SERVICE MANUAL #03
Contents
1. 55 ME RENE ana PEL AE SEE Re Ta Ils THE SERIA THT A Css Tes Ee vni FERE es iE Ede i hd poids SPECIFICATIONS OPERATIONS DATA Ma PRODUCT SPECIFICATIONS SRS OPERATING REFRIGERATION SYSTEM INSTALLATION o IV SERVICING THE SmartChill 2 IN a SERVICE SuSE RRA IV b UPDATING THE SERVICE DATE siscccsscscssosnasesncenssivonsnsessacssenseeeuonsasccasesdesoundenste IV C OEE LING THE COCK wa aerei E ES SER VICE isso IV e SERVICE MENU DIAGNOSTIC TEST IV f SERVICE MENU REF N SYSTEM AND AIR PROBE IV g SERVICE MENU PROBES ALARM TEST eii es sensato SERVICE MENU DISPEAY TEST IV i SERVICE MENU DEFROST SYSTEM amp COIL PROBE TEST SERVICE MENU FAN OUTPUT TEST IV k SERVICE MENU PRINTER TEST V SmartChill FACTORY SETTINGS a eset bte 54 REV 04 06 FACTORY SEP TINGS MODE SSAA V2. dante mutua 18 Ville BY TIME CHILL OR FREEZE MODE 19 BY TEMP CHILL OR FREEZE MODE ee 19 VIIL g BY PRODUCT CHILL OR FREEZE MODE 20 VIELE DEFROSTMODE pem aE 20 IX SERVICE PROCU DURE nba 20 IX a TEMPERATURE AIR SENSORS 20 IX b EXPANSION VAL VE e 21 DEFROSTHEA TER VR 22 IX d DOOR PERIMETER HEATERS 200 only eee 22 COMPRESSOR SA ed 22 CONDENSER FAN ASSEMBLY scien aii ae Oa 23 Deo CONDENSER aS aes 23 IX PRESSURE CONTR OD vec RM ale 24 EVAPORATOR 24 IX J EIETERIDRIBE dlc bei oe 25 Xk EVAPORATOR BLOWER 25 EXT CHECKING POR LEAKS RTs 25 IX m EVACULATING 26 Tem CHARGING SYSTEM 27 IX o SYSTEM CLEAN UP INTRODUCT ION encre even eterno ntn nnno nn rano due 28 REPEACING DOOR GASKETS 29 X WIRING DIAGRAM RBC50 8 1
3. 43 4 ALIEN 1 7 fatl 25 0 CRY i 54 REV 04 06 30 54 REV 04 06 XI WIRING DIAGRAM RBC100 MODELS ELLETHLDE RM COMMEST VD DEEP PS JONES ELEPTRI LEV 211 1 HOH PM L1 E 201 3 OFF 11 IFAT 01 8 H I7 FAR 13 0 Al 131 10 501 15 11L 1E 31 IEF TRA IF TEHR Lu LIN LINTALTUE MU A HA ETALE FALT HEP FHS LE BL LE eee DARE LO HII TEH HEH LF METI l xn Fu hh HIA HEATER H HWP EHR UE PELAT DAP ATE FEEL Ci THE LLER 54 REV 04 06 XII WIRING DIAGRAM RBC200 MODELS WARNING ELECTRICAL AND GROOWDIRG COWNECT IONS MUST COMPLY WITH THE APPLICABE PORTIONS OF THE NATIONAL ELECTRICAL OTHER LOCAL ELECTRICAL CONTROL BOARD Ji2 1 YCC 118 2 12 3 YPP 45 1 16 2 LOW 111 1 HIGH 111 2 BLAST COMP 111 3 MAIN COMP 111 4 BLAST IEFRUST 11 1 WAIN DEFROST 11 ALARM J1L T PUR FAIL J11 8 1 9 211 10 411 11 211 12 08 1 POWER SUPPLY BOARD Ce UNB 6 Che 1 32 MAINTENANCE COMPRESSOR
4. 0 seno 30 XI WIRING DIAGRAM RBC100 MODELS 4 4 4 seen seen 31 XII WIRING DIAGRAM RBC200 5 2 22 32 TROUBLE SHOOTING 33 XIV REPLACEMENT PARTS LISTXV 0 0000042 38 AV I es 39 54 REV 04 06 2 GENERAL INFORMATION INTRODUCTION Blast Chillers are food processing refrigerators designed for rapid chilling of product from 140 F to 40 F in approximately 90 minutes for reheating and or serving at a later time These models aid in preserving food quality texture and nutritional value in addition to enhancing food safety All of the information illustrations and specifications contained within this manual are based on the latest product information available at the time of printing OPERATION Refer to the instructions contained in the Owner s Manual Form Number TR35850 for specific operating instructions CLEANING Detailed cleaning instructions are included with each unit however special care must be given to the condenser coil s These must be cleaned QUARTERLY This surface must be kept free of dirt and grease for proper system operation This can be done with a vacuum cleaner using a brush attachment o
5. Traulsen Refrigeration SERVICE MANUAL 03 Instructions for the Installation Troubleshooting and Repair of Traulsen SmartChill Equipped Blast Chiller Models 50 Ib Capacity Under counter Models 100 Ib Capacity Reach In Models 200 Ib Capacity Roll In amp Roll Thru Models 4 This Manual is prepared for the use of trained Authorized Traulsen Service Agents and should not be used by those not properly qualified This manual is not intended to be all encompassing but is written to supplement the formal training on the job experience and other product knowledge acquired by Authorized Traulsen Service Agents Before proceeding with any work you should read in its entirety the repair procedure you wish to perform to determine if you have the necessary tools instruments and skills required to perform the procedure Only a trained Authorized Traulsen Service Agent should perform procedures for which you do not have the necessary tools instruments and skills Reproduction or other use of this Manual without the express written consent of Traulsen is prohibited 375 60240 00 1 TABLE OF CONTENTS L TABLE OE SADECE II GENERAL INFORMATIQN nie SIN TRODUC TION tr ee Il b OPER ASTON SCLEEAINIING EE E APPLICABLE MODELS os WIRING DIAGRAMS
6. NL KG mnn x a adimi etd bree a E u E VALVE NOTE It is recommended that the filter drier be changed when this part is replaced 54 REV 04 06 21 SERVICE PROCEDURE Continued DEFROST HEATER WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES NOTE This procedure applies to all blast chill models with the exception of Model RBC50 Remove the evaporator cover Disconnect wire leads to defrost heater Unscrew floor bracket in front of evaporator coil Remove copper wires holding defrost heaters in place Remove the defrost heater from the coil being careful to prevent damage to coil fins Reverse procedure to install DS p IX d DOOR PERIMETER HEATERS RBC200 only WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES 1 Remove the breaker caps from around the perimeter of the door opening 2 Locate the existing wire connections in the foam insulation at the top center of the door opening under the breaker area and disconnect 3 With the ends of the new wire at the top center of the door opening place the new heater wire around the perimeter of the door opening under the breaker caps and secure in place with aluminum tape Some replacement of insulation may be required 4 Make the wire c
7. TEMPERATURE AIR SENSORS WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES Access the evaporator s Remove the cabinet sensor from the maintenance evaporator Remove coil sensors from both the maintenance and blast chill evaporators Remove the food temperature probe receptacle from cabinet ceiling Disconnect the sensor probe wiring assembly connector from the controller oe ee 54 REV 04 06 20 SERVICE PROCEDURE Continued pe CABINET SENSOR 6 Reverse the procedure to install replacement sensors IX b EXPANSION VALVE WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW 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 Pump down refrigeration system Warning after pump down refrigerant lines will contain pressure Access the expansion valve Detach expansion valve bulb from suction line Remove expansion valve from the liquid line at inlet and outlet of valve Install new expansion valve into inlet line and fasten bulb to suction line The use of a heat blocking material is advised NOTE Make sure expansion valve bulb is attached parallel to suction line and makes good contact il
8. IV b UPDATING THE SERVICE DATE Pressing the button beside UPDATE sets the last date of service to the current date If date is INVALID set clock to current date and time IV c SETTING THE CLOCK Press the button beside SET CLOCK in order to display the menu below SYS PAR SET CLOCK gt ITEM MONTH gt lt VALUE MARCH gt lt CANCEL ENTER gt ITEM Toggles through selection options MONTH DAY YEAR HOUR MINUTE Pressing the buttons beside the UP right or DOWN left arrows changes the selected date or time numbers Pressing the button beside ENTER saves the new date and time selected and displays the last date of service menu Pressing the button beside CANCEL does not save any changes made to the date or time and returns to the last date of service menu IV d SERVICE MENU Pressing the button beside NEXT when the last date of service menu is displayed prompts the following service menu SERVICE MENU EXIT lt REFR AIR DEF COIL gt lt PROBES ALARM FANS gt lt PRINTER DISPLAY gt NOTE From the service menu the following service modes can be selected SERVICE MENU Diagnostic test REFR AIR Refrigeration system amp air probe test 54 REV 04 06 6 IV SERVICING THE SmartChill CONTROL Continued e PROBES ALARM View current probes reading and change status of alarm output DISPLAY Illuminates entire display DEF COIL Defrost system amp coil probe test FANS
9. OPERATING DATA DATA RBC50 RBC100 RBC200 RBC200RT H P 1 1 2 HP 1 2 HP 3 4 HP 3 4 HP BTU 1 1350 2280 3780 3780 H P 2 1 2 HP 1 14 HP n a 4 hp air cooled 3hp water cooled 2 BTU 10 F evaporator 2 3668 2 5460 2 3780 2 18 700 3 Refrigerant 1 R 404A R 404A R 404A R 404A Refrigerant charge 1 20 oz 49 oz 20 oz 20 oz Refrigerant charge 2 20 oz 92 oz n a 3 n a 3 Cond Unit Amp Draw RLA 1 n a 9 6 15 2 15 2 Cond Unit Amp Draw RLA 2 n a 5 7 30 7 30 7 Unit Voltage 115 60 1 220 115 115 60 1 1 115 60 1 1 Full Load Amps 18 6 2 x 9 3 15 1 15 2 1 15 2 1 1 Self Contained Holding or Primary Compressor 2 Blast Chilling or Secondary Compressor 3 These may vary depending upon type of remote condensing unit selected REFRIGERATION SYSTEM INSTALLATION Traulsen blast chillers with the exception of Model 50 require the use of a floor drain or floor mounted condensate evaporator for condensate removal Refer to Section IILh of the blast chill owner s manual for more information Remote refrigeration installation requirements apply only to Models RBC200 and RBC200RT A remote condensing unit operating on 404 refrigerant is required for Blast Chill operation on these models remote condensing unit s should be capable of providing 18 700 BTU hr 10 F suction and 90 F ambient at the evaporator coils of the blast Chill sec
10. MULLCON HTR SYMBOL DEFINITIONS TB TERMINAL TRANSFCRHER CUN CONTACTOR COIL RELAY COIL SOL OLENDID HIR MOTOR OTM THERMISTOR CONNECTION NSEPARANLE CONNECTION SOLID LIME STD DASHED LINE WIRING SWITCH NORMALLY CLOSED CONNECTOR END GRONO Fu FUSE HTR HEATER TRIAL CR CONTACT RELAY BLOWER CAPACITOR 270 652946 00 ELECTRICAL DIAGHAN BLAST CHILLER 200 1157 6071 REV D PRINTED M THE amp TROUBLE SHOOTING CONDITIONS POSSIBLE SOLUTIONS PRINTER ERROR 1 Check for the correct style of paper in the printer It must use Thermal paper 2 1 4 inch roll 2 Check the paper tension bar located under the bottom of print head Tension Bar must be in the up position to allow it to feed paper thru 3 Check for paper jam 4 Check the cutting wheel on the printer head The wheel must be all the way to the right in the ready position 5 Check the wiring from the relay board to the control board and the wires from the control to the printer 6 Paper must be installed correctly It must come off the top of the roll with the treated side up as it passes thru the print head 7 Ifthe unit has two printers you might try to swap the two printers to help confirm the printer is not repairable 8 Should the Printer causes the unit to have a power interruption while asking to print the label the issue will
11. Chill Communication software 54 REV 04 06 35 TROUBLE SHOOTING Continued CONDITIONS LOW SUCTION PRESSURE POSSIBLE SOLUTIONS Solenoid valve restricted Restriction in drier Loss of refrigerant Poor air flow due to bad blower motor or iced up evaporator coil Expansion valve blocked HIGH HEAD PRESSURE Improper airflow across condenser Extreme ambient conditions Overcharge of refrigerant Air in system WILL NOT DEFROST Defrost heater malfunction Wired wrong or faulty connection Relay contacts open Coil temperature sensor failure Controller malfunction board malfunction Power High voltage board Thermal fuse opened PRINTER ERROR ON Paper not feeding correctly 1 2 3 4 5 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 1 2 3 1 DISPLAY Printer harness Printer mechanism printer board error Printer power supply malfunction Controller malfunction DISPLAY BLANK Power supply to controller Controller D21 on Main power supply Should read 5v 12 amp 8 5v Display harness Display board malfunction Controller malfunction ERR SHORT OR Probe open OPEN Temperature is normally displayed Wire connections Controller malfunction Out of range actual temperature range 40 F to 200 F PRINTER DOES NOT PRINT Controller malfunction TEST Printer malfunction Prin
12. Control back to the main Menu 1 The Main Menu will have a new setting that will say Z Start MAIN MENU AIR F lt BY TEMP BY DUCT gt lt BY TIME Z START gt 00 00 00 MORE gt 2 Press the E Z Start button to the next screen that will say SELECT PROBE lt 1 3 gt lt 2 00 00 00 CONTINUE gt 3 Press the button beside each of the numbers to display the temperature being read by the food probes Now press the continue button 4 The control will start the operation instantly 5 To remove the unit from the operation you need to press the number that is displaying Done 6 The following screen will appear PRINT PROBE _ RECORD gt LABEL gt lt NONE gt 7 Print the desired information or press None 8 The above steps will need to be repeated for all numbered food probes that are programmed 9 The alarm that was to tell the customer to CLEAN THE CONDENSER COIL every 265 days will not be displayed on all version controls later than version 2 0 54 REV 04 06 39
13. NOT install a new compressor until the clean up procedure has been completed If a massive moisture contamination or POE oil breakdown has occurred remove the old compressor as outlined in section IX E drain the oil and hold for replacement 1 Recover refrigerant based on current EPA guidelines 2 Remove filter drier and metering device NOTE POE oil applications it should always be assumed that the metering device is restricted after contamination These devices CAN NOT be flushed clean and reused 3 Flush high and low sides of refrigeration system with nitrogen to displace any trapped oil and contaminates 4 Reassemble refrigeration system to include compressor 032 size liquid line drier and new metering device NOTE The use of low flow nitrogen through the system while welding is mandatory to prevent oxidation carbon plating that will lead to further contamination NOTE The use of a suction drier is recommended when moisture contamination is present The suction drier should be removed within 48 hours of installation to prevent further performance issues Also install a new liquid line drier for maximum system clean up S Replace new oil into the compressor 6 Purge system with nitrogen for 5 minutes Pressure should be applied to the high side and allowed to vent through the port on top of the compressor 7 Evacuate system for 30 minutes 8 Repeat steps 5 and 7 two additional times NOTE The final vacuum shou
14. PRINTER options are OPTIONS DESCRIPTION YES Label printer is installed NO No label printer installed V d SETTINGS BLASTING DIFF U BLASTING DIFF 4 U HOLDING DIFF 3 F f U ANTI SHORT 1 1 lt gt Blasting differential is the temperature difference between set point temperature the actual temperature for opening the compressor solenoid when in chill or freeze mode SETTINGS HOLDING DIFF U BLASTING DIFF 4 F U HOLDING DIFF 3 F 1 U ANTI SHORT 1 lt BACK Holding differential is the temperature difference for hold mode V f SETTINGS ANTI SHORT U BLASTING DIFF 4 F 1 U HOLDING DIFF 3 F U ANTI SHORT 1 lt BACK ANTI SHORT is the minimum time between closing and opening the compressor solenoid Select NEXT to access additional menu options 54 REV 04 06 11 SmartChill FACTORY SETTINGS Continued V g SETTINGS DEFROST TIME U DEFROST TIME 40 U DEFR TEMP 50 F U DEFR INTVL 3 HR BACK DEFROST TIME is the length of defrost time in minutes V h SETTINGS DEFROST TEMP U DEFROST TIME 40 U DEFR TEMP 50 F U DEFR INTVL 3 HR BACK DEFROST TEMP is the set point for the coil temperature Vj SETTINGS DEFROST INTVL U DEFROST TIME 40 U DEFR TEMP 50 F U DEFR INTVL 3 HR BACK Defrost interval is the time interval betwe
15. Refrigeration Gauge manifold Dial a Charge Valve core Removal Kit Vacuum Pump Ilg THE SERIAL The serial tag is permanently affixed sticker on which is recorded vital electrical and refrigeration data about your Traulsen product as well as the model and serial number This tag is located at the front corner on the right interior wall on all blast chiller models An example is shown below READING THE SERIAL TAG e Serial The permanent ID of Your Traulsen Model The model of your Traulsen e Volts Voltage e Hz Cycle TOTAL CURRENT e PH Phase MINIMUM CIRCUIT AMPS MAXIMUM OVERCURRENT PROTECTION Total Current Maximum amp draw LIGHTS WATTS E HEATERS AMPS e Minimum Circuit Minimum circuit required a B REFRIGERANT TYPE Lights Light wattage DESIGN PRESSURE HIGH e Heaters Heater amperage REFRIGERANT DESIGN PRESSURE HIGH Refrigerant Refrigerant type used e Design Pressure High amp low side operating pressures and refrigerant charge e Agency Labels Designates agency listings 54 REV 04 06 4 SPECIFICATIONS OPERATIONS DATA PRODUCT SPECIFICATIONS DIMENSIONS RBC50 RBC100 RBC200 RBC200RT Length Overall in 57 1 2 34 48 1 2 48 1 2 Depth Overall in 34 1 4 41 5 8 37 1 2 41 1 8 Height Overall in 34 1 80 1 8 89 1 2 89 1 2 1 Height shown to work top height over control is 53
16. bad sensor should be changed out 3 Check the Thermal fuse located near the evaporator coil If it is open the heater will not come on to raise the temperature past the termination point 4 to program 85 see manual amp scroll thru until you see the defrost time The length of defrost should be set to 40 min 54 REV 04 06 33 TROUBLE SHOOTING Continued CONDITIONS POSSIBLE SOLUTIONS SYSTEM CONTROL ERROR 5 Proceed in program 85 going thru the program to confirm the DEFROST SENSOR FAILURE unit is set up to meet the requirements of the unit e g Set up for Continued a RBC100 or RBC200 SYSTEM CONTROL ERROR 1 Check all Food probes that are selected at this time CURRENT PROBE IS BAD 2 Check for moisture on top of the Food Probe Harness connections located in the ceiling and inside the box 3 Check for proper sealing of the opening thru the Exterior top of the cabinet where the Food Probe Harness passes thru 4 Check the wire connections on top of the Food Probe Harness for breaks in solder joints or corrosion on the joints SYSTEM CONTROL ERROR 1 No Food Probes were plugged into the sockets NO PRODUCT PROBES 2 With the Food Probes not inserted into the sockets the Customer CHECK THE FOOD PROBES selects the Temperature mode 3 With the Food Probes plugged into the sockets amp inserted into the product all three food probes could ha
17. the refrigerant and moves air across compressor to aid in cooling the compressor Dual Pressure Control Low side monitors suction pressure at compressor Shuts compressor OFF when RBC200 amp RBC200RT only low pressure setting is reached cut out Allows compressor to run when pressure rises to cut in setting High side monitors discharge pressure at compressor Shuts compressor OFF when high side pressure setting is reached cut out Allows compressor to run when pressure returns to cut in setting The differential is the difference in pressure between open and closed states of the pressure switch Start Capacitor Wired in series with the start windings to help start compressor motor Run Capacitor Continually in circuit to help compressor motor during operation Thermal Overload Removes power from compressor if the internal temperature of the compressor becomes too high auto reset Start Relay Senses current of run winding of compressor motor Normally open contacts close when run winding draws a high amperage at start and brings the start capacitor and start windings into the circuit As the motor reaches operating speed less amperage through run winding the normally open contacts open and removes the start capacitor and start windings from the circuit Evaporator Fan Draws air from the cabinet and moves air through the evaporator coil Air should blow toward the door Defrost Heater Defrosts evaporator coil and pr
18. 344 28488 00 ALL MODELS HINGE BRACKET 344 28487 00 ALL MODELS SMARTCHILL COMMUNICATION SOFTWARE 375 60175 01 RBC100 HORIZONTAL BREAKER CAP 345 60011 04 RBC100 VERTICAL BREAKER CAP 345 60011 05 RBC100 RBC200 LOCK KEEPER 346 60018 00 RBC100 RBC200 LOCK KEEPER BRACKET 346 60019 00 RBC100 STANDARD PRINTER 950 60355 00 RBC100 RBC200 SMARTCHILL CONTROL KIT SER 60461 00 RBC100 DOOR HINGED RIGHT 200 60059 00 RBC100 TRAY SLIDE 342 60014 00 RBC100 PRINTER COVER 701 60741 00 ALL MODELS STANDARD PRINTER PAPER 400 60003 00 ALL MODELS OPTIONAL LABEL PAPER 400 60004 00 ALL MODELS SMART PROBE RED 333 60086 01 ALL MODELS SMART PROBE BLUE 333 60086 02 ALL MODELS SMART PROBE GREEN 333 60086 03 RBC200 200RT LOUVER ASSEMBLY 500 60138 00 RBC200 200RT ROLL IN RAMP 501 60409 00 RBC200 200RT STANDARD PRINTER 950 60355 00 RBC200 200RT PRINTER COVER 701 60724 01 RBC200 200RT DOOR HINGED LEFT 200 36064 00 RBC200 200RT DOOR GASKET 341 37698 00 RBC200 200RT DIGITRAUL to SMARTCHILL RETRO FIT KIT SER 60442 02 RBC100 DIGITRAUL to SMARTCHILL RETRO FIT KIT SER 60442 01 FOOD PROBE HARNESS DIGITRAUL II SER 60489 00 50 RETROFIT FROM 50 SER 60428 00 RBC200 200RT BLOWER MOTOR 325 60013 10 RBC100 BLOWERMOTOR 325 60013 11 ALL MODELS SMARTCHILL COMMUNICATION SOFTWARE 375 60175 01 54 REV 04 06 38 XV AMENDMENT NOTE UNITS BUILT AFTER 06 01 06 WILL HAVE THE FOLLOWING CHANGES Completion of these steps will bring the
19. 4 REV 04 06 13 SmartChill FACTORY SETTINGS Continued V m SECURE SETTINGS DEFROST U MACH MODEL U MACHINE SIZE 50 lt BACK DEFROST is selection for chiller to defrost by GAS on RBC50 models and ELE for all other models Press the button beside NEXT to exit factory settings V n SECURE SETTINGS SAVING CHANGES FACTORY SETTINGS DO YOU WISH TO SAVE THESE NEW SETTINGS NO YES YES Saves the new settings to memory NO Exits Factory Settings without saving changes When the new settings have been saved the below message will be displayed NEW SOFTWARE HAS BEEN INSTALLED SYSTEM PARAMETERS HAVE BEEN SET 54 REV 04 06 14 VI CONTROLLER SERVICE PROCEDURES VI a CONTROLLER BOARD The controller has two LED S to assist in troubleshooting LED D1 POWER is illuminated indicating that power is supplied to the controller board LED D25 flashes indicating that the control board is communicating to the SmartChill amp computer software used in Versions up to 1 12 This will be seen only on version 2 0 and later power Power to Displa 9 RS232 a output on early Relay Board HIP versions 12 PIN CONNECTOR printers to printer to Relay Board J 15 FOOD PROBE HARNESS CONNECTIONS J11 J 13 COIL AND AIR SENSOR CONNECTIONS J 12 MAIN POWER TO BOARD RED WHITE amp BLACK WIRE J 11 CONNECTION TO RELAY BOARD ALL FUNCTIONS 9
20. ARM OFF BACK gt This screen displays the value of each product probe If no value s shown find the source of the problem The probes could still be programmed The alarm output can also be changed from OFF to ON Return to the main menu by pressing the button beside BACK and the alarm output will return to the OFF state IV h SERVICE MENU DISPLAY TEST From the service menu pressing the button beside DISPLAY illuminates the entire display see below Pressing any key will return the display to the service menu This option can also be used as a test for the keypad since any key press will return to the previous menu NOTE If the screen does not display as shown above the display board needs to be replaced If display does not return to the service menu then the keypad needs to be replaced 54 REV 04 06 8 IV SERVICING THE SmartChill CONTROL Continued IV i SERVICE MENU DEFROST SYSTEM amp COIL PROBE TEST From the service menu pressing the button beside DEF COIL displays the defrost system and coil probe test DEFROST TEST lt HEATER OFF BLAST TEMP 16 F MAINT TEMP 14 F BACK gt The defrost heat selection includes OFF BLAST MAINT or BOTH and can be changed by pressing the button beside HEATER OPTIONS DESCRIPTION OFF Defrost heater should not be energized BLAST Blast defrost heater should energize and coil temperature should slowly increase MAINT Mai
21. Otherwise ERROR will appear on the display prompting you to locate the source of the problem If the optional label printer is installed pressing the button beside LABEL to send out a test print can run the label test print Pressing the button beside BACK can access the service menu V SmartChill FACTORY SETTINGS FACTORY SETTINGS MODE The FACTORY SETTINGS MODE allows service personnel to return various control settings to their factory preset parameters To enter from the keypad press MORE from the MAIN MENU Press SETUP and change the password PIN to 85 Press and hold the upper left upper right and lower right keys simultaneously Then release all keys V b RESETTING THE SERIAL NUMBER To enter the serial number press the button beside SERIAL NUMBERS which changes the digit to edit and then use the UP arrow to increment the value of the selected digit from 0 9 FACTORY SETTINGS VERSION 1 12 lt S N 000000 400 1 lt RESET NEXT gt NOTE The digits between the T and the next letter will need to be all O s to allow easier access into the Security screen later RESET Resets all the parameters to the factory preset values and erases all recorded cycles in memory NEXT Continues to the next Factory Setting menu 54 REV 04 06 10 SmartChill FACTORY SETTINGS Continued SETTINGS LABEL PRINTER LABEL PRINTER lt RESET NEXT gt LABEL
22. RS232 CONNECTION TO CONNECT 9 EARLIER SYLE CONNECTION FOR THE RS232 TO THE CUSTOMERS PC 6 POWER TO THE PRINTER GRAY amp BLACK WIRE 5 SIGNIAL OUT TO THE LABEL PRINTER RED WIRES ONLY 4 SIGNIAL OUT TO THE LABEL PRINTER WHITE WIRES ONLY 3 SIGNIAL OUT TO THE PAPER PRINTER RED WIRES ONLY J 2 SIGINAL OUT TO THE PAPER PRINTER WHITE WIRES ONLY J 1 SIGNIAL OUT TO THE LED DISPLY ON FRONT OF KEY PAD D 21 POWER ON LED 54 REV 04 06 15 VI CONTROLLER SERVICE PROCEDURES Continued VI b RELAY BOARD The relay board has a series of LED s and test points to assist in troubleshooting When the LED is illuminated the component should be energized 893171 REV CS From DC Power Board 4 Control 113 1 110 VOLT OUT PUT TO THE DIFFERENT COMPONENTS J 3 12 PIN CONNECTION FROM THE SMARTCHILL CONTROL J 4 POWER CONNECTION FROM THE POWER SUPPLY BOARD J 13 POWER OUT TO THE SMARTCHILL CONTROL THESE VOLTAGES RANGE FROM 12 VOLTS TO 8 5 VOLTS amp TO 5 0 VOLTS The two black wires are ground only When the LED is illuminated the component should be energized K 1 THE LOW SPEED FAN RELAY K 2 THE HIGH SPEED FAN RELAY 54 REV 04 06 16 12 pin connectors from Control Board 13 COMPONENT FUNCTION Compressor Pumps refrigerant through refrigeration lines and components Condenser Fan Draws air across condenser coil to aid in removing heat from
23. Tests fan outputs PRINTERS Sends test pattern to printer s IV e SERVICE MENU DIAGNOSTIC TEST Pressing the button beside SERVICE MENU prompts the following menu DIAGNOSTIC MAXIMUM RUN CYCLES MINIMUM SINCE DEF FAILURE CYCLES CLEAR gt Pressing the button beside DIAGNOSTIC returns you to the service menu Pressing the button beside RUN CYCLES displays in the lower left corner of the display the number of cycles ran since last cleared Pressing the button beside SINCE DEF displays in the lower left corner of the display the number of cycles ran since last defrost Pressing the button beside MAXIMUM displays in the lower left corner of the display the maximum air temperature of the cabinet Pressing the button beside MINIMUM displays in the lower left corner of the display the minimum air temperature of the cabinet Pressing the button beside FAILURE displays in the lower left corner of the display the failure since last service cleared If there is more than one failure pressing the lower left button will cycle through all the failure Below is a complete list of all possible failures DEFR HEAT Defrost Heater Malfunction SYSTEM FAIL Chiller Not Cooling Properly OVER TEMP Internal Air Temperature Exceeds 150 F CONTROL Control Board Malfunction INTERRUPTED Chilling Cycle Has Been Interrupted Either Loss Of Main Power Or By Inadvertently Switching Power OFF PROBE One Of The Probes Have Malfunction
24. all tubing connections 10 a If any leaks are detected repair leak and recheck for additional leaks 10 b If no leaks are discovered evacuate system as outlined in section IX M NOTE Install a permanent high side access port for future system diagnostics 11 Charge the system and check for proper operation EVACULATING THE SYSTEM WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW 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 Introduction Refrigeration reclaiming equipment is required Our goal in system evacuation is to remove all the non condensable possible No evacuation method will remove 100 of the moisture and air from within the refrigeration circuit Because of this guidelines and methods must be developed and adhered to ensuring only harmless amounts of contaminants remain in the system GUIDELINES e Use only two stage vacuum pump 2 CFM or greater and electronic micron gauge e Set output valve on nitrogen bottle to equal appropriate pressure for the design rated refrigerant at 100 on the P T chart e Evacuate from high and low sides of the system No chemical additive or alcohols are to be used to dry up a system Blow down of system with DRY NITROGEN prior to evacuation is acceptable and many times d
25. at chilled temperature by selecting hold mode from main menu Unit will also go into hold mode automatically when all active probes have reached the target temperature when in BY TEMP mode 1 2 Unit is in IDLE mode Hold mode is initiated 54 REV 04 06 18 SEQUENCE OF OPERATION Continued NOTE When the hold mode is initiated two timers run One tracks the time in the hold mode and the other tracks the time since the last defrost hold mode defrosts at a programmable interval 2 The refrigeration system will cycle on the air temperature of the cabinet 1 ON at the set point plus differential 2 OFF when set point reached NOTE Set point and differential are selected in the factory setup menus 2 b The hold mode has an automatic defrost cycle after a programmable interval of operation in the hold mode 2 b 1 When the defrost cycle is complete and the unit returns to the hold mode the evaporator fans will not operate until the coil temperature is below 25 F 3 Hold pressing the exit key terminates mode NOTE If the HOLD MODE is terminated by the operator with the defrost cycle in progress the defrost mode will continue until completion before going into idle mode VIILe BY TIME CHILL OR FREEZE MODE 1 Unit is in IDLE mode 2 Chill type is selected and a cycle time is entered then start key is pressed 3 The refrigeration system will cycle on the blasting air temperature set point 3 a ON at
26. b RESETTING THE SERIAL NUMBBR 5 teh Nae SEEPTINGS EABBLEPRINTER kon Vid SETTINGS BLASTING DIFE a Ve SBEITINGS HOLDINCFDIEE Vif SEBTEINGSSANTTESHOR T Vit SETTINGS DEPROS TIME PIRE RUM i SEUTINGS DBPROST LEM Diii oh Val SETTINGS DEPROS UINTY atic dee ent Val SE ETINGS SECURITY CODE 56 vedete vena a ao V k SECURE SEDTINGS MACH MODEL Val SECURE SETTINGS MACHINE SIZE Sol Van SECURE SETTINGS DEFROST TYPE ita V n SECURE SETTINGS SAVING CHANGES Table of Contents Continued Page Vile SETTINGS DEFROST INTY Luise 15 VIa CONTROLLER BOARD 15 VEb RBLAY BOARD ste 16 VII COMPONENT FUNCTION esseseeseeseseeseeseccossescesossescesorsercosoesoceorsesceesoesocsoroesoreorsereesorseroeee 17 VIII SEQUENCE OF OPERATION esos eek ia 18 VIILa REFRIGERATION SYSTEM HOLD MODE me 18 REMOTE REFRIGERATION SYSTEM RBC200 18 IDEE MODE geeignet eph pereo iium edis de M coc 18 MIL HOED MODE inodo iato etate
27. be with the Smart Chill Board and must be changed out with a version 1 12 or higher to correct the problem SYSTEM CONTROL ERROR 1 The Box Temperature has exceeded 160 All fans compressors OVER TEMPERATURE and heaters turn off CONTACT SERVICE 2 The Refrigeration Systems have failed to come on to cool the box 3 Cabinet Air Sensor could be bad and could be reading higher than 160 and will cause this Error message 4 The power must be turned off and then back on to reset the control SYSTEM CONTROL ERROR 1 Check all operation sensors Cabinet air senor Maintenance coil CHILL TIME HAS sensor and Blast Chill coil sensor EXCEEDED 6 HOURS 2 Check the refrigeration systems for proper operation The lack of either refrigeration system will cause the chill time to run longer 3 Check the blower motors for proper operation Observe the Blower Motor housing amp blower wheels for any deformation 4 Check the operation of the unit If the control was in a By Temp or By Time mode for more than six hours the unit will shut down and the only way to make it come back on is to turn off the power and then restart the unit SYSTEM CONTROL ERROR 1 Both Defrost Sensors did not achieve defrost termination DEFROST SENSOR FAILURE temperature 50 2 Go to program 75 until you reach the Def coil button Press this button and observe the temperature of both sensors If one or both read strange or open circuit the
28. ck the two coil sensors They should not be reading high temperature as this will result in the compressor running excessively long and freezing the evaporator up 7 The refrigeration system could be causing the coil to ice up if not functioning correctly 54 REV 04 06 34 TROUBLE SHOOTING Continued CONDITIONS POSSIBLE SOLUTIONS CORROSION OCCURING ON 1 Use a Food Grade Silicone and with all power off to the unit CONTROL BOARD spread a light coating of the silicone on all exposed connections 2 Look for high humid conditions UNIT TRIPS A GROUND 1 Go to the relay box and with the power off to the unit pull all of FAULT BREAKER the wires off of terminal 1 and reinstall them one at a time Once you force the breaker to trip this will tell you which component has failed RBC200 NOT HOLDING 1 The temperature must be equal from top to bottom in cabinet TEMP IN IDLE MODE 2 remote condenser will come on every other cycle on Control Versions 1 12 and later RBC50 FOOD PROBE 1 Should the Food Probes fail to read any temperature you will HARNESS need to check them for breaks in the wires or separation of the insulation 2 Look at the Sockets in the ceiling of the box were the Food Probes plug into for any broken pieces 3 Pullthe Socket Plate down to inspect the top of the sockets for broken wires or corrosion 4 Should the Harness be bad it will have
29. e cavity with the blower S Remove the bolts that secure the evaporator blower from the housing panel 6 Reverse the procedure to install the new evaporator blower pope IX l CHECKING FOR LEAKS WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES WARNING THIS PROCEDURE REQUIRES THE USE OF REFRIGERANTS BE CERTAIN THE WORK AREA ISWELL VENTILATED SAFETY GOGGLES AND GLOVES SHALL BE WORN SINCE REFRIGERANTS MAY CAUSE INJURY TO THE SKIN 54 REV 04 06 25 SERVICE PROCEDURE Continued 1 Access the refrigeration system NOTE Recover remaining refrigerant based on current 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 Close bottle valve and gauge valve 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 F on the P T chart nin NOTE See system data plate for design refrigerant 8 Open nitrogen bottle valve 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
30. ed Air Coil or Product PRINTER Printer Not Responding Or Out Of Paper Label Pressing the button beside CLEAR clears the current item IV f SERVICE MENU REF N SYSTEM AND AIR PROBE TEST REFN AIR prompts the following menu REFRIGERATION TEST lt SOLENOID OFF CABINET TEMP 14 F lt COMP USAGE BACK gt 54 REV 04 06 7 IV SERVICING THE SmartChill CONTROL Continued Pressing the button beside SOLENOID can test the compressor function The options for SOLENOID are OPTIONS DESCRIPTION OFF Refrigeration not operational MNT Maintenance Compressor MNT amp LOW Maintenance compressor and Low Fan Speed BLST amp HI Maintenance compressor Blast Chill Compressor and High Speed Fans The current air temperature inside the cavity is also displayed The service menu can be accessed by pressing the button beside BACK and all outputs will return to their OFF state Pressing the button beside COMP USAGE displays the days and hours since the last cleaning of the condenser coil NOTE After cleaning the condenser coil press the button beside CLEANED COIL to reset the day and hour for both to read 0 The previous menu can be accessed by pressing the button beside BACK and all outputs will return to their OFF state IV g SERVICE MENU PROBES ALARM TEST From the service menu pressing the button beside PROBES ALARM prompts the following menu PRODUCT PROBE TEMPS 1 74 F 73 F 3 2 73 F lt AL
31. en automatic defrosts Select NEXT to access additional menu options V j SETTINGS SECURITY CODE FACTORY SETTINGS VERSION 1 12 S N 000000 400 1 lt RESET NEXT gt The security code is required in order to access the additional options Press the button beside the LEFT arrow to select digit to be adjusted and then the button beside the UP arrow to increment the value of the selected digit 54 REV 04 06 12 SmartChill FACTORY SETTINGS Continued ENTER SECURITY CODE FOR NEXT SETTINGS 000000 Press button beside ENTER to continue to secured Options or press the button beside EXIT to exit the factory settings mode NOTE If the incorrect serial number was entered the below message will appear on the display INCORRECT CODE PLEASE CALL TRAULSEN FOR INFORMATION If the correct code was entered the below menu will appear on the display allowing the service personnel to proceed on to the secure options U MACH MODEL U MACHINE SIZE 50 BACK V k SECURE SETTINGS MACH MODEL MACH MODEL 1 MACHINE SIZE 50 1 lt gt MACH MODEL is not an option SECURE SETTINGS MACHINE SIZE U MACH MODEL RBC U MACHINE SIZE 50 BACK MACHINE SIZE is the distinction in capacity between the different model size blast chillers either 50 100 or 200 Do not select any other size than actual chiller size 5
32. esirable See System Clean Up 54 REV 04 06 26 SERVICE PROCEDURE Continued e Evacuate to 200 microns of mercury E Access the refrigeration system 2 Connect low BLUE side of gauge manifold to schrader valve on compressor access line and high RED side of gauge manifold to schrader valve on filter drier line NOTE If there is no high side access install a permanent sweat on tap Connect centerline of gauge manifold to vacuum pump Turn vacuum pump on and open both sides of gauge manifold Pull a vacuum to 200 microns Charge system and check for proper operation m ub IX n CHARGING SYSTEM WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW 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 2 Besure the refrigeration system is checked for leaks and properly evacuated before charging as outlined under LEAK CHECK and EVACUATING SYSTEM 3 Connect high side of gauge manifold to the liquid line make certain both valves on the gauge manifold are closed NOTE Put initial charge to system through the high side to prevent liquid refrigerant from reaching the compressor 4 Connect refrigerant bottle to center connection of gauge manifold check the refrigerant bottle to confi
33. events water droplets from evaporator coil from freezing before they can drain to the condensate pan Operates only during defrost cycle Air Temperature Sensor Monitors air temperature inside the cabinet Coil Temperature Sensor Monitors the Evaporator temperature during defrost cycle Food Temperature Probe Monitors temperature of food product Solenoid Valve Normally closed When energized allows refrigerant to flow from receiver to evaporator coil Door Perimeter Heater Prevents condensate from forming on doorframe Controller Performs the following functions a Displays all data for the current mode of operation b Cycles refrigeration system to maintain cabinet temperature c Monitors power failures Power Supply Board Provides DC voltage to control system Relay Board Performs the following functions a Cycles defrost heaters during defrost cycle b Cycles compressor solenoid to maintain cabinet temperature 54 REV 04 06 17 SEQUENCE OF OPERATION REFRIGERATION SYSTEM HOLD MODE Ne 5 The controller monitors the air temperature and senses need for cooling The relay that controls the maintenance compressor is energized The expansion valve monitors the evaporator superheat and meters the amount of refrigerant entering the evaporator The controller senses the air temperature requirements have been met 4 De energizes the relay that controls the com
34. ing equipment is mandatory S Disconnect the liquid line at the expansion valve 54 REV 04 06 24 SERVICE PROCEDURE Continued 6 Remove the screws from the coil mounting bracket 7 Remove the coil 8 Reverse the procedure to install new coil and then proceed to the next step NOTE It is recommended that the filter drier be changed when this part is replaced 9 Evacuate the system 10 Charge system and put unit back into operation IX j FILTER DRIER WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW 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 Pump down refrigeration system Warning after pump down refrigerant lines will contain pressure Remove filter drier from liquid line Install a new filter drier Evacuate the system po DE NOTE The use of reclaiming equipment is mandatory S Charge system and put unit back into operation IX k EVAPORATOR BLOWER WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES Access the refrigeration system Remove the tray slides and pilasters from the interior 50 and RBC100 only Remove the evaporator cover and open the evaporator fan panel Disconnect the wire leads at the junction box on the top of the unit and pull them into th
35. ld be 200 microns or less Charge the system and replace any panels or covers removed 9 Charge the system and replace any panels or covers removed 54 REV 04 06 28 SERVICE PROCEDURE Continued 10 Reconnect power and check proper operation REPLACING DOOR GASKETS WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES NOTE Before attempting to install a new gasket both the unit and the gasket itself should remain at room temperature for at least 48 hours especially in a low temperature area 1 To begin removing the gasket to be replaced grasp it firmly by one corner and pull it out 2 Insert the new gasket by the four corners first by using a rubber mallet or hammer with a block of wood 3 After the corners are properly inserted work your way towards the center from both ends by gently hitting with a mallet until the gasket is completely seated in place see below diagram for proper gasket placement Inside Door Pan Gasket Assembly Vertical Gasket Retainer NOTE The gasket may appear too large but if it is installed as indicated above it will slip into place 54 REV 04 06 29 X WIRING DIAGRAM RBC50 MODELS CF CRITIONS co LAT gt Hs D A 1 7 HOH 11 2 2I A14 UTBET 01 8
36. mbly 2 Remove the screws from the mounting clamps on the front and rear of the motor 3 Remove the motor bracket and fan assembly from the mounting bracket Proceed to perform either step 4 a or 4 b 4 a To replace the fan blade only loosen the setscrew that secures the fan blade to the motor shaft and remove the fan blade from the motor Install the new fan blade with the setscrews between the motor and the blades OR 4 b To replace the fan motor disconnect the lead wires from the motor 5 Reverse the procedure to install CONDENSER COIL WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES WARNING THIS PROCEUDRE REUQIRES 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 NOTE This procedure applies to all blast chill models with the exception of Model 50 1 Evacuate the refrigeration system 54 REV 04 06 23 IX SERVICE PROCEDURE Continued NOTE The use of reclaiming equipment is mandatory Remove fan guard and fan shroud from condensing coil Disconnect inlet and outlet lines at the soldered connections nearest the condenser coil Remove coil from mounting plate Reverse procedure to install coil then proceed to the next step Aa NOTE Itis recommended that the filter drier be changed when this part is replaced 6 Evacuate the refrige
37. nt Chill mode is terminated when pre programmed condition is met If product used BY TEMP mode all the product probes have reached the target chill temperature Or if product used BY TIME when time expires Soe NOTE If BY TEMP mode was programmed once the temperature of the probe reaches the target temperature the display will alternate with DONE and the buzzer will sound At the end of the chill cycle the unit will enter idle mode VIILh DEFROST MODE 1 The defrost mode can be entered manually from the idle mode or automatically from the hold mode 2 Defrost cycle length is by set minutes or until both coil sensors reaches set point NOTE Minutes and coil temperature are adjustable in the Factory Settings mode If the defrost mode was entered from the hold mode the unit will return to the hold mode 3 After either the time has expired or evaporator temperature probes reach set point defrost heat turns OFF NOTE 50 unit uses hot gas defrost Therefore the compressors will operate during defrost operation NOTE RBC100 only activates the MAINT heater since the coils are combined NOTE RBC200 heaters MAINT and BLAST operate independently That is when a sensor reaches its set point its respective heater will turn OFF a Defrost heaters are OFF b Compressors are OFF c Fans are OFF 5 Fan Delay After drip cycle compressors are enabled but fans stay OFF for three minutes IX SERVICE PROCUDURE
38. ntenance defrost heater should energize and temperature should slowly increase BOTH Both Blast and Maintenance defrost heaters should energize and temperature should slowly increase Both the coil temperatures are displayed If not find the source of the problem Pressing the button beside BACK will allow the main menu to be displayed Doing so also turns the heater OFF IV j SERVICE MENU FAN OUTPUT TEST FAN MODE TEST lt FAN OFF BACK gt From the service menu pressing the button beside FANS displays the fan output test The options for fans are NONE LOW and HIGH OPTIONS DESCRIPTION NONE All evaporator fans de energized LOW Low air flow mode for soft chill mode If not find the source of the problem HIGH High air flow mode If not find the source of the problem 54 REV 04 06 9 IV SERVICING THE SmartChill CONTROL Continued IV k SERVICE MENU PRINTER TEST From the service menu pressing the button beside PRINTER displays the printer test menu this sends a test print to the printer s PRINTER TEST RECORD READY lt LABEL READY BACK gt NOTE LABEL READY will not appear on the display if the optional label printer is not included with the particular unit Pressing the button beside RECORD sends a test print out to the standard paper printer The READY on the display will change to RUNNING then to SUCCESS if the print completes successfully
39. onnections and push back up into the foam and use spray foam to seal into insulation HEATER WIRE BREAKER TRIP EXTERIOR SIDE BREAKER STRIP MOUNTING SCREW N BREAKER STRIP T BREAKER STRIP 5 Reinstall the breaker caps COMPRESSOR WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW 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 54 REV 04 06 22 SERVICE PROCEDURE Continued NOTE This procedure applies to all blast chill models with the exception of Model 50 1 Access the condensing unit and evacuate the refrigeration system NOTE The use of reclaiming equipment is mandatory Disconnect lead wires and conduit at the compressor junction box Disconnect suction and discharge lines from the compressor Remove the compressor Install new compressor and connect wire leads and conduit at compressor junction box Install new filter drier Evacuate system Charge system and put unit into operation spo hus IX f CONDENSER FAN ASSEMBLY WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES NOTE This procedure applies to all blast chill models with the exception of Model 50 1 Remove the fan guard from the top of the condenser asse
40. pressor Unit is cycled by controller VIILb REMOTE REFRIGERATION SYSTEM RBC200 only 1 2 7 The controller must be in a chill or hold mode The controller monitors the air temperature and senses a need for cooling 2 The relay that controls the solenoid valve is energized 2 a 1 Solenoid valve is energized and refrigerant flows to the evaporator 2 2 Fans are operating at high speed The low pressure switch closes with the rise in pressure 3 a The compressor motor is energized and refrigerant is pumped through the system The expansion valve monitors the evaporator superheat and meters the amount of refrigerant entering the evaporator The controller senses the air temperature requirements have been met 5 a De energizes the relay that controls the solenoid valve 5 b Solenoid valve is de energized and closes Refrigerant flow to the evaporator stops 5 Fan operation changes to low speed Compressor continues to run Low pressure control opens as pressure drops 6 a Compressor motor de energized Unit is cycled by controller IDLE MODE 1 4 5 Conditions 1 Unit connected to correct voltage 1 b Safety thermostat closed Door heater energized Main switch closed controller energized 3 a Main contactor energized contacts close Controller displays main menu Controller maintains cabinet air temperature at hold mode temperature HOLD MODE Product can be held
41. r a stiff brush or Wisk broom Care must be taken not to damage the condenser coil fins For more information please refer to section IV a IV c of the Blast Chill Owner s Manual APPLICABLE MODELS This manual applies to the following Traulsen models RBC50 Under counter Blast Chiller Models RBC100 Reach in Blast Chiller Models RBC200 Roll in Blast Chiller Models RBC200RT Roll Thru Blast Chiller Models PLEASE NOTE This manual refers to the above models built after July 2003 equipped with SmartChill control For information regarding models built prior to that date please contact the factory In addition models UBC50 RBC400 and RBC400RT are not covered by the procedures in this manual Please contact the factory for more information WIRING DIAGRAMS Refer to the wiring diagrams on page 31 thru 32 for any service work performed on the unit Should you require another copy please contact Traulsen Service at 800 825 8220 and provide the model and serial number of the unit involved 54 REV 04 06 3 GENERAL INFORMATION Continued TOOL REQUIREMENTS For most jobs a standard set of hand tools a VOM with AC current tester electrically conductive field service grounding kit along with a temperature tester or thermometer are adequate However in some cases the following additional tools may be required as well Refrigeration Reclaiming Equipment Acetylene torch Nitrogen Bottle with Gauges
42. ration system NOTE The use of reclaiming equipment is mandatory 7 Charge system and put unit into operation IX h PRESSURE CONTROL WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW 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 Pump down refrigeration system Warning after pump down refrigerant lines will contain pressure Front seat the suction service valve Disconnect wire leads to pressure switch Disconnect capillary tube from compressor fitting Remove pressure control from mounting bracket Replace pressure switch and connect capillary tube to compressor fitting Put unit back into operation 5 205 0 8 IX i EVAPORATOR COIL WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW 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 Access the refrigeration system Pump down refrigeration system Warning after pump down refrigerant lines will contain pressure Remove defrost heaters as outlined in section IX C RBC100 amp RBC200 only Disconnect the suction line at the soldered joint closest to the coil M rd cun NOTE The use of reclaim
43. rm direction for liquid S Purge the hose from the refrigerant tank to the manifold gauge 6 Open high side of gauge manifold and allow appropriate amount of refrigerant to flow into the refrigeration system 7 Disconnect the hose from the receiver valve 8 Reconnect power to the unit and check for proper operation and high pressure leaks NOTE Adjust charge as needed based on superheat and operating pressures 9 Disconnect power to the unit and replace any panels or covers removed 10 Reconnect power to the unit 54 REV 04 06 27 SERVICE PROCEDURE Continued SYSTEM CLEAN UP INTRODUCTION When a refrigeration system is accessed in service some degree of system clean up is required There are two levels of clean up BASIC Conduct procedure as outlined under EVACUATING SYSTEM and incorporating a drier change this is recommended only when system exposure is limited MASSIVE The use of Polyol Ester POE oil in systems using R 134a and R 404A as well as in many other applications require that every system failure be treated as a massive clean up WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW 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 If a compressor burnout or failure has occurred DO
44. ter power supply board malfunction PRINTER OUTPUT IS NOT Controller malfunction RECOGNIZABLE PRINTER DOES NOT 1 Printer out of paper message on display PRINT OPERATOR MODE 2 Printer malfunction 3 Printer power supply malfunction NO RESPONSE FROM 1 Controller LED D210n KEYPAD 2 Check keypads 3 Check connection to control board PRODUCT NOT CHILLED 1 Product temperature probes not located 2 Correctly or sensor malfunction 3 System malfunction Refer to SYSTEM TROUBLESHOOTING 54 REV 04 06 36 TROUBLE SHOOTING Continued CONDITIONS POSSIBLE SOLUTIONS PRODUCT FROZEN AT 1 Product too thick in pans EDGES 2 Too long of run time in Manual Chill Mode 3 Surface protection option not selected 4 Soft Chill Mode not used 5 Controller malfunction 6 board malfunction 7 Power High voltage board 54 REV 04 06 37 XIV REPLACEMENT PARTS LIST MODEL NUMBER PART DESCRIPTION PART NUMBER 50 POWER PACK ASSEMBLY 900 60233 00 RBC50 RBC100 6 HIGH STAINLESS STEEL LEGS 344 13168 01 RBC50 UNIVERSIAL TRY SLIDE 701 60115 00 RBC50 DOOR GASKET 341 60005 00 RBC50 LOUVER ASSEMBLY 500 60154 00 RBC100 DRAIN PAN 701 60150 00 RBC100 PROBE CABLE HOOK 344 60081 00 RBC100 DOOR GASKET 341 60030 00 ALL MODELS HINGE BODY 344 28482 00 ALL MODELS HINGE COVER 344 28486 00 ALL MODELS HINGE CAM
45. the set point plus differential 3 b OFF when set point is reached 4 If SOFT CHILL has been selected the refrigeration system will cycle when the air temperature reaches within five degrees of the set point Then the fans cycle to low speed and the refrigeration system continues to cycle on and off to maintain the set point temperature If CHILL was selected the set point remains the same until the end of the cycle 5 Chill mode is terminated when time expires 5 Buzzer sounds until muted 6 At the end of a chill cycle the unit will enter the hold mode If the end of the chill cycle is acknowledged by pressing STOP RESET key the unit will enter the idle mode BY TEMP CHILL OR FREEZE MODE Unit is in IDLE mode Chill type is selected and a target temperature is entered then start key pressed and probe selected The refrigeration system will cycle on the blasting air temperature set point Chill mode is terminated when all the product probes reach the target chill temperature Se NOTE Once the temperature of the probe reaches the target temperature the display will alternate with DONE and the buzzer will sound At the end of the chill cycle the unit will enter idle mode 54 REV 04 06 19 SEQUENCE OF OPERATION Continued VIILg BY PRODUCT CHILL OR FREEZE MODE Unit is in IDLE mode Product type is selected The refrigeration system will cycle on the blasting air temperature set poi
46. tion 4 HP air cooled and 3 HP water cooled remote condensing units are available from Traulsen as an optional accessory Actual capacity of the remote condensing unit and line sizing will depend on the length and layout of the connecting piping from the remote condensing unit to the Blast Chill unit These utilize a 1 2 liquid and 1 1 8 suction lines A qualified refrigeration engineer or technician should design the proper line sizing The low pressure cut out of the remote condensing unit should be adjusted to obtain an evaporator coil temperature NO LOWER THAN 15 F If the length of the connecting piping is 40 feet or less the condensing unit low pressure cut out settings will be approximately 15 2 PSIG cut out and 25 3 PSIG cut in For more information please contact the factory 54 REV 04 06 5 IV SERVICING THE SmartChill CONTROL IV a SERVICE MODE The SERVICE MODE allows service personnel to exercise the loads and monitor the input of the control independently to determine if the control the electromechanical components and the refrigeration system are operating properly To enter Service Mode using the keypad press MORE from the MAIN MENU then press SETUP Change the password PIN to 75 Press and hold the upper left upper right and lower right buttons Then release all keys CAUTION Electro static discharge will damage the control board Use an anti static grounding kit when servicing the computer control box
47. to be replaced 5 the Harness you will have to replace to complete top due to the harness being foamed into the top at the time of manufacture 6 You will have to pull the Control Panel and disconnect the Food Probe Harness in the back ductwork 7 Remove the Stainless Steel Work top 8 Remove top that contains the Food Probe Harness and install the new one in its place 9 Reinstall all of the parts to normal working positions RBC50 SMART CHILL 1 On the 50 it has been found that the Defrost Time setting CONTROL can possibly be set to 40 min 2 Should this be true of the unit you are working on you will need to go into program 85 and navigate thru the settings to press the Reset button in the first screen and then go thru until you get to the Security screen 3 Press the Reset button again 4 settings will default to original settings RBC100 Use the button to the right of Machine Size to change from the 100 to the 50 and then press Exit 5 In the next screen press the Yes button to save your changes 6 Proceed to the Main Menu 7 back into the 85 program and press the rest button for the second time Then go to the screen that shows the defrost time 8 Usethe down arrow to change the defrost button to 15 min 9 Press the Back button to go back to the first screen in program 85 to enter the correct serial number this allows usage of the Blast
48. ve an open circuit CONTROL IS STUCK IN THE 1 Check to be sure the customer has Thermal Paper in the paper FIRST SCREEN printer 2 Check version of the control a version 1 01 or 1 04 can allow this to occur if no paper is in the system MENU 75 DIAGNOSTAIC ERRORS Printer 1 Printer has had a problem either label or Record Probe 2 Probe has stopped reading Power Interrupted 3 Power has been Interrupted Over Temp 4 Boxtemperature has exceeded 160 F Def Heater 5 Defrost Heaters did not make temp Either one or both Flash Memory 6 Memory has been reset manually V1 08 or earlier PRODUCT DETECTED 1 Check Food Probes STARTING HOLDING MODE 2 Airtemp has exceeded 70F for 10 minutes 3 An assumption has been made that product is in the box turn on holding cycle MAINTENANCE COIL IS 1 Check the Maintenance compressor for proper cycling on and off ICED UP This may be caused by the contacts on the relay sticking closed 2 Check to see if the customer did not clear all of the probes upon completion and then starting next batch 3 This will result in the unit not being allowed to go into a defrost cycle until the coils ice up 4 Go thru the steps to remove all products and allow the unit to go into a defrost cycle S Should the Maintenance Compressor not shut off look on top of unit to see if the contacts might be stuck closed 6 Ifthe relay is functioning correctly you will need to go to the evaporator and che
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