LevControl LC PLUS ALL OUR SYSTEMS COMPLY WITH DIRECTIVE 73/23 EEC - 89/336 OPERATING INSTRUCTIONS Cod. 71503277/0-12/97
WARNING!!! THE OPERATIONS LISTED BELOW AND THOSE MARKED BY THIS SYMBOL ARE STRICTLY PROHIBITED TO THE USER. 1. ELECTRICAL CONNECTIONS 2. WATER CONNECTIONS 3. MACHINE INSTALLATION 4. MACHINE TESTING 5. REPAIRS TO ANY MACHINE COMPONENTS 6. DISMANTLING OF THE MACHINE AND/OR ITS COMPONENTS 7. ADJUSTMENT AND CALIBRATION 8. MAINTENANCE AND CLEANING OF: ELECTRICAL COMPONENTS, ELECTRONIC COMPONENTS, MECHANICAL COMPONENTS, REFRIGERATION SYSTEM COMPONENTS 18
1. LEVCONTROL LC PLUS RETARDER-PROVER GENERAL INFORMATION Modular chambers for the storage and proving of bread dough, comprising: Polyurethane panels injected directly between two galvanised steel sheets, covered with non-toxic plastic film. The panel attachment system ensures perfect sealing and rigid framework. The modular design means that chambers can be constructed with dimensions in multiples of 40 cm to optimise use of available space and while allowing for future expansion or modification. 60 mm thick insulation panels provide a heat transfer coefficient of 0.33 Kcal/m2h C. Air circulation system: Castel Mac international patent. Our system, which comprises a series of vertical ducts in stainless steel and horizontal ducts in impact-resistant anti-condensation plastic, ensures a uniform, low velocity air flow within the chamber. The horizontal anti-condensation ducts in polystyrene prevent the formation of condensation and dripping water. Computer: monitors operating parameters to ensure that they are maintained at the programmed values. The programmable functions are as follows: - Time, temperature and humidity in phase 1 (RETARDING) - Temperature and humidity in phase 2 (CON- SERVING) - Time, temperature and humidity in phase 3 (PRE-PROVING) - Time, temperature and humidity in phase 4 (PROVING) - Local time - Baking time (CYCLE END) Also: - Programmed settings can be modified without having to stop the machine or interrupt the cycle in progress. - Ventilation in the four phases can be automatic or continuous, with the possibility to program the ventilation speed for each phase. - Sleep function with automatic start-up at the end of the cycle (if enabled). - Timed oven switch-on before end of cycle. IMPORTANT: The duration of phase 2 is automatically calculated by the computer on the basis of the cycle start time, the cycle end time and the time values programmed for phase 1, 3 and 4. In phase 1, the humidity is programmed only for positive temperature values. The program will be retained in memory even in the event of an electrical power failure. Phase 1 starts the moment the dough is introduced into the chamber and the START key is pressed. The duration of phase 2 varies EXAMPLE: Local time or cycle start Product baking time or cycle end I a PHASE II a PHASE III a PHASE IV a PHASE Time + Temperature + Time + Time + Temperature + Humidity +(time is Temperature + Time + Humidity calculated Humidity Humidity automatically) 19
according to the cycle start time (the CYCLE END time being pre-programmed). The operating temperature range is from -25 C to +40 C, and the humidity can be programmed between 65% and 95%; when the programmed temperature is below +3 C, the computer automatically excludes humidification (which would otherwise lead to the formation of ice). Program flexibility means that the chamber may used just for storage or just for proving (manual key). The standard humidification system consists of an electronic humidifier. The vapour generated is dispersed by the air circulation system to ensure uniform distribution. Compressor power ratings range from 1.5 HP up to 4 HP for large chambers. Compressor sizing is optimised to ensure reliable operation even in particularly difficult conditions. LC PLUS COMPUTER CONTROL PANEL PROGRAMMING Local time Phase 1 retarding Phase 2 conserving Phase 3 pre-proving Phase 4 proving The control panel provides the following functions: * Programmable baking time (end cycle time) * Manual operating mode (for proving only or refrigeration only). * 24-48-72 hour cycle programming * Digital readout of time, temperature and humidity. * Temperature and humidity control using electronic sensors. * Phase indicator lights. * Interior lighting with insulated lights operated from external switches. 20
2. LEVCONTROL LC PLUS SYSTEM TECHNICAL CHARACTERISTICS ISOTHERMIC CHAMBER: - Modular panels in widths of 40-80-120 cm and 240 cm high. - Insulation: 6 cm of injected polyurethane sandwiched between internal and external sheets of galvanised steel coated with impact and scratch resistant PVC film. - Single-leaf door mounted on a panel 120 cm wide by 240 cm high to provide an opening of 95x210 cm. Double door mounted on a panel 120 cm 2wide and 220 high to provide an opening of 100x190 cm. Special doors*-available on request: sliding door. framed PP8 door for chambers 92 cm wide, providing an opening of 79x194 cm. WARNING: Semi-hermetic refrigeration unit with air-cooled condensing (water-cooled condensing available on request): * Power supply: 3-phase 220-240V/380-400V/50 Hz. * Refrigerant: Freon R 22 - R 404 A. Special evaporator designed specifically for controlled proving, with: * Copper tube/aluminium fin coils. * 600W heating elements. * L o w power blowers for slow, uniform ventilation. * Evaporator housing in anti-condensation polystyrene. * Double-recirculation air system, with horizontal ducting in anti-condensation polystyrene and vertical ducting in stainless steel to ensure uniform distribution of temperature and humidity Fully-electronic control panel with touch-sensitive keys (for easy cleaning and protection against dust and humidity). Standard humidification system: humidifiers with electronic vapour generation. Possibility to increase humidity during proving phase. Secondary flow 2 blowers Double main Vertical air circulation ducts in stainless steel 21
3. INSTALLATION OF THE RETARDER PROVER WARNING!!! THESE OPERATIONS MUST ONLY BE CAR- RIED OUT BY A LICENSED TECNOMAC INSTALLER IMPORTANT The customer, at his own expense and under his own responsibility, must: 1) Provide an electrical power supply for the chamber in full compliance with applicable standards (earth connection, etc.) with its own thermal-magnetic circuit breaker and an amp rating compatible with the kw rating of the machine. The electrical system must incorporate a differential circuit breaker for safety. REFRIGERATION UNIT COMLPRESSOR THERM AL - MAGNETIC CUTOUT RATING EXTERNAL LINE THERMAL - MAGNETIC CUTOUT RATING 220 V 380 V 220 V 380 V 1.5 HP 10 AMP. 10 AMP. 25 AMP. 16 AMP. 2.0 HP 1 EVAP. 10 AMP. 10 AMP. 25 AMP. 16 AMP. 2.0 HP 2 EVAP. 10 AMP. 10 AMP. 32 AMP. 16 AMP. 3.0 HP 16 AMP. 10 AMP. 32 AMP. 20 AMP. 2) Provide the water supply and waste connections as shown in figures A1 and A2: A) A 1/2 water supply pipe with shut-off cock, filter and check valve. B) A waste pipe with a trap with a diameter of at least 1 1/2 at floor level. A1 TECNOMAC Tecnomac 22
Tecnomac GB Scarico a sifone aperto Raccordo Tubo di drenaggio Ø 1 A2 Sifone SCARICO ACQUA A SIFONE APERTO When selecting the site for installation of the chamber, check that: A) A) The ambient temperature never exceeds 40 C. B) The water supply pressure is not less than 1 atmosphere (14 Psi) and does not exceed 5 atmospheres (70 Psi). If the supply pressure exceeds 5 atmospheres, install a pressure reducing valve in the supply line to the machine. C) the condensing unit is installed away from heat sources and in a well-ventilated position. The two sides and the rear of the condensing unit should be at a distance of least 20 cm from walls and 20 cm from the ceiling. The distance between the condensing unit and the chamber must not exceed 20 metres IMPORTANT: Make all water connections before proceeding with the electrical connections. Install a 1/2 water supply pipe for the electronic humidifier (cold drinking water) with a shutoff cock, check valve and filter (not included in the supply). If the ambient temperature exceeds 40 C, we recommend that the condensing unit is installed remotely in a cooler, well-ventilated room; alternatively use a water-cooled condenser (available on request). In any event, the distance between the condensing unit and the chamber must not exceed 10 metres. WARNING IF THE COMPRESSOR UNIT IS INSTALLED ON THE FLOOR, A SAFETY CAGE MUST BE PROVID- ED. TECNOMAC 23
18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4. DESCRIPTION OF THE CONTROL PANEL F1 (1) Phase 1 programming key (14) SLEEP function selection key (2) Phase 2 programming key (15) Manual operation start key (3) Phase 3 programming key (16) Oven switch-on selection key (4) Phase 4 programming key (17) Manual defrosting selection key (5) SLEEP function programming key (18) Remote control signal reception (6) Manual programming key (19) Display for programmed values/operating data (7) Temperature programming key (8) Humidity programming key (20) Arrow keys to increase/decrease value (9) Phase time + clock programming key (21) Current phase indicator LED (10) Oven switch-on programming key (22) Control panel on/off switch (11) Cycle end time and day programming key (23) Humidifier on/off switch (12) Cycle end day indicator LED (24) Interior light on/off switch 24 (13) 4-phase cycle start key
5. PROGRAMMING INSTRUCTION POWER UP On/off switch 22 set to ON. PROGRAMMING Flag key 13. Corresponding LED off. Programming the control panel. The display shows the current time. a) SETTING THE CURRENT TIME Hold key 9 pressed and the corresponding LED will start to flash. Enter the hour using arrow keys 20. To set the minutes, press key 9. again. Enter the minutes using arrow keys 20. WARNING: you do not need to confirm these values as they are automatically stored in memory. Each time a function key is pressed, the corresponding LED will illuminate. The key will be deactivated automatically after a few seconds. b) PROGRAM DATA For all the other programmable data: PROGRAMMING THE RETARDER PROVER OPERATING CYCLE Press key F1 F1 the corresponding LED will illuminate Press temperature key 7, the corresponding LED will illuminate, Using arrow keys 20 set the desired temperature value (e.g. -5 C). With key F1 illuminated, press key 9, and using arrow keys 20 F1 set the required hours for phase 1. Press key 9 again to pass to the minutes position Set the required number of minutes using arrow keys 20. 25
Press phase 2 key F2, the corresponding LED will illuminate.. Press temperature key 7 and with arrow keys 20 set the required temperature (e.g. 2 C). With key F2 illuminated, press humidity key 8 and then set the required humidity using arrow keys 20 Press phase 3 key F3 (e.g. 80% HG)., the corresponding LED will illuminate. Press temperature key 7 and enter the required temperature value using arrow keys 20. With F3 illuminated, press humidity key 8 and set the required humidity value using arrow keys 20 (e.g. 85% HG). Press clock key 9 and enter the required time for phase 3 (e.g. 02.30). N.B. to pass from the hours position to the minutes position press clock key 9 once again. Press phase 4 key F4, the corresponding LED will illuminate.. Press temperature key 7 and enter the required temperature value using the arrow keys 20. Press phase 4 key F4 illuminated, press humidity key 8 and set the required humidity value using arrow keys 20 (e.g. 85% HG). Press clock key 9 and enter the required time for phase 3 (e.g. 02.30). N.B. to pass from the hours position to the minutes position press clock key 9 $ once again. CYCLE END TIME Press END TIME 11,the corresponding LED will illuminate Enter the cycle end time using arrow keys 20. 26
N.B. To pass from hours to minutes on the display press END TIME 11 once again.. 24-48-72 HOUR CYCLE SELECTION Press END TIME 11 and hold pressed until the values are no longer displayed. Select the required cycle using arrow keys 20. STARTING THE RETARDING/PROVING CYCLE Press the flag key 13. The corresponding LED will illuminate. The machine will start after a pause of few seconds. Once the machine is running, the following information will be displayed on the control panel: the temperature inside the chamber (display); the indicator light corresponding to the current phase will be illuminated; the indicator light corresponding to the selected cycle will be illuminated. The cycle will be performed automatically in accordance with the selected program. MANUAL PROGRAMMING (Use for proving only or refrigeration only) Press manual key 6, the corresponding LED will be illuminated. Press temperature key 7 and use arrow keys 20 to set the required temperature value. With the manual key illuminated, press humidity key 8 (if the chamber is to be used for proving) and set the required value using arrow keys 20. Start the program by pressing the manual key 15. SLEEP FUNCTION With this function, you can only set the temperature and humidity. With SLEEP key 5 and then temperature key 7 Set the required temperature value using arrow keys 20. 27
With SLEEP key 5 illuminated, press humidity key 8 and set the required humidity using arrow keys 20. N.B. The values set are automatically memorised.. The CYCLE END function has no effect in manual mode as once manual operation has been selected it will continue indefinitely. Select the SLEEP function by pressing key 14.. IMPORTANT In manual mode, you can either set positive temperature values if the machine is to be used for proving or negative temperatures if it is to be used as a refrigeration chamber. OTHER FUNCTIONS OF THE LEVCONTROL LC PLUS The system allows you to the temperature and humidity settings (but not the time settings) for each phase even when the cycle is running without interrupting the cycle. Temperature and humidity settings may also be changed when the machine is operating in manual mode. FUNCTION TEST To test all the program functions: On power up, all the LEDs of the control panel will illuminate in succession (test positive). If one or more LEDs do no light up, this indicates a microprocessor fault. If the test is positive but the machine does not start, look for external faults (electro-mechanical components). CYCLE END At the end of the programmed cycle, the computer automatically updates the cycle end date by 24 hours. This means that the same program can be repeated every day without having to re-program. To repeat the program used on the previous day, simply press flag key 13. SECURITY KEY The computer is equipped with a keypad lock to prevent accidental modification of the preset or current program by unauthorised/inexperienced staff. Even when the keypad is locked, the various functions of the current program or the program set prior to application of the lock will still be executed as normal. key in BLUE position = keypad enabled key in RED position = keypad disabled 28
ELECTRICAL POWER FAILURE a) In the event of an electrical power failure: all the programmed data are retained in memory; the current time is retained memory; the status of the current cycle is retained in memory; the cycle is executed in memory. b) On restoration of the power supply: the cycle is resumed from the point at which it would have arrived if there had not been a power failure; the duration of the power failure is shown on the display. c) modification of programmed data following a prolonged period without power: if a cycle is interrupted for a prolonged period, it will be necessary to reprogram the machine taking into account the physical status of the product. SLEEP FUNCTION The SLEEP function allows the system to operate after the cycle has been completed, so that a product that has not been removed from the chamber at the end of the cycle can be stored in the pre-programmed temperature and humidity conditions. To select the SLEEP function, press the corresponding key on the control panel. This function can be selected or deselected at any time before the end of the cycle without having to interrupt the cycle in progress. OPERATION IN SLEEP MODE Independent humidity and temperature values may be set for SLEEP mode operation. This function (if selected) will automatically start at the end of the 4-phase cycle and will continue indefinitely. During SLEEP mode, ventilation is automatic at maximum speed. TO EXCLUDE SLEEP MODE Press SLEEP function selection key 14 to deselect the function Press cycle start/stop switch 13 to stop cycle. In this situation the system is off and the computer is ready for programming. AUTOMATIC DEFROSTING OF THE EVAPORATOR Automatic defrosting during phases 1-2-3. There are two types of defrosting which are selected according to the programmed temperature: electric defrosting for temperatures in the range -20 C to + 8 C air defrosting for temperatures in excess of +8 C. 29
OPERATING CYCLE Example: D = defrosting 3 hours D 6 hours D 6 hours D 6 hours D 3 hours D 0 start of current cycle start of next phase The first defrosting takes place 3 hours after the start of the cycle and is then repeated every 6 hours. The duration of the defrosting cycle is 20 minutes. Defrosting is performed automatically for 20 minutes at the start of each phase. The defrosting cycle is given priority over the temperature and humidity settings * If the programmed temperature is between -20 C and +8 C, defrosting will be performed electrically. * If the programmed temperature exceeds +8 C, defrosting will be by air. * Defrosting does not occur between phase 3 and phase 4. MANUAL DEFROSTING: The defrosting function may be activated or deactivated by pressing the manual defost key. If the manual defrost key is pressed during the course of an automatic defrosting cycle, it will have no effect. If an automatic defrosting cycle is programmed to start during manual defrosting, the programmed defrosting cycle will be ignored. The defrosting indicator LED will remain illuminated throughout the duration of the defrosting cycle. PROGRAMMING THE OVEN SWITCH-ON TIME This function allows you to switch on the oven at a preset time before the end of the cycle. Press key 10 and use arrow keys 20 to enter the amount of time (in hours and minutes) before the cycle end time at which the oven relay switch is to be activated (this relay remains activated for approx. 10 seconds). N.B.: If the oven switch-on time is greater than the time required to perform the automatic cycle, relay 7 will not be activated. ENABLING THE OVEN SWITCH-ON FUNCTION The oven switch-on function can selected or deselected by pressing key 16. The corresponding LED illuminates to indicate that the function is enabled 30
6. MAINTENANCE AND CLEANING WARNING!!! THESE OPERATIONS MAY ONLY BE CARRIED OUT BY A LICENSED TECNOMAC INSTALLER Always disconnect the electrical power supply to the machine before all cleaning and maintenance operations. CLEANING THE CONDENSER If dust is allowed to build-up on the front of the condenser it will gradually reduce the efficiency of the refrigeration circuit. Inspect the condenser at frequent intervals and clean with a non-metallic brush or a vacuum cleaner. DRAINING DEFROST WATER The machine is predisposed for automatic defrosting 3 hours after the start of the programmed cycle and subsequently every 6 hours at the transition between one phase and the next. Defrosting is performed electrically if the programmed temperature is below +8 C. Check that the drain pipe is free from obstruction and that the water drains correctly. Fig. A2. THIS OPERATION MUST ONLY BE CARRIED OUT WITH THE MACHINE SWITCHED OFF. WARNING!!! IN THE EVENT OF THE FOLLOWING MALFUNCTIONS, THE USER MUST NOT ATTEMPT TO SOLVE THE PROBLEM HIMSELF BUT MUST SEEK ASSISTANCE FROM LICENSED TECNOMAC TECHNICIAN. 1. THE CONTROL PANEL DOES NOT FUNCTION - DISPLAY ALARMS 31
DISPLAY DESCRIPTION AL 1: Chamber temperature alarmtemp. AL 2: Major alarm on digital input 2 AL 3: Major alarm on digital input 3 AL 4: Minor alarm on digital input 4 AL 5: minor alarm on digital input 5 AL 6: evaporator temp. sensor AL 7: humidity sensor AL 8: power failure ALARMS POSSIBLE CAUSE sensor faulty Short-circuit of sensor wires Sensor wires broken Sensor terminal block loose Compressor thermal-magnetic protection tripped Input 2 circuit not closed Input 3 circuit closed Compressor thermal protection tripped Min and/or max pressure switch Input 4 circuit not closed Input 5 circuit closed Sensor faulty Short-circuit of sensor wires Sensor wires broken Sensor terminal block loose Sensor faulty Short-circuit of sensor wires Sensor wires broken Sensor terminal block loose Jumpers incorrectly positioned on board Power supply interrupted for more than 15 minutes RIMEDY Renew the sensor Repair connecting wires Repair sensor connection Check terminal block J2 Reset compressor protection Check wiring against circuit diagram Check wiring against circuit diagram Check compressor thermal protection Check pressure values and pressure switches Check wiring against circuit diagram Check wiring against circuit diagram Renew the sensor Repair connecting wires Repair sensor connection Check terminal block J2 Renew the sensor Repair connecting wires Repair sensor connection Check terminal block J2 Check positions of jumpers against circuit diagram Check connections in supply line PCO BOARD - LEVCONTROL LC PLUS RELAY OUTPUTS: Out nr. 01 Cooling output (compressor) Terminal block J5 (4-5) Out nr. 02 Defrosting output (heating elements) Terminal block J5 (1-2) Out nr. 03 Evaporator fans output Terminal block J6 (10-11) Out nr. 04 Heating output (heating elements) Terminal block J6 (7-8) Out nr. 05 Humidification output (fans or control) Terminal block J6 (4-5) Out nr. 06 Dehumidification output (fans) Terminal block J24 (7-8) Out nr. 07 Oven Out nr. 08 Phase 3 output (max humidification) (standard LevControl only) Terminal block J24 (1-2) Out nr. 09 Chamber interior light outpu Terminal block J22 (9-10-11) Out nr. 10 Major alarm output (with interruption of cycle) Terminal block J22 (5-6-7) Out nr. 11 Minor alarm output (cycle continues) Terminal block J22 (1-2-3) DIGITAL INPUTS: In nr. 01 Door microswitch (interior light on when door is open) Terminal block J4 (1-6) In nr. 02 NC major alarm input (generates major alarm when open) Terminal block J4 (2-6) In nr. 03 NO major alarm input (generates major alarm when closed) Terminal block J4 (3-6) In nr. 04 NC minor alarm input (generates minor alarm when open) Terminal block J4 (4-6) In nr. 05 NO minor alarm input (generates minor alarm when closed) Terminal block J4 (5-6) In nr. 06 NO keypad lock input (locks keypad when closed) Terminal block J3 (1-6) ANALOGUE INPUTS: In nr. 01 Temp. sensor input (temperature inside chamber) Terminal block J2 (1-2) In nr. 02 Temp. sensor input (evaporator temperature) Terminal block J2 (3-5) In nr. 03 Humidity sensor input (humidity inside chamber) Terminal block J1 (2) - J2 (8-9) 32
EXAMPLE OF A 24-HOUR RETARDER PROVER CYCLE FOR BREAD DOUGH Important: Mixes containing a high percentage of water require less humidity. PHASETIME HOURS TEMPERATURE C HUMIDITY % I a PHASE 3h 30 5 II a PHASE +3 75% III a PHASE 1h 30 +26 85% IV a PHASE 3h +26 85% Optimum temperature and humidity settings will vary according to: - the type of flour - the quantity of water used in the mix 33