TRAULSEN RBC50, RBC100 & RBC200 BLAST CHILLERS

Transcription

1 TRAULSEN RBC50, RBC100 & RBC200 BLAST CHILLERS basic service guide -NOTICE- This Manual is prepared for the use of qualified personnel. It should not be used by those not properly qualified. Before proceeding with any work, you should read, in its entirety, the procedure you wish to perform in order to determine if you have the necessary tools and skill required to perform the procedure. Procedures for which you do not have the necessary tools and/or skill should not be performed.

2 1 TRAULSEN RBC50, RBC100 & RBC200 BLAST CHILLER BASIC SERVICE GUIDE Table of Contents Page Programming The Control... 2 General Troubleshooting Replacing The Control Board... 5 Replacing Either Printer...6 Repairing Moisture Damage...7 Verifying Control Version... 8 Locating Refrigerant Leaks... 9 Resetting The Control...10 Parts List...11 Main Menu Interior air temperature Press to chill BY TEMP Press to chill BY PRODUCT Press to start a chill cycle BY TIME Time Press to quickly start a Chill Cycle Press to access LEGEND: additional menus Push button to left or right of any feature marked by or to select that feature. Push button to left or right of any feature marked by or to change value of that feature. One button start means safe food every cycle!

3 2 Programming the Control How to Set Correct Date & Time 1. From the Main Menu Screen press MORE, then SETUP. The display will change to the Password Screen. 2. From the Select Supervisor Screen, use the UP and DOWN arrows to the left and right of PASSWORD to select 57. Press ENTER. The display will change to the Set Up Screen. MAIN MENU AIR 35 F BY TEMP BY PROD BY TIME 08:05:01 MORE MAIN MENU 08:06:01 HOLD PROD PRINT DEFROST SETUP BACK 3. From the Set Up Screen press the button to the right of SYSPAR. 4. The ITEM list will display date and time elements in the following order. a) MONTH (JANUARY DECEMBER) b) DATE ( ) c) YEAR ( ) d) DAY OF WEEK (SUNDAY SATURDAY) e) HOUR (0 23) f) MINUTE (0 59) g) DLS - Daylight Savings TIme (ENABLED DISABLED) e) LOW ALARM (-30 0) SYS PAR: SET CLOCK ITEM:MONTH VALUE:APRIL CANCEL ENTER 5. Press the button to the left of ITEM to select between the different items. Adjust the VALUE for each ITEM using the UP and DOWN buttons. SYS PAR: SET CLOCK ITEM:MONTH VALUE:APRIL CANCEL ENTER 6. Press ENTER to return to the MAIN MENU. SYS PAR: SET CLOCK ITEM:YEAR VALUE:04/14/10 CANCEL ENTER

4 3 TRAULSEN RBC50, RBC100 & RBC200 BLAST CHILLER BASIC SERVICE GUIDE General Troubleshooting PROBLEM: Extended or unsafe chill times. a. Is the door closed properly? If not close door. b. Excessive product load. Reduce product loaded. c. Has pan been covered with a lid, plastic wrap or foil, and is this not in direct contact with the product? Cover product correctly. d. Product too large or loaded too deep in pans. Reduce product size or depth. e. Too much ice on evaporator coil. Cover product (if not already) and/or run manual defrost prior to next chill cycle. f. Dirty condenser coil. Clean condenser. g. Evaporator coil iced (below). Press MORE - DEFROST to start a manual defrost. h. Refrigeration system issue. Contact service. PROBLEM: Upon cycle start probe temps appear cooler than expected. a. Product temp within cooked batches vary. Verify actual product temp with thermometer (probed piece). b. Probe placed incorrectly. Reset probe placement. c. Very small product (potsticker). Use chill by time. d. Product held too long at room temp prior to chilling. Verify actual product temp with thermometer (probed piece). PROBLEM: Previously observed/expected high product temps differ from those shown on cycle data printout. a. See above for possible causes. b. Bad food probe. Replace probe. c. Batch started incorrectly. Start chill cycle according to owner s manual instructions. d. Moisture damage to the control. Replace control. PROBLEM: Occasional defrost sensor warning. Coil did not defrost to target temp, usually the result of too much ice build-up from either: a. A very long chill cycle/large product load. b. Starting a new cycle close to when the chiller would need to automatically defrost. c. Product releasing a lot of moisture during chilling. d. A combination of 2 or more of the above. PROBLEM: No data available for printing or later than actual start time or start temperature data appears on cycle/data printouts for a given probe. a. Product (probe) added to active chill cycle incorrectly (i.e. failure to press ADD/REMOVE and/or CONTINUE). PROBLEM: Product freezing. a. Chilled product not removed and additional product added. Remove when DONE. b. Chill cycle By Time set for too long. Reduce chill time. c. High water content product (ex. soup). Use SOFTCHILL.

5 4 General Troubleshooting (cont d.) PROBLEM: Incorrect date/time shown on display and/or printouts. a. Incorrect time and/or date setting. Correct date and/or time settings. b. Control issue. Replace control. PROBLEM: Defrost appears to have occured before chill cycle completion. Defrost will not occur until all food probes have reached target temp (DONE). a. Chiller completed chill cycle for all probes. Retrieve cycle data after defrost. PROBLEM: Chiller will not print or display reads MEDIA ERROR. a. Check to insure paper is properly loaded, remove any paper jam. b. If upon completing above the control continues to display MEDIA ERROR, cycle power OFF, then ON again (req d for control versions prior to 2.0). c. Printer requires replacement. PROBLEM: Evaporator Coil Icing. a. Hot product placed in chiller for long time without starting a chill cycle. b. Uncovered liquid product, cover product with plastic wrap. c. Refrigerant leak. Call service. d. Failed coil sensor. Call service. e. Other system problem. Call service. PROBLEM: Continuous defrost sensor warning. a. Failed defrost heater. Call service. b. Failed defrost sensor. Call service. PROBLEM: No data available for printing or later than actual start time or start temperature data appears on cycle/data printouts for a given probe. a. Product (probe) added to active chill cycle incorrectly (i.e. failure to press ADD/REMOVE and/or CONTINUE). PROBLEM: Probe(s) display -99 temperature. a. Check the probe plug connection. Properly secure probe connection. b. Food probe failure. Damaged or defective food probe. Replace food probe. PROBLEM: Food probe in use does not display product temperature. a. Check the probe plug connection. Properly secure probe connection. PROBLEM: Power loss notification. a. Power was lost to the Blast Chill unit. If product was inside the unit see the printout to determine if product temperature was compromised. The printout will show the temperature before and after the interruption. PROBLEM: Cannot program a new batch. a. Unit may be in a defrost cycle. Wait until defrost cycle completes.

6 5 TRAULSEN RBC50, RBC100 & RBC200 BLAST CHILLER BASIC SERVICE GUIDE Replacing The Control Board WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW PROPER LOCKOUT/TAGOUT PROCEDURES. 1. Remove thumb screws & control cover (see fig. 1). Fig. 1 Fig Remove Five (5) #2 Phillips head screws (see fig. 2). 3. Disconnect ten (10) electrical connections (see fig. 3). Fig Re-assemble in reverse order. 5. Restore power. 6. If previously authorized by Traulsen, insert original control in pre addressed mailer and return to Traulsen.

7 6 Replacing Either Printer WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW PROPER LOCKOUT/TAGOUT PROCEDURES. 1. Remove four (4) thumb screws & control cover (see fig. 1). 2. Remove paper or labels and spindle 3. Remove two (2) #2 Phillips head screws securing the printer (see fig. 2). 4. Disconnect two (2) electrical connections (see fig. 3). Discard old printer. 5. Re-assemble in reverse order using a new printer. 6. Restore power. Fig. 1 Printer Details LEGEND 1) 2) 3) 4) Printer Power Port-Red Harness Printer Data Port-White Harness Cutting Wheel Cartridge Paper Folded To Point For Easy Feed 5) Feed Roller 6) Feed Roller Tension Arm 7) Thermal Paper or Label Stock Fig. 2 Fig. 3 NOTE: Order printer supplies from Traulsen or your local Hobart Sales/Service Office. Record Paper: p/n , Labels: p/n NOTE: Record paper is also available from: Office Depot (item# ) or Staples (item# PMF-5233).

8 7 TRAULSEN RBC50, RBC100 & RBC200 BLAST CHILLER BASIC SERVICE GUIDE Repairing Moisture Damage WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW PROPER LOCKOUT/TAGOUT PROCEDURES. 1. Access the control boardand/or printers by removing four (4) thumb screws & control cover (see fig. 1). 2. Remove the control board (see page 5) and/or printers (see page 5 and 6) which might be effected moisture or grease. Fig Spray any electrical contacts (see fig. 2) which exhibit evidence of grease or water damage (indicated by a green color, see inset) with a commercial contact cleaner. This will dislodge the contamination. 5. Wipe away any debris or excess contamination using a cotton swab. Allow adequate time to dry. 6. Reassemble the control in reverse order. Fig. 2

9 8 Verifying The Control Version 1. On the main menu display press MORE. MAIN MENU AIR 35 F BY TEMP BY PROD BY TIME 08:05:01 MORE 2. Press SETUP. The SELECT SUPERVISOR screen will be displayed. MAIN MENU 08:06:01 HOLD PROD PRINT DEFROST SETUP BACK 3. Enter PASSWORD/PIN Press the top left, top right, and bottom right buttons at the same time. 5. The control version will appear on the display. SELECT SUPERVISOR: PRESET SUPERVISOR PASSWORD (PIN): 00 CANCEL ENTER SELECT SUPERVISOR: TIM SMITH PASSWORD (PIN): 85 CANCEL ENTER FACTORY SETTINGS VERSION 2.0 S/N:T00000A00 RESET NEXT

10 9 TRAULSEN RBC50, RBC100 & RBC200 BLAST CHILLER BASIC SERVICE GUIDE Locating Refrigerant Leaks WARNINGS DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW PROPER LOCKOUT/TAGOUT PROCEDURES. WARNING: THIS PROCEDURE REQUIRES THE USE OF REFRIGERANTS. BE CERTAIN THE WORK AREA IS WELL VENTILATED. SAFETY GOGGLES AND GLOVES SHALL BE WORN SINCE REFRIGERANTS MAY CAUSE INJURY TO THE SKIN. 1. Access the refrigeration system, recovering remaining refrigerant per EPA guidelines. 2. Connect the low (BLUE) side of gauge manifold to schrader valve.. 3. Connect refrigerant bottle to center of gauge manifold and open valve on bottle to purge hose to manifold gauge. 4. Open valve on low side of gauge manifold and charge system with a small amount of R-22 refrigerant (1-2 ounces). 5. Close bottle valve and gauge valve. 6. Disconnect refrigerant bottle and connect nitrogen bottle. 7. Set output valve on nitrogen bottle to equal the appropriate pressure, for the design rated refrigerant at 100 degrees F on the P/T chart (see system data plate for design refrigerant). 8. Open nitrogen bottle and gauge manifold valve (low side) and allow pressure to equalize. 9. Shut off both valves and disconnect the nitrogen bottle. 10. Using a leak detector, check for leaks at all tubing connections. a) If any leaks are detected, repair leak and recheck for additional leaks. b) If no leaks are discovered, evacuate system as per accepted industry procedures. 11. Install a permanent high side access port for future system diagnostics. 12. Charge the system and check for proper operation.

11 10 Resetting The Control Refers To Older Control Versions Only If memory reaches capacity during a chill cycle there is potential that some printout data could be incorrect (date & time). This will reset on it s own, however to do so manually... STEP 1 MAIN MENU AIR 35 F BY TEMP BY PROD BY TIME 08:05:01 MORE Main Menu display press MORE STEP 3 SELECT SUPERVISOR: TIM SMITH PASSWORD (PIN): 85 CANCEL ENTER Enter PASSWORD/PIN 85. STEP 6 FACTORY SETTINGS VERSION 2.0 S/N:T00000A00 RESET NEXT Serial number will be displayed. Press NEXT. STEP 2 MAIN MENU 08:06:01 HOLD PROD PRINT DEFROST SETUP BACK Press SETUP. STEP 4 Press the top left, top right, and bottom right buttons at the same time. LABEL PRINTER (NO) RESET STEP 7 NEXT Display will ask LABEL PRINTER (NO), press the UP arrow to select YES. DISPLAY WILL SHOW SELECT SUPERVISOR: PRESET SUPERVISOR PASSWORD (PIN): 00 CANCEL ENTER SELECT SUPERVISOR screen STEP 5 FACTORY SETTINGS VERSION 2.0 S/N:T00000A00 RESET NEXT FACTORY SETTINGS menu. Press RESET. LABEL PRINTER(YES) RESET STEP 8 Press NEXT. NEXT STEP 9 BLASTING DIFF (4) F HOLDING DIFF (3) F ANTI-SHORT(1) BACK NEXT Press NEXT. MACH. MODEL (RBC) MACHINE SIZE(50) RESET STEP 12 MACH. MODEL (RBC) MACHINE SIZE(50) RESET EXIT EXIT STEP 10 DEFROST TIME (40) DEFR. TEMP (50) F DEFR. INTVL (3) HR BACK NEXT Press NEXT. STEP 13 FACTORY SETTINGS DO YOU WISH TO SAVE THESE NEW SETTINGS NO YES Press YES. STEP 11 ENTER SECURITY CODE FOR NEXT SETTINGS: (000000) EXIT ENTER Press ENTER. (do not change code) DISPLAY WILL SHOW NEW SOFTWARE HAS BEEN INSTALLED SYSTEM PARAMETERS HAVE BEEN SET! Display will ask MACHINE SIZE. Press RESET, then using the UP or DOWN arrow change for your model. For RBC50 = 50, RBC100 = 100, RBC200 = 200. Press EXIT. 14. The display will return to the MAIN MENU. Repeat steps Press EXIT. 16. Press YES.

12 11 TRAULSEN RBC50, RBC100 & RBC200 BLAST CHILLER SERVICE GUIDE Parts List MODEL NUMBER PART/DESCRIPTION PART # RBC50 CORDSET - 115V RBC50 POWER PACK ASSEMBLY RBC50/RBC100 6 HIGH STAINLESS STEEL LEGS RBC50 STAINLESS STEEL SIDE PANEL RBC50 UNIVERSAL TRAY SLIDE RBC100 LOUVER ASSEMBLY RBC100 DRAINPAN RBC100 PROBE CABLE HOOK ALL MODELS HINGE BODY ALL MODELS HINGE COVER ALL MODELS HINGE CAM ALL MODELS HINGE BRACKET RBC100 HORIZONTAL BREAKER CAP RBC100 VERTICAL BREAKER CAP RBC100/200/400 LOCK KEEPER RBC100/200/400 LOCK KEEPER BRACKET RBC100/200/400 SMARTCHILL CONTROL KIT SER RBC100 DOOR - HINGED RIGHT RBC100 TRAY SLIDE RBC100 PRINTER COVER ALL MODELS STANDARD PRINTER PAPER ALL MODELS LABEL PAPER ALL MODELS SMART PROBE RBC200/200RT LOUVER ASSEMBLY RBC200/200RT ROLL-IN RAMP RBC200/200RT RECORD/LABEL PRINTER RBC200/200RT PRINTER COVER RBC200/200RT DOOR - HINGED LEFT RBC400/400RT LOUVER ASSEMBLY RBC400/400RT ROLL-IN RAMP RBC400/400RT RECORD/LABEL PRINTER RBC400/400RT PRINTER COVER RBC400/400RT DOOR - HINGED LEFT Blue Mound Road, Fort Worth, TX (800) Traulsen. All rights reserved.