrost termination.

BLG/TLG CABINET COMPONENT AMP DRAW

ITEM

PART

VOLTAGE

NO.

RATING CABINET

AMPS AT AMPS AT

208 VOLTS 230 VOLTS NOTES

Coil Defrost Heater 17-09408 230 V

Coil Defrost Heater 17-01311 230 V

Condensate Heater 230 V

Condensate Heater 201I130 230 V

BLG/TLG-48, 52

BLG/TLG-74, 80

BLG-48, 52, 74, 80

TLG-48, 52, 74, 80

3.9

6.3

1.2

1.2

Door Frame Heater 17-09419 115 V BLG/TLG-48, 52, 74, 80 .33 ea

Door 31-02602 120V BLG/TLG-48, 74 .55 ea

Door

Door

31-02603

31-02604

120V

120V

BLG/TLG-48

BLG/TLG-52, 80

.55 ea

.76 ea

4.3

7

1.3

1.3

.37 ea

.60 ea

.60 ea

.84 ea

Door 31-02605 120V BLG/TLG-52

Drain Heater 17-00404 115 V BLG/TLG-48, 52, 74, 80

ITEM

PART

VOLTAGE

NO.

RATING CABINET

.76 ea

0.05

.84 ea

0.06

AMPS AT

AMPS AT

104 VOLTS 115 VOLTS

Check Red or Black Leg

Check Red or Black Leg

Check Red or Black Leg

Check Red or Black Leg

Check Black Leg

Check Black Leg

Check Black Leg

Check Black Leg

Check Black Leg

Check Black Leg

NOTES

Coil Defrost Heater 17-09407 120 V

Condensate Heater A321-130 115 V

Condensate Heater 323I130 115 V

Door Frame Heater 17-09419 115 V

Door 31-02600 120V

Drain Heater 17-00404 115 V

BLG/TLG-27

BLG-27

TLG-27

BLG/TLG-27

BLG/TLG-27

BLG/TLG-27

4.3

2.3

2.3

0.33

.81 ea

0.05

4.8

2.6

2.6

0.37

.90 ea

0.06

Check Black Leg

Check Black Leg

Check Black Leg

Check Black Leg

Check Black Leg

Check Black Leg

11

I.

J.

D.

E.

F.

G.

H.

FINAL CHECK LIST

A.

B.

C.

Check operating pressures.

Check electrical requirements of unit to supply voltage.

Set temperature control for desired temperature range.

Check sight glass for proper refrigerant charge, if provided.

Check system for proper defrost settings and operation.

Check condensing unit for vibrating or rubbing tubing. Dampen and clamp as required.

All valves should be completely opened counter-clockwise.

Check packing nuts on all service valves.

Replace all service valve caps and latch unit covers.

Check and set the door tension at the Torque Adjustment.

SERVICE INSTRUCTION

1. High head pressure and high back pressure:

A. Condenser coil clogged or restricted

B. Condenser fan motor defective.

C. Air discharge in rear of cabinet restricted.

2. Low back pressure and low head pressure:

A. Restriction in system.

C. Leak in system

3. Pressure normal – cabinet warm:

A. Coil blocked with frost (see #4).

C. Control set too warm.

4. Cabinet not cycling – coil blocked with frost:

A. Defective temperature controller.

C. Location too hot.

E. Condenser fan motor defective.

F. Defrost heater not operating.

5. Copressor starts and runs – but cycles on overload:

D. High head pressure (see #1).

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Temperature sensor, defrost heater and fan motor replacement

Before making any change, technician should:

1. Disconnect power to the cabinet

2. Remove screws from venturi and pull down

To change a temperature sensor (cabinet zone sensor or defrost termination sensor), simply disconnect the sensor wires from the controller and replace the new sensor in the original position. Use plastic tie to tighten the zone sensor. Insert the sensor for defrost termination firmly into the evaporator coil, in between the fins. Make sure the sensor wires do not touch or are not close to any heater rods.

To change defrost heater – remove screws from drain pan and pull down – remove screws from coil mounting straps – spring straps open – remove heater shield – pull heater out of slots in coil fins.

To change fan motor – disconnect fan motor leads – remove screws from fan guards and motor mounts.

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MASTER-BILT PART LIST

The table below gives Master-Bilt part numbers. Use this chart when ordering replacement parts for your

BLG/TLG cabinets. Always Advise Cabinet Serial Number When Ordering Parts

Description BLG/TLG-

27HD

Ballast 23-01706

BLG/TLG-

48HD

23-01706

BLG/TLG-

52HD

23-01706

BLG/TLG-

74HD

23-01706

BLG/TLG-

80HD

23-01706

Bulb

Bulb Holder Bottom

Bulb Holder Top

Bulb Shield Inner

Bulb Shield Outer

Coil Defrost Heater

Compressor

Compressor Contactor

Compressor Relay

Compressor Run Capacitor

Compressor Start Capacitor

Compressor Switch

Condensate Heater “T”

Condensate Heater

Electric, TLG

Condensate Heater, BLG

Electric (Optional)

Condenser Coil

Condenser Fan Blade

Condenser Fan Motor

Door Frame Heater

Door-L.H. (Black)

Door-R.H.

Drain Heater

Drier

Electronic Controller

Evaporator Coil

Evaporator Fan Blade

Evaporator Fan Guard

Evaporator Fan Motor

Expansion Valve

Female Door Plug

Female Plug

Front Control

Heater Safety Control

Leg (TLG only)

Leg Leveler

Light Switch

07-13241

15-13093

13-00311

17-09419

31-02600

17-00404

09-09171

19-13918

07-13288

15-13106

25-01324

13-13181

09-09825

21-00568

21-00577

19-13897

19-01164

27-00558

27-00592

23-50793

23-01689 23-01689 23-01689 23-01689 23-01689

23-00335

23-00336

23-01692

23-00335

23-00336

23-01692

23-00335

23-00336

23-01692

23-00335

23-00336

23-01692

23-00335

23-00336

23-01692

23-01462

17-09407

03-14799

19-13936

23-01464

17-09408

03-14968

19-13934

03-14980

03-14978

23-01464

17-09408

03-14968

19-13934

03-14979

03-14978

23-01464

17-01311

03-14973

19-13934

03-14977

03-14975

23-01464

17-01311

03-14973

19-13934

03-14977

03-14975

19-13118

17-00380

03-14979

19-13118

17-00421

03-14979

19-13118

17-00421

03-14976

19-13118

17-00421

03-14976

19-13118

17-00421

323I130

A321-130

323I130

17-00421

07-14009

15-13093

13-01283

17-09419

31-02602

31-02603

17-00404

09-09711

19-13918

07-13289

15-13106

25-01324

13-13182

09-09758

21-00568

21-00577

19-13897

19-01164

27-00558

27-00592

23-50793

323I130

17-00421

07-14009

15-13093

13-01283

17-09419

31-02604

31-02605

17-00404

09-09711

19-13918

07-13289

15-13106

25-01324

13-13182

09-09758

21-00568

21-00577

19-13897

19-01164

27-00558

27-00592

23-50793

323I130

17-00421

07-14009

15-13093

13-01283

17-09419

31-02602

17-00404

09-09711

19-13918

07-13290

15-13106

25-01324

13-13182

09-09759

21-00568

21-00577

19-13897

19-01164

27-00558

27-00592

23-50793

323I130

17-00421

Sight Glass

Temperature Sensor (2)

Terminal Block

19-13932 19-13932

19-01091

19-13932

19-01091

19-13932

19-01091

07-14009

15-13093

13-01283

17-09419

31-02604

17-00404

09-09711

19-13918

07-13290

15-13106

25-01324

13-13182

09-09759

21-00568

21-00577

19-13897

19-01164

27-00558

27-00592

23-50793

19-13932

19-01091

14

Accessories (Includes HD Models)

Description BLG/TLG-

27HD

Baskets (Cantilever)

20” X 22” X 5”

Baskets

(Conventional)

22”X 22-3/4”X 5”

Baskets

(Conventional)

24-3/4”X22”X5”

Casters (4) 3”

Diameter

Casters (6) 3”

Diameter

BLG/TLG-

48HD

33-01458

33-01419

BLG/TLG-

52HD

33-01376

A200-11140 A200-11140 A200-11140

BLG/TLG-

74HD

33-01458

33-01419

BLG/TLG-

80HD

33-01376

A212-11140 A212-11140

Shelves (Cantilever)

Shelving Clips (4)

A200-11170 A200-11170 A200-11170 A212-11170 A212-11170

33-01473 33-01474 33-01475 33-01474 33-01475

33-01402 33-01453 33-01448 33-01453 33-01448

33-01011 33-01011 33-01011 33-01011 33-01011

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.

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