SERVICE MANUAL #07
Contents
1. Refer to the wiring diagrams on pages 16 thru 18 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 ll f 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 IDE f TOOL REQUIREMENTS cont d Refrigeration Reclaiming Equipment Acetylene Torch Nitrogen Bottle With Gauges Refrigeration Gauge Manifold Dial a Charge Valve Core Removal Kit Vacuum Pump Il g THE SERIAL TAG The serial tag is a 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 inside all blast chiller models An ex ample is shown below FORT WORTH TX SERIAL VOLTS TOTAL CURRENT AMPS MINIMUM CIRCUIT AMPS MAXIMUM OVERCURRENT PROTECTION LIGHTS WATTS HEATERS AMPS REFRIGERANT DESIGN PRESSURE TYPE HIGH REFRIGERANT DESIGN PRESSURE UL TYPE HIGH 370 60294 00 REV A READING THE SERIAL TAG e Serial The permanent ID of your Traulsen Model The model of your Traulsen Volts Voltage e Hz Cycle e PH P2. Traulsen Refrigeration SERVICE MANUAL 07 Instructions For The Installation Troubleshooting And Repair Of Traulsen epicon Equipped Blast Chiller Models Undercounter Model TBC5 Reach In Model TBC13 Roll In Roll Thru Models TBC1H TBC1HR TBC2H amp TBC2HR 2 rendi ormai e 7 E EE pa NOTICE 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 Procedures for which you do not have the necessary tools instruments and skills should be performed only by a trained Authorized Traulsen Service Agent Reproduction or other use of this Manual without the express written consent of Traulsen is prohibited FORM NUMBER TR99999 REV 8 13 TABLE OF CONTENTS TABLE OF CONTENTS GENERAL INFORMATION a Introduction b Operation c Cleaning d Applicable Models e Wiring Diagrams f Tool Requirements g The Serial Tag Ill SPECIFICATIONS OPERATING DATA a Product Specifications b Operating Data c Refriger
3. 5 V CONTROL ARCHITECTURE inr 2 2 D J moet EX i e Fims E Ed 8 8 p sa om ee cse 57 57 111217277127 171211117 2 97 2 cH LE 44 EN ni 49 AA KEE s E E E vut E KE AL KE Koh KEE s KEE p f Laj Er MI b jame 3338 Et lage EC A Y ma 20 7 3 EN u a VP N 1 gt 1 O e Pa 3 Pu pH SHOW LEGEND 1 UI Power 5 Label Printer Communication 2 USB Port used 6 Paper Printer Power 3 USB Port unused T Paper Printer Communica tion 4 Label Printer Power Compressor Condenser Fan Dual Pressure Control TBC1H 8 TBC2H only Start Capacitor Run Capacitor Thermal Overload Start Relay Evaporator Fan Defrost Heater Air Temperature Sensor Coil Temperature Sensor Food Temperature Probe Solenoid Valve Door Perimeter Heater Controller Povver Supply Boards Relay Board Thermal Fuse VI COMPONENT FUNCTION Pumps refrigerant through refrigeration lines and components Draws air across condenser coil to aid in removing heat from the refrigerant and moves air across compressor to aid in cooling the compressor Low side monitors suction pressure at compressor
4. the unit Will enter the idle mode VII f CHILL OR FREEZE MODE BY TEMP 1 Unitis in IDLE mode 2 Chill type is selected and a target temperature is entered then start key pressed and probe selected 3 The refrigeration system will cycle on the blasting air temperature set point 4 Chill mode is terminated when all the product probes reach the target chill temperature VII SEQUENCE OF OPERATION cont d VII f CHILL OR FREEZE MODE BY TEMP cont d NOTE Once the temperature of the probe reaches the target temperature the display will alternate with DONE and the buzzer will sound a Atthe end of the chill cycle the unit will enter idle mode VII g BY PRODUCT CHILL OR FREEZE MODE 1 Unitis in IDLE mode 2 Product type is selected 3 refrigeration system will cycle on the blasting air temperature set point 4 Chill mode is terminated when pre programmed condition is met If product is chilled using BY TEMP mode all the product probes have reached the target chill temperature Or if product used BY TIME when time expires NOTE If BY TEMP mode was programmed once the temperature of the probe reaches the target temper ature the display will alternate with DONE and the buzzer will sound a Atthe end of the chill cycle the unit will enter idle mode Vil h DEFROST MODE 1 The defrost mode can be entered manually from the idle mode or automatically from the hold mode 2 Def
5. 358 28924 42 1 2 1 2 Ramp 501 61449 00 112 112 Printer Access Panel Louver Panel Assembly Sensor Jumper Harness Povver Supply Harness Povver Harness I O Hybrid Relay Harness Maintenance Compressor Condenser Coil Solenoid Valve 1 Solenoid Valve 2 Filter Drier Condenser Fan Blade Condenser Fan Motor Cabinet Air Sensor green Coil Sensor blue Liquid Line Sensor yellow Thermal Expansion Valve 1 Thermal Expansion Valve 2 Evaporator Coil Evaporator Fan Run Capacitor 701 60717 00 900 60138 05 333 60445 00 333 60446 00 333 6045 1 00 333 60452 00 321 60236 00 325 60122 00 325 60001 00 325 60001 01 325 60103 00 325 60088 00 32560214 00 33 60405 01 337 60406 01 337 60407 01 325 60080 42 325 60080 29 322 60068 00 325 60218 00 337 60006 02 337 60070 00 Hybrid Relay 337 60360 01 Povver Supply 331 60451 00 Epicon Control 950 604 72 00 Food Probe 333 604 35 00 I O Board 950 60461 00 Relay Board 950 60462 00 Feed Paper Button for Printer opindle for paper roll Printer 8 33 60423 00 344 60070 00 950 60469 00 1 1 2 NO NO AD HNO AN AQ GD NO NYO a a a AQ AQ 1 1 2 AA DANDAANANNNDAPANNNNNNNN DN NM HA Traulsen 4401 Blue Mound Road Fort VVorth TX 76106 Phone 800 825 8220 Fax Svce 817 740 6757 Website www traulsen com Quality Refrigeration HOURS OR OPERATION Monday thru Friday 7 30 am 4 30 pm CS
6. 5 2 Condenser RLA nja See Notes See Notes See See Unit Voltage 115 115 115 Phase Hz 5 5 5 50 5 5 Full Load Amps 19 3 13 4 14 9 14 9 14 9 2 14 912 NEMA Plug Type 5 20 14 20 Hard Wire Hard Wire Hard Wire Hard Wire 17 Self Contained Holding or Primary Compressor 2 Blast Chilling or Secondary Compressor 3 Varies with remote system lll c REFRIGERATION SYSTEM INSTALLATION All Traulsen blast chillers with the exception of model TBC5 require the use of a floor drain or floor mounted condensate evaporator for condensate removal Refer to Section IV h of the blast chill owner s manual for more information Remote refrigeration installation requirements apply only to models TBC1H TBC1HR and TBC2H TBC2HR A remote condensing unit op erating on R 404A refrigerant is required for Blast Chill operation on these models The remote condensing unit s should be capable of providing 18 700 BTU hr 10 F evaporator temperature and 90 F ambient Air cooled and water cooled remote condensing units are available from Traulsen as an optional accessory Please note that these should be adequate for any installation within a 25 foot radius from the cabinet Beyond this distance the actual capacity of the remote condensing unit and line sizing may change depending upon the length and layout of the connecting piping from the remote condens ing unit to the Blast Chiller These utilize a 1 2 liquid an
7. I O Board Relay Board Feed Paper Button for Printer opindle for paper roll Printer 21 Part Number 200 60791 01 282543 341 60197 00 358 13186 42 358 13190 00 358 60023 00 358 28924 42 340 60240 00 342 6007 7 00 342 6007 8 00 348 10012 00 348 10012 01 201 6057 5 00 701 61173 00 509 50170 01 700 60543 00 333 60396 05 321 60233 00 322 60056 00 325 60001 00 325 60103 00 325 60135 00 337 60405 01 337 60406 01 337 60407 01 341 60062 00 325 60080 31 322 60053 00 325 60073 01 333 60391 00 337 60006 00 337 60070 00 337 60451 00 337 60451 00 950 60472 00 333 60435 00 950 60461 00 950 60462 00 337 60423 00 344 60070 00 950 60469 00 Quantity NNN DA AQ AS GJ ol A AQ AQ AQ M XIV TBC13 REPLACEMENT PARTSLIST Description Door Assembly Hinged Right Door Assembly Hinged Left Door Hinge Body Door Hinge Cover Door Minge Bracket Door Hinge Cam Door Gasket Lock Cylinder Lock Clip Lock Bolt Lock Key Tray Slide Pilaster Casters kit of four with bolts Printer Access Panel Louver Panel Assembly Sensor Jumper Harness Povver Supply Harness Povver Harness I O Hybrid Relay Harness Chill Compressor Maintenance Compressor Condenser Coil Solenoid Valve Filter Drier Condenser Fan Blade Condenser Fan Motor Cabinet Air Sensor green Coil Sensor blue Liquid Line Sensor yellow Thermal Expansion Valve 1 Thermal Ex
8. Shuts compressor OFF when 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 Wired in series with the start windings to help start compressor motor Continually in circuit to help compressor motor during operation Removes power from compressor if the internal temperature of the compressor becomes too high auto reset 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 Draws air from the cabinet and moves air through the evaporator coil Defrosts evaporator coils and prevents water droplets from evaporator coil from freezing before they can drain to the condensate pan Operates only during defrost cycle Monitors air temperature inside the cabinet Monitors the suction line temperature at evaporator during defrost cycle Monitors temperature of food product Normally closed
9. blank controller Compressor will not run current draw trips overload Defrost time too long exceeds 50 minutes Compressor short cycles Control response to touch appears slow TROUBLESHOOTING POTENTIAL CAUSE a b oS diu 0 QO TH 0 QO TH ococo on No power to unit System problem Door not closed properly Too much product loaded Excessive product depth Pan has been covered with a lid plastic wrap or foil and this is not in direct contact with the product Product loaded is of a high density Dirty condenser coil Evaporator coil iced Probe not available Probe not placed in product Food probe placed in product below 90 F Damaged or defective food probe Door open Hot product inside but no probe placed Previously chilled product not removed Chill cycle By Time set for too long High water content food ex soup Food chilled uncovered Printer out of paper Paper loaded incorrectly Feed roller tension arm open Paper jam Printer malfunction Door out of alignment or gasket issue Door sweep worn out of adjustment TBC1H Electric door heater malfunction Varied product temps within batch Probe placed incorrectly Small mass product ex chicken tender Product held at room temp too long Main circuit breaker open Fuse open on control power suppl
10. thermometer Relocate probe Use chill by time Verify actual product temp using a manual thermometer Close breaker Replace fuse Close internal breaker Replace control board Switch power to ON position Remedy power supply issue Replace start capacitor Replace compressor Replace rotor Requires additional diagnosis to determine cause Replace sensor Confirm and correct wiring Adjust defrist settings as needed Replace defrost heater Look for ice formation Replace TXV Relocate chiller to warmer environment Replace low pressure control Replace air sensor Replace control board Replace board Replace solenoid valve Update latest operating system software Recalibrate touchscreen SYMPTOM 15 16 17 TB 19 Lovv suction pressure High head pressure Chiller will not defrost Printout shows wrong date and or time Water on the floor near the blast chiller XII TROUBLESHOOTING cont d POTENTIAL CAUSE a Solenoid valve restricted b Restriction in filter drier Loss of refrigerant d Poor air flow e Expansion valve blocked Improper air flow across condenser Extreme ambient conditions Refrigerant overcharge Air in system Defrost heater malfunction VVired vvrong or faulty connection Relay contacts open Coil sensor failure Control malfunction Relay board malfunction Open fuse a Date time
11. IBRATE than each of the five plus symbols t as closely as possible to do so Note use of a stylus is highly recommended NOTE The units are calibrated from the factory and should only be recalibrated if necessary Exercise extreme caution when recalibrating as improper inputs while calibrating can result in difficultly navigating the control Touch Touch Touch Touch Touch Point 1 Point 2 Point 3 Point 4 Point 5 PRINTERS This feature allovvs you to PARAMETERS check each printer for proper operation Press START DEFROST to initiate an on demand defrost Press PRINT CHART to test the record printer Press DOVVNLOAD SERVICE DATA to transfer all temperature data as shown Press PRINT LABEL to test the label on the TEMPERATURE menu through printer on models supplied vvith the the USB port to a thumb drive optional label printer Press DOWNLOAD RAW DATA to PRINT CHART PRINT LABEL sc TN transfer all data in memory through the USB port to a thumb drive NOTE this TEMPERATURES feature requires use of special software Displays key temperature sensor data Expected values available from Traulsen for each should be in similar to those shown below DIAGNOSTICS AMBIENT 66 F omes saws current Press each OUTPUT one at a time in CABINET 34 F ir coro Order to change test status from OFF MAINT EVAP IN 63 F to ON Record the re
12. RANTS 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 burn out or failure has occurred DO NOT install a new compressor until the clean up pro cedure has been completed If a massive moisture contamination or POE oil break down 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 In POE oil applications it should always be assumed that the metering device is restricted aftre a 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 sys tem 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 installtion to prevent further performance issues Also install a new liquid line drier for maximum system clean up 5 Replace new oil into the compressor 6 Purge system with nitrogen for 5 minutes Pr
13. T
14. WER 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 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 5 Install new expansion valve into inlet line and fasten bulb to suction line mi 59255 NOTE Make sure expansion valve bulb is attached parallel to suction line and makes good contact Vill SERVICE PROCEDURES cont d VIII b EXPANSION VALVE cont d ar a J T PI TII mi MIRA EXPANSION VALVE TUTTI ee Y TIT TT T NOTE It is recommended that the filter drier be changed when this part is replaced VIII c DOOR PERIMETER HEATERS TBC1H TBC1HR TBC2H TBC2HR 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 u
15. WHITE YELLOW POT START RELAY COMP UP STREAM PRINTER 1 COMPRESSOR NOTE 1 PRINTER 2 15 OPTIONAL X VVIRING DIAGRAM MODEL TBC13 ux1v3H 3504 15098330 Q O 3ATVA 1SO333G QNOO 1INIVW Ald allHM WOVE j WV33IS dh MX de 06 sanzi I1OV1dIDIN YAWYOISNVULINIYIND N31V3H 3IVSN30QNO2D 1 4313Wlil3d E i 17 XI WIRING DIAGRAM MODEL TBC1H TBC1HR NOTE hi PRINTER 1 PRINTER 2 IS OPTIONAL PERIMETER HEATER p 2 au BLACK 6015 2 GND 5 e mm gt gt pa e UW FW Wr DEFROST VALVE NAL THERMAL DEFROST FUSE _ HEATER 18 SYMPTOM 1 10 11 12 13 14 No display on control Batch requires too much time to chill product down to temperature or time target Auto mode does not appear to work when placing probe in hot product Chill cycle starts with no product present Unwanted product freezing Food drying out during chilling Printer not printing Condensation on exterior surface Upon starting a chill cycle the product temperature displayed appears cooler than expected cooked temperature Nothing runs
16. When energized allows refrigerant to flow from receiver to evaporator coil Prevents condensate on door frame 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 Provides DC voltage to control system Performs the following functions a Cycles fans b Controls outputs to heaters and compressor relays TBC4H TBC1HR TBC2H and TBC2HR only Monitors cabinet air temperature Opens circuit to defrost heater if cabinet temperature exceeds 230 F 7 VII SEQUENCE OF OPERATION VII a REFRIGERATION SYSTEM HOLD MODE 1 The controller monitors the air temperature and senses a need for cooling a The relay that controls the compressor is energized 3 The expansion valve monitors the evaporator superheat and meters the amount of refrigerant entering the evaporator 4 The controller senses the air temperature requirements have been met a De energizes the relay that controls the compressor 5 Unitis cycled by controller VII b REMOTE REFRIGERATION SYSTEM TBC1H TBC1HR TBC2H amp TBC2HR only 1 The controller must be in a chill or hold mode 2 The controller monitors the air temperature and senses a need for cooling a Therelay that controls the solenoid valve is energized 1 Solenoid valve is energized and refrigerant flows to the evaporator 2 Fans are operating at hi
17. ading and then MAINT EVAP CORE 42 F ww gre turn the OUTPUT off before proceeding BLAST EVAP IN 32 vu wu to the next one BLAST EVAP CORE 37 F ___ BLAST EVAP OUT 3ZF Cmmemsseesesss NOTE If you do not turn each OUTPUT BLAST LIQUID LINE 66 F 2 Off before proceeding to the next one MAINT LIQUID LINE 66 F a c a you can potentially cause damage to C ax that component SOFTWARE Selectthis feature when updating the control s operating software Normal readings for each OUTPUT should be The current software versions are displayed at the top of the TOOLBOX main menu Contact Traulsen at 800 LS EVAP FANS 3 7A 55 825 8220 to verify if you have the latest software versions HS EVAP FANS 3 9A 15 u MAINT COND FAN 1 15A 25A To update the control insert a thumb drive containing the BLAST COND FAN latest software into the USB port Note all files must be MAINT COMP 7 5A 1 5A located in the root directory Updates should be performed BLAST COMP in the following order if necessary DEFROST VALVE n a BUZZER n a Update Board Update UI Board NOTE The maintenance compressor Update HTML has an anti cycling feature of 1 minute Allovv the cabinet to idle for at least Follow the instructions provided with the software update 1 minute before beginning a test and any on screen instructions Do not remove the thumb drive until all updates have been completed
18. ation System Installation IV SERVICING THE EPICON CONTROL a Overview b The Toolbox c Setting The Clock d Service Menu e Service Menu Features V CONTROL ARCHITECTURE a Controller Board VI COMPONENT FUNCTION VII SEQUENCE OF OPERATION a Refrigeration System b Refrigeration System BC compressor on TBC1H only c IDLE Mode d Hold Mode e By Time Chill Freeze Mode f By Temp Chill Freeze Mode g By Product Chill Freeze Mode h Defrost Mode 1 ar HA AKA A N NY SERVICE PROCEDURES a Temperature Sensors b Expansion Valve c Door Perimeter Heaters d Compressor e Condenser Fan Assembly f Condenser Coil g Pressure Control h Evaporator Coil i Filter Drier j Evaporator Blower k Checking For Leaks l Evacuating The System m Charging The System n System Clean Up o Replacing The Door Gasket IX WIRING DIAGRAMS TBC5 X WIRING DIAGRAMS TBC13 XI WIRING DIAGRAMS TBC1H MODELS TROUBLESHOOTING XIII TBC5 REPLACEMENT PARTS LIST XIV TBC13 REPLACEMENT PARTS LIST XV TBC1H REPLACEMENT PARTS LIST Visit the Resource Center www traulsen com to review the Operator s Video for this product 9 10 10 10 11 11 11 11 11 12 12 13 13 14 14 15 16 17 18 19 20 21 22 23 GENERAL INFORMATION Il a INTRODUCTION Blast Chillers are food processing refrigerators de signed for rapid chilling of product from 140 F to 40 F in ap
19. d 1 1 8 suction lines Proper specification of the remote condensing unit needed and line sizing should be defined by a qualified refrigeration engineer or technician based on the jobsite installation needs 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 IV SERVICING THE EPICON CONTROL IV a OVERVIEVV Traulsen s TBC Series blast chillers are equipped with the epicon microprocessor control This is protected from damage by a surrounding heavy gauge metal be zel Itincludes several diagnostic features built within the TOOLBOX s SERVICE menu The control itself has no serviceable parts Should you encounter a faulty or damaged control it will need to be replaced IV b THE TOOLBOX The TOOLBOX can be accessed by pressing the MANUAL tab and then the TOOLBOX icon on top of the MANUAL menu screen Product Toolbox The control will now display the TOOLBOX menu It includes three security levels TOOLBOX Manual From the MANUAL menu screen press the TOOLBOX icon PROGRAM Press USER for operator level access This provides open access allowing you to Set the Clock Adjust Defrost Time and Settin
20. essure 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 should be 200 microns or less 9 Charge the system and replace any panels or covers removed 10 Reconnect power and check for proper opertion VIII SERVICE PROCEDURES cont d IX o 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 15 IX WIRING DIAGRAM MODEL TBC5 PERIMETER HEATER HYB RLY 2 PURPLE lt 0 J15 el GND 16 RUN CAP
21. gh speed 3 The low pressure switch closes with pressure rise a The compressor motor is energized and refrigerant is pumped through the system 4 The expansion valve monitors the evaporator superheat and meters the amount of refrigerant entering the evaporator 5 The controller senses the air temperature requirements have been met a De energizes the relay that controls the solenoid valve 1 Solenoid valve is de energized and closes Refrigerant flow to the evaporator stops 2 Fan operation changes to low speed 6 Compressor continues to run Low pressure control opens as pressure drops a Compressor motor de energized T Unitis cycled by controller VII c IDLE MODE 1 Conditions a Unit connected to correct voltage b Safety thermostat closed 2 Door heater energized 3 Main switch closed controller energized a Main contactor energized contacts close 4 Controller displays main menu 5 Controller maintains cabinet air temperature at hold mode temperature VII HOLD MODE Product will be held automatically at chilled tempera ture when all active probes have reached the target temperature when in any mode If a BY TIME mode is selected the unit enters hold mode automatically after the time has expired 8 VII d HOLD MODE cont d 1 Unit is in IDLE mode 2 Hold mode is initiated NOTE When the hold mode is initiated two timers run One tracks the time in the hold mode and the other t
22. gs Download Cycle Data Search Chill Cycle History and Upload Recipes to the PRODUCT menu SERVICE SUPERVISOR TOOLBOX SET DATE TIME SCHEDULE DEFROST DOVVNLOAD CYCLES Press SUPERVISOR for supervisor access Note that this not intended for every day access and adjustments and so is passvvord protected Enter your access code to proceed The factory default code is 1234 This can be changed in the SUPERVISOR level DATA MANAGEMENT UPLOAD PRODUCTS HOME IV c SETTING THE CLOCK Begin by pressing MANUAL TOOLBOX USER then press SET DATE TIME The display will change to the SET DATE TIME screen IV c SETTING THE CLOCK continued To adjust the Date and time settings Back 1 Press DAY MONTH the field will be highlighted adjust this parameter 5 1 2 3 Proceed to the next IV d SERVICE MENU Press SERVICE to access the service menu Note that YEAR HOUR MINUTE as needed after doing so 19 APR 2013 Toggle the LEFT RIGHT arrows at bottom to parameter 4 Press SAVE TIME to save these settings this is password protected The factory default code is 4401 Enter the access code to proceed TOOLBOX The SERVICE menu will appear TOOLBOX ee tj S ad IERBKIT V2 1 IV SERVICING THE EPICON CONTROL cont d IV e SERVICE MENU FEATURES CALIBRATE This features allows for calibration of the touchscreen s accuracy Press CAL
23. hase Total Current Maximum amp draw e Minimum Circuit Minimum circuit required e Lights Light wattage Heaters Heater amperage Refrigerant Refrigerant type used Design Pressure High amp low side operating pressures and refrigerant charge e Agency Labels Designates agency listings Ill SPECIFICATIONS OPERATING DATA INSTALLATION Ill PRODUCT SPECIFICATIONS DIMENSIONS Length Overall in Depth Overall in TBC5 TBC13 54 41 34 716 234 112 Height Overall in 34 74 Capacity 12 20 Pans 10 Capacity 18 26 Pans 5 13 Capacity Product Weight 100 lbs 200 lbs TBC1H 48 1 2 37 5 8 90 3 8 1 Rack 1 Rack 300 Ibs TBC1HR 48 1 2 41 1 4 90 3 8 1 Rack 1 Rack 300 Ibs TBC2H 48 1 2 71 5 6 90 3 8 2 Racks 2 Racks 600 Ibs TBC2HR 48 1 2 75 1 4 90 3 8 2 Racks 2 Racks 600 Ibs lll b OPERATING DATA DATA Single or Dual System TBC5 Single Remote Chill Compressor n a BTU HR BTU HR 4300 n a n a TBC13 Dual NO 1 2 2820 1 1 4 5710 TBC1H Dual Yes 1 2 2820 18 700 TBC1HR Dual Yes 1 2 2820 18 700 TBC2H Dual Yes 2 1 2 2 2820 2 18 700 2 TBC2HR Dual Yes 2 1 2 2 2820 2 18 700 2 Refrigerant Type R 404A R 404A R 404A 404 R 404A R 404A Refrigerant Charge oz 29 31 20 25 25 2 2912 Refrigerant Charge n a 45 See Note See Notes See UE See gt Condenser RLA 11 7 105 10 5 10 9 2 10
24. he 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 confirm direction for liquid 5 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 1 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 Through low side of system 9 Disconnect power to the unit and replace any panels or covers removed 10 Reconnect power to the unit IX n SYSTEM CLEAN UP INTRODUCTION When a refrigeration system is accessed in servce 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 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 IX n SYSTEM CLEAN UP INTRODUCTION cont d WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES WARNING THIS PROCEDURE REQUIRES THE USE OF REFRIGE
25. igh 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 desirable See System Clean Up Evacuate to 200 microns of mercury 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 3 Connect center line of gauge manifold to vacuum pump 4 Turn vacuum pump on and open both sides of gauge manifold 5 Pull a vacuum to 200 microns 6 Charge system and check for proper operation VIII SERVICE PROCEDURES cont d IX m 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 Be sure 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 t
26. nder 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 connections and push back up into the cabinet to allow for breaker caps to be reinstalled INSULATION HEATER WIRE BEHIND BREAKER EXTERIOR SIDE 10 BREAKER STRIP MOUNTING REPLACE eo BREAKER STRIP 5 Reinstall the breaker caps VIII e 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 NOTE This procedure applies to all blast chill models 1 Access the condensing unit and evacuate the refrigeration system NOTE The use of reclaiming equipment is mandatory Vill SERVICE PROCEDURES cont d VIII d COMPRESSOR cont d 2 Disconnect lead wires and conduit at the compressor junction box 3 Disconnect suction and discharge lines from the compressor 4 Remove the compressor 5 Install new compressor and connect wire leads and conduit at compressor junction box 6 Install new filter drier T Evacuate system 8 Charge system and put u
27. nit into operation VIII e 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 1 Remove the fan guard from the top of the condenser assembly 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 4a or 4b 4 a To replace the fan blade only loosen the set screw that secures the fan blade to the motor shaft and remove the fan blade from the motor Install the new fan blade with the set screws between the motor and the blades 4 b To replace the fan motor disconnect the lead wires from the motor 5 Reverse the procedure to install VIII g CONDENSER 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 NOTE This procedure applies to all blast chill models 1 Evacuate the refrigeration system NOTE The use of reclaiming equipment is mandatory 11 VIII f CONDENSER COIL cont d 2 Remove fan guard and fan shroud from condensing coil 3 Disconnect inlet and outlet lines at the soldered connections nearest the conden
28. pansion Valve 2 Evaporator Coil Evaporator Fan Cord amp Plug Run Capacitor Horn Hybrid Relay Power Supply Epicon Control Food Probe I O Board Relay Board Feed Paper Button for Printer Spindle for paper roll 22 Part Number 200 60763 00 200 60763 01 344 28482 00 344 28486 00 344 28487 00 344 28488 00 341 60223 00 358 13186 42 358 13190 00 358 13189 00 358 28924 42 340 60240 00 342 60108 00 CK1 701 60717 00 500 60543 00 333 60445 00 333 60446 00 333 60451 00 333 60452 00 321 60236 02 321 60243 12 322 60067 00 325 60001 04 325 60103 00 325 60202 00 338 60058 00 337 60405 01 337 60406 01 337 60407 01 325 60080 42 325 60080 29 322 60068 00 325 60013 11 333 60454 00 337 60006 02 337 60070 00 337 60360 01 337 60451 00 950 60472 00 333 60435 00 950 60461 00 950 60462 00 337 60423 00 344 60070 00 Quantity NON 9 GW VN PO CW NA AQ cll S A XV TBC1H TBC1HR TBC2H amp TBC2HR REPLACEMENT PARTS LIST TBC2H TBC1HR 2 Description Part Number Qty Qty Door Assembly Hinged Left 200 60802 00 1 2 1 2 Door Hinge Body 344 28482 00 3 6 3 6 Door Hinge Cover 344 28486 00 3 6 3 6 Door Hinge Bracket 344 2848 7 00 3 6 3 6 Door Hinge Cam 344 28488 00 3 6 3 6 Door Gasket Lock Cylinder 341 60225 00 358 13186 42 1 2 1 2 1 2 1 2 Lock Clip 358 13190 00 1 2 1 2 Lock Bolt 358 13189 00 1 2 1 2 Lock Key
29. proximately 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 b OPERATION Refer to the instructions contained in the Owner s Manual form number TR35938 for specific operating instructions Il c CLEANING Detailed cleaning instructions are included with each unit however special care MUST be given to the con denser coil s These must be cleaned WEEKLY 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 or a stiff brush or wisk broom Care must be taken not to damage the condenser coil fins For more information please refer to section V a V e and V f of the Blast Chill Owner s Manual Il d APPLICABLE MODELS This manual applies to the following Traulsen models TBC5 Undercounter Blast Chiller TBC13 Reach In Blast Chiller TBC1H amp TBC2H Roll In Blast Chillers amp TBC2HR Roll Thru Blast Chillers PLEASE NOTE This manual refers to the above models built after June 2012 equipped with the epi con control For information regarding models built prior to that date please contact the factory Il e WIRING DIAGRAMS
30. racks the time since the last defrost hold mode defrosts at a programable interval a 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 b The hold mode has an automatic defrost cycle The operator can program the interval between defrost cycles to suit their operational needs 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 20 F 3 Hold mode is terminated by pressing the exit key NOTE If the HOLD MODE is terminated by the op erator with the defrost cycle in progress the defrost mode will continue until completion before going into idle mode VII e BY TIME CHILL MODE 1 Unitis 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 a ONatthe set point plus differential b OFF when set point is reached 4 If SPEED has been selected the refrigeration system will cycle on the new blasting air temperature set point after softchill condition is met i e 70 percent of time has expired 5 Chill mode is terminated when time expires a Buzzer sounds until muted 6 Atthe end ofa chill cycle the unit will enter the hold mode a If the end of the chill cycle is acknowledged by pressing the STOP RESET key
31. rost cycle length is by set minutes or until the coil temperature reaches set point a 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 All TBC blast chillers include a hot gas defrost Therefore the compressors will operate during defrost operation 4 Unit waits for two minutes to allow water to drip off evaporator coils a Hot gas solenoid OFF b Compressors are OFF c Fans are OFF 5 Fan Delay After drip cycle compressors are enabled but fans stay OFF until the evaporator coil s reach 20 degrees F Vill SERVICE PROCEDURES VIII a TEMPERATURE AIR SENSORS WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES 1 Access the evaporator s 2 Remove the cabinet sensor from the maintenance evaporator 3 Remove coil sensors from both the maintenance and blast chill evaporators 4 Remove the food temperature probe receptacle from cabinet ceiling 5 Disconnect the sensor probe wiring assembly connector from the controller ar Tm m i B Ur b ud HH HA IN NU Ur We AN d a sorte ye RT CABINET itt SENSOR 6 Reverse the procedure to install replacement sensors VIII b EXPANSION VALVE WARNING DISCONNECT THE ELECTRICAL PO
32. ser coil 4 Remove coil from mounting plate 5 Reverse procesure to install coil then proceed to the next step NOTE It is recommended that the filter drier be changed when this part is replaced 6 Evacuate the refrigeration system NOTE The use of reclaiming equipment is mandatory 7 Charge system and put unit into operation VIII g 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 1 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 5 Remove pressure control from mounting bracket 6 Replace pressure switch and connect capillary tube to compressor fitting T Putunit back into operation mo m VIII SERVICE PROCEDURES cont d VIII h 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 1 Access the refrigeration
33. settings incorrect a Condensate evaporator not installed b Condensate evaporator not connected to power supply c Condensate evaporator malfunction 90 SOLUTION Remedy solenoid restriction Replace filter drier Diagnose leak and recharge system Insure proper air flow around system Please TXV Insure proper air flow around system Relocate chiller to cooler environment Correct refrigerant charge Evacuate cleanse system then recharge Replace defrost heater Verify correct wiring and connections Replace relay Replace coil sensor Replace control board Replace relay board Replace fuse Set correct date and or time on the control Install condensate evaporator Plug in condensate evaporator Replace condensate evaporator 5 REPLACEMENT PARTS LIST Description Door Assembly with Lock Door Hinge Door Gasket Lock Cylinder Lock Clip Lock Bolt Lock Key Tray Slide Front Pilaster Rear Pilaster Casters without brake Casters with brake Printer Access Panel Condensate Pan Stainless Steel Bullnose Work Louver Panel Assembly Cabinet Harness Compressor Condenser Coil Solenoid Valve Filter Drier Condenser Fan Blade Cabinet Air Sensor green Coil Sensor blue Liquid Line Sensor yellow Air Filter Thermal Expansion Valve Evaporator Coil Evaporator Fan Cord amp Plug Run Capacitor Horn Hybrid Relay Power Supply Epicon Control Food Probe
34. system 2 Pump down refrigeration system Warning after pump down refrigerant lines will contain pressure 3 Disconnect the suction line at the soldered joint closest to the coil NOTE The use of reclaiming equipment is mandatory 5 Disconnect the liquid line at the expansion valve 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 i 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 1 Pump down refrigeration system Warning after pump down refrigerant lines will contain pressure 2 Remove filter drier from liquid line 3 Install a new filter drier 4 Evacuate the system NOTE The use of reclaiming equipment is mandatory 5 Charge system and put unit back into operation 12 VIII j EVAPORATOR BLOWER WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES 1 Access the refrigeration system 2 Remove the tray slides and pilasters from
35. the interior TBC5 and TBC13 only 3 Remove the evaporator cover and open the evaporator fan panel 4 Disconnect the wire leads at the junction box on the top of the unit and pull them into the cavity with the blower 5 Remove the bolts that secure the evaporator blower from the housing panel 6 Reverse the procedure to install the new evaporator blower VIII SERVICE PROCEDURES cont d IX k 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 IS WELL VENTILATED SAFETY GOGGLES AND GLOVES SHALL BE WORN SINCE REFRIGERANTS MAY CAUSE INJURY TO THE SKIN 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 5 Close bottle valve and gauge valve 6 Disconnect refrigerant bottle and connect nitrogen bottle 7T Setoutput valve on nitrogen bottle to equal the appropriate pressure for the design rated refrigerant at 100 degrees F on the P T chart NOTE See system data plate for design refrigerant 8 Open nitrogen bottle
36. valve and gauge manifold valve low side and allow pressure to equalize 9 Shutoffboth valves and disconnect the nitrogen bottle 10 Using a leak detector check for leaks at all tubing connections a leaks are detected repair leak and re check for additional leaks b If no leaks are discovered evacuate system as outlined in section VIII M NOTE Install a permanent high side access port for future system diagnostics 11 Charge the system and check for proper operation IX EVACUATING 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 condensables possible No evacuation method will remove 100 of the moisture and air from within the refrigeration circuit Because of this guide lines and methods must be developed and adhered to ensuring only harmless amounts of contaminants remain in the system GUIDELINES Use only a two stage vacuum pump 2 CFM or greater and electronic micron gauge Set output valve on nitrogen bottle to equal appropriate pressure for the design rated refrigerant at 100 degrees F on the P T chart Evacuate from h
37. y Internal circuit breaker open Control power supply malfunction Main ON OFF switch OFF Low incoming voltage Start component malfunction Compressor windings shorted Locked rotor Excessive head pressure Coil sensor failure Incorrect wiring Incorrect defrost settings Defrost heater malfunction Improper air flow over evaporator coil Expansion valve malfunction Low ambient conditions Low pressure control inoperative Failed air sensor Control malfunction I O board malfunction Solenoid valve malfunction Obsolete software Calibration off 19 SOLUTION Check povver supply and circuit breaker Call for service Close door completely Adjust the load to not exceed capacity of the unit Reduce pan load Cover product correctly Allow additional chilling time Clean condenser coil Allow chiller to defrost Press DONE to release probe for use Place probe in product Manually program cycle and select probe Replace with new food probe Close door Press CANCEL then place probe to start cycle Remove DONE product before starting a new chill cycle Reduce cycle time Use DELICATE method Cover food before placing in chiller Replace paper Replace paper with thermal side up Close feed roller tension arm Correct paper jam Replace printer Check door alignment and gasket for proper seal Adjust replace door sweep Call for service Verify actual product temp using a manual
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