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FOSTER BLast Chiller Service Manual

1. ooo ec 54 3 13 PROBE POSITIONS 1 E t H 380ud SUN LVL H3TIIHO LSV1d YVINGOW OL OL E MP vut a s Tus A a1ISOddO 335 2 1109 OL Qv31 7 33S NOI1V201 dil H3AO 38O0Hd LVLS AL343VS 13NYd 3008 1IX3 S380ud 1109 55
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4. ABW 50 3 10 PARAMETER SETTING Within the control system there are approximately thirty set parameters shown on the following page To check or modify the parameters Ensure that the display is off Three bars will be displayed in 17 Hold down the Increment Decrement buttons VA and simultaneously press the On Off button The time display will show SEt The parameters are numbered 0 to 30 The parameter number is shown in display 25 and the value of that parameter is shown in display 24 Use the Increment and Decrement buttons VA to adjust the displayed parameter and use the Function button to select the next parameter number Pressing the Program button writes the parameter to the non volatile memory and returns to standby mode If necessary to reset all the parameters to their factory set default values press hold the start stop button and then press the Program button and the Alarm button simultaneously The Program LED will flash and the controller will revert to standby mode Note the above procedure will erase any programmes that have been previously entered Dip Switch Selection Situated on the Tuscan Board is a series of Dip Switches For chilling purposes only switch 1 should be in the On position Software Parameters No Parameter Range VD 0 Differential Chill DIFFCHIL 1 Differential Freeze DIFFREEZE 2 Differential Hold DIFFHOLD 3 Thaw Band DIFFTHAW 4 Thaw Pulse THA
5. save parameter value C D CHE a Probe Temp flashes increment Temp value save parameter value 22 Temp flashes increment Temp value gt gt save parameter value Temp flashes increment Temp value save parameter value Select Hard Soft Chill toggle parameter value save parameter value og Set Print Sample Rate increment parameter value save parameter value and setting mode San Initiate Manual Defrost Standby Hold Mode Red LED illuminates during defrost Hours Minutes parameter values set to 00 00 Displays and Indications Probe Temp LED Hard Chill LED Air Temp LED Soft chill LED Time Display Temp Display Hold Function LED Compressor LED Program LED s 1 6 2 1 6 3 1 6 4 1 6 5 1 6 6 1 6 7 1 6 8 1 7 1 2 In this section the behaviour of the Controller is described in the form of a list of events with regard to the system refrigeration components Where outputs are stated to be in a high or low state a low state indicates the board relay output contacts to be open circuit and a high state indicates the relay to be closed and hence live Power Connected to Unit The Controller is a sleep mode seven bars are displayed on the fascia
6. O1 01 O1 P28 Hours 00 00 00 00 00 00 00 00 00 00 00 00 P29 Minutes 00 00 00 00 00 00 00 00 00 00 00 00 12 1 13 ELECTRICAL CONNECTIONS 1 13 1 Ratings Nominal Supply Voltage 230Va c 10 Supply Fequency 50 60 Hz 198 254 Temperature Range 0 to 70 Humidity 8096 1 18 2 Mains Services Mains Supply 1 Live L1 1 Neutral N1 1 Earth E Compressor Solenoid Valve 1 Switched Live C Evaporator Fans 2 Switched Live F Defrost 2 Switched Live D Alarm 1 Switched Live A Common Neutral 5 Neutral N 1 13 3 Sensors Food Probe 2 Screw Terminals PRB1 Air Probe 2 Screw Terminals PRB2 Resistor 5 1Kohm 2 Screw Terminals Door Switch 2 Screw Terminals DS Printer Connection Plug In Connection BK GA Printer Connections NI E L Bit Switches I III i OFF 1 2 3 4 WYGOBHBHB h n n uk II I II I II I I I debe s N N N N D D F FC PRB 1 PRB 2 PRB 3 DS Remote Keypad 1 14 RESISTANCE VALUES The following table relates to resistance values against temperature 60 656 ohms 10 3448 ohms 20 12100 ohms 30 1679 ohms 0 5107 ohms 30 19455 ohms 20 2381 ohms 10 C 7754 ohms 60 C 100181 ohms 13 2 OPERATING INSTRUCTIONS FOR THE Mk3 M
7. exit and save the new Control Parameter values the Start Stop button must be pressed The controller reverts to the on condition If any other buttons are pressed the changed values will not be held If no buttons are pressed for two minutes whilst the Service Parameter Setting Mode the controller will revert to the Sleep State without saving any of the changes 1 11 2 Control Parameters Fixed or Programmable F or P No ForP Description ttin Limit 1 P Cooling Temperature Differential C li t Point ling Temperature Differential High point of the coolin ration range 1101 2 Hold Temperature Differential Hol t Point Hold Temperature Differential hol int of Hol rating range itoi 3 P Compressor Rest Time MnS m Minimum Tim tween suc r ration to 1 4 P Defrost Termination Temperature NOT USED used with suitable Evaporator Temperature Pr 20 01 5 P Defrost Termination Time Mins Maximum defrost time duration t 6 P Number of Defrosts Per Day Determin uration between automati frost to 24 7 P Defrost Type 1 0 Hot Gas 1 or Electric 0 determines whether both the defrost and condensing unit outputs or 8 P Drain Down Time Mins 12 P Print Out Language Determines the Language Printed when Downloading t the Print i lish 1 Danish tch h 13 Hold Alarm Duration dins Maxi t A 14 P Display Offset 15 P Chill Freeze Select 1 0 _
8. Manual Defrost Button 90 Used to manually start Defrost when the unit is in Standby Hold mode 1 4 INDICATING DISPLAYS AND LED S Time Display 4 green 5 x 8 dot matrix LED segments show time left to run in Timed mode 0000 in Food Temperature mode and shows Time Elapsed in Hold mode time since end of cycle Temperature Display 3 green 5 x 8 dot matrix LED segments show Air Temperature during Timed and Hold modes via Air Probe Shows Product Temperature in Food Probe Mode via Food Probe By use of Increment Button the display will show the temperature of the Probe not controlling the cycle Food Probe Temperature LED llluminates green during Product Cooling cycle used in conjunction with Temperature Display Air Temperature LED green during Timed Cycle and Hold Cycle used in conjunction with Time Display and Temperature Display Hold Function LED Illuminated green to show when unit is in Hold Mode Chill Programme LED green in conjunction with Programme LED s programme A to J inclusive to show that the selected programme is set as a Hard Chill Program Chill Programme LED 5 green in conjunction with Programme LED s programme to J inclusive to show that the selected programme is set as a Soft Chill Program Programme Display 1 green 5 x 8 dot matrix LED segment shows the selected Programme A to J inc Also shows the F
9. Overtemperature LED flashing red in the event of the Counter Cabinet Alarm internal temperature exceeding the present Overtemperature Alarm Setting 14 Food Control Cooling LED illuminated green prior to and during the Cooling Phase of a Food Temperature Control programme Time Control Cooling amp z LED illuminated green prior to and during the Cooling Phase of a Cooling Time Control programme Hold amp LED illuminated green during the Hold Phase Programme 1 P1 LED illuminated green when Programme 1 is selected Programme 2 P2 LED illuminated green when Programme 2 is selected Programme 3 P3 LED illuminated green when Programme 3 is selected Run LED illuminated green during programme operation Programming LED illuminated green during programming procedure Hold Alarm LED illuminated green after Hold Alarm is muted Key Symbols Switches the controller between sleep and on states 70 Starts or stops a selected controller programme SET Used to enter programming sequence and acknowledge programme settings 94 Used to alter time or temperature values during programming sequence 5 Used in conjunction with the gt Key to initiate a manual defrost X Will mute the audible Hold Alarm permanently or the Food Temperature Alarm for a period of ten minutes 15 2 2 2 2 1 2 2 2 N 241 24 2 24 3 244 2 4 5 SURROUNDINGS A
10. VO Key Depressed The Controller switches on fascia panel indicates program time and internal air temperature Any one of ten stored programs may be selected Program settings may also be altered Start Stop Key Depressed The selected Controller is indicated Chill Phase If the selected program is a Food Temperature Control Program the following sequence of events will occur See list of Control parameters Page 9 and 10 The fascia panel dispays Chill Time set to zero amp Food Temp measured by Food Probe 1 The Evaporator fan output goes high and the refrigeration cycle begins The Chill Time displayed on the fascia panel will increment from zero If internal Air Temp is higher than the preset Air Temperature plus Chill Temperature Differential 1 the Condensing Unit output goes high When the internal air temperature pulls down to the preset Air Temperature the Condensing Unit output goes low This Chill Phase continues until the preset Food Temperature is reached The displayed Chill Time stops incrementing amp holds the displayed value Duration of Chill Phase Or if the selected program is a Chill Time Control program the following sequence of events occurs The fascia panel displays Chill Time and Air Temperature The evaporator fan output goes high and the refrigeration cycle begins The Chill Time displayed on the fascia panel will decrement from the programmed value If the internal air temperature is higher th
11. Food Probe 2 Screw Terminals PRB4 Food Probe 2 Screw Terminals PRB5 BK GA Printer Connections N1 E L OFF ON Bit Switches h n n u k NNN NN NN DD F P Remote Keypad PRB1 PRB2 PRB3 DS PRB4 5 1 14 RESISTANCE VALUES The following table relates to resistance values against temperature 60 C 656 ohms 10 C 3448 ohms 30 C 1679 ohms 0 5107 ohms 20 2381 ohms 10 7754 ohms 33 20 12100 ohms 30 19455 ohms 60 C 100181 ohms 3 2 MODULAR BLAST CHILLERS amp FREEZERS 2 0 USER OPERATION GUIDELINES From Feb 1997 to Feb 2000 The Modular Blast Chiller Freezer Temperature Controller maintains and displays a coldroom air temperature for a time period necessary to chill or freeze the stored product The Controller also carries out automatic defrosting and performs various alarm functions 2 1 FASCIA INDICATORS AND KEYS Food Temp Control Indicator Compressor Run Time Control Indicator Evaporator Fan Run Hold Indicator Time Display Temp Display Programme Display 9 Food Temperature Amber Outside Alarm Settings Over Temperature Flashing Red Overtemp Alarm 20000 94 Sleep On Key Set Key Defrost key Start Stop Key Time Temp Key Alarm Mute Key 2 1 1 Indicators Temp Display Normally indicates Food
12. KELI s 38088 38084 aa 48 ug ag ua ud 4 ATadNS 3000 30154538 8019535 E 0001 i x L X xX Alans d 1 1 9 JON Em woTI4 3017091 Mans Y 938 1 30091 AdAS _ k M EET 3 8 aj a HM 9j Oo wg m 71 26 2 tT 23 3 1 MODULAR BLAST CHILLERS amp FREEZERS 1 OPERATING INSTRUCTIONS FOR THE Mk4 MICROPROCESSOR As of Feb 2002 1 1 INTRODUCTION The cabinet and counter Blast Chiller Controller is a drop in replacement for the Blast Chiller Controller Itis a microprocessor based temperature controller which may be fully programmed to perform process operations for various Chilling Freez ing applications The Controller performs many functions including Automatic Defrost Initiation amp Full Alarm Warning The display Fascia panel and micro processor control board forms a single integral unit from here to referred to as the Controller 1 2 GENERAL SYSTEM OPERATION The Controller applies proportional control of the refrigeration system components in order to maintain an integral air temperature necessary to cause rapid Chilling and Freezing Upon completion of the Chill or Freeze Phase determined through product temperature measurement or a programmed time period the int
13. 2 15 18 36054 792 30 IWJ MALH INWA 8015538 4 AMO 30 LIB 95 5015538 035 SSTINN TVD TN 3408v SY 3000 900702 NEYO IONN 38 8 XOG 5 OL 2 2 g NOTI N3RO 4 9 W ANdLNO 1504130 01 O3103MNOO 36 Ol AVAL dud 10N YOLVYOdVA Ol C3123NNO9 39 OL NOTI P GIV3H GBSIIOdYA 1 SION 3000 310705 I 21 WIRING DIAGRAM 2 8 OHO dodo X104HON NNA1S 9Nbi QvOH 3 01 4989 01 480 uo1vua5iud3u 821504 02 080 01 989 CAMS SEINN TeV TW lt JO ON 1sv18 102 40 501539 ONIHIM e AMO 30 CH 0 ANdINO 1508130 01 Q3123NNCO 38 Ol GIVI AVAL Z uide INAINO MOIVMOXNA3 01 Q3123NN02 01 51 05 4969 00 OZ 280 ST300N OL lid Z z 5 6 2080 791 380 1 990 SWOON ALI NYAI USOA 313108 3000 3400 38 oL anw 981 90 coe 200 86
14. until the cause of the alarm is removed ie until the coldroom internal temperature falls below 80 or power is disconnected Hold Differential from the Controller Hold Temp Cooling Cooling Phase Hold Phase 2 2 TEMPERATURE CONTROLLER OPERATION When preset programme is initiated the controller will enter the Cooling Phase and cause the air temperature within the coldroom to fall dramatically in order to rapidly chill or freeze the stored product The duration of the Cooling Phase may be controlled in two ways through actual product temperature measurement using the Food Probe or by setting a fixed Cooling Time Upon completion of the Cooling Phase the Controller will enter the Hold Phase and the air temperature within the coldroom will rise in order to prevent further chilling or freezing and hold the product at the desired storage temperature 2 2 1 Defrosting The controller will perform automatic defrosting every six hours after a programme is initiated Defrosting of the evaporator coil will occur for a period of ten minutes or until the coil has reached a temperature of 30 after which moisture from the coil is allowed to drain away for a further two minutes During this perios dEF will be shown in the Temp Display Following this period the refrigeration cycle will recommence and rEC Recovery will be shown in the Temp Display for a period of five minutes or until the evaporator coil cools to 5 C at which point the evaporator
15. 15 15 15 15 Max Freeze Cooling P18 Set Point C 10 10 10 10 10 10 Min Freeze Cooling _ 3 19 Set Point 35 35 35 35 35 35 Soft Chill P20 Temperature 2 Soft pm Time 29 79 70 70 70 70 Soft Chill Food 22 Temperature 5 3 3 poa 9 yim Umit 45 45 15 45 45 t5 Graph Print Out P24 Low Point 10 10 10 10 10 10 P25 Year 00 00 00 00 00 00 26 01 01 01 01 01 01 27 Date 01 01 01 O1 Ot 01 P28 Hours 00 00 00 00 00 00 29 Minutes 00 00 00 00 00 00 P30 3 Probe Software 0 0 0 0 0 0 P31 Capcity Control 0 0 0 0 0 0 32 1 13 2 1 13 3 ELECTRICAL CONNECTIONS Ratings Nominal Supply Voltage Supply Range Humidity Mains Services Mains Supply Compressor Solenoid Valve Evaporator Fans Defrost Alarm Common Neutral Sensors Printer Connection 230Va c 10 Supply Fequency 50 60 Hz 198 254 Temperature Range 0 to 70 C 8096 1 Live L1 1 Neutral N1 1 Earth E 1 Switched Live C 2 Switched Live F 2 Switched Live D 1 Switched Live A 5 Neutral N Plug In Connection Food Probe 2 Screw Terminals PRB1 Air Probe 2 Screw Terminals PRB2 Resistor 5 1Kohm 2 Screw Terminals Door Switch 2 Screw Terminals DS
16. 16 F Maximum Chill Cooling Set Point C Maximum allowable Chill Temperature Set Point Active when Chiller Operation is selected rameter 15 1 17 F Minimum Chill Cooling Set Point C Minimum allowable Chill Temperature Set Point Active when Chiller Operation is selected rameter 15 1 18 F Maximum Freeze Cooling Set Point C Maximum allowable Freeze Temperature Set Point Active when Freeze Operation is selected 19 F Minimum Freeze Cooling Set Point C Minimum allowable Freeze Temperature Set Point Active when Freez ration i lect rameter 15 1 20 P Soft Chill Temperature Soft Chill Air Temperatur t 21 P Soft Chill Time 96 Under a Cooling Time Control Program the percentage of Cooling Time after which the Air Temperatur t Point ri to the value Soft Chill Temperature 7 to 1 22 P Soft Chill Food Temperature C Under a Food Temperature Control Program the measured Food Temperature at which the Air Temperatur t Point ri to the value Soft Chill Temperature 10 to 10 23 Soft Chill Limit 1 11 3 Service Parameters Additional Information Display Offset P14 Allows the display temperature and hence operating temperature
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18. 6 82 7891 GADNVHO 1515 90 39 85 A mwa 8 3000 TVD 1 SALON 3311041409 8 1518 ge 83 15 18 22 WIRING DIAGRAM 2 8 ON WHOS 3 39 0 0 30 NI 86 2 01 ava SLN 3190 se 0634 NNA1S SNbI Qvou H31S04 431 15 SSJINA 3187 Vv efo i 331108INO2 FP LSV s Amo aw an T m 1 81 0 1509330 Oi 36 01 YILVIH AVAL JON 20 00 2 Gvv 4 00 aw 109110 BOLYHOdVA3 Oi 31994402 38 OL 30NYu0 90 5 VINIH NOMAN BGIVIH 3NEINNSO H31Y3H 1 SION ama 19 INOA A8 NOLLdIHOS3G MOTHA N3349 HIVI a m 2 1100 90 IMA ONMIA amp 96 4 01 7991 03 38 sarge 3 8 3 ES 5 86 6 2 7891 HOISIS3H 0 3009 3100
19. Food Probe fault occurs during a Cooling Time Programme the Controller will continue to operate normally Indicates Air Probe Failure If an Air Probe fault occurs during either a Food Temperature or Cooling Time Control Programme the Condensing Unit output goes low Indicates Evaporator Coil Failure if Probe is fitted A probe is not fitted however in its place a 5 1 Kohm resistor is fitted If this fails it will not effect the cooling cycle as the defrost will terminate using the time setting 1 8 1 9 1 9 1 1 9 2 1 9 3 1 9 4 1 9 5 1 9 6 1 10 HARD OR SOFT CHILL Hard Soft Chilling is used to minimise surface damage to delicate products The Soft Chill function raises the Air Temperature during the latter part of the Cooling Phase The Air Temperature during the Cooling Phase while Soft Chill is selected rises to the value of the Soft Chill Set Parameter temperature Under a Cooling Time Control Programme the Soft Chill level becomes active after the percentage value of the Soft Chill Set Time relative to the pre set Cooling Time has lapsed Under a Food Temperature Control Programme the Soft Chill becomes active when the Soft Chill Food Temperature measured by the Food Probe is reached Soft Chilling can only be selected if the Programme Settings Food Temperature Cooling Air Temperature and Hold Air Temperature are set above the value of the Surface Protection Limit USER PROGRAMME SETTINGS The following is
20. GUARD SHELL DETAIL AND PL Ss 95 a LI 48 oo 58 A F15247085 mS FOOD PROBE F15247515 3 3 MODULAR BLAST CHILLERS amp FREEZERS MK 1 Control Panel Up To February 1997 3 0 BLAST CHILLER 3 1 3 2 3 2 1 INTRODUCTION The Blast Chiller is an essential component in the Chill chain process of food production Advanced food preparation is more common in todays catering operations allowing cooking staff to plan ahead and reduce the working days peaks and troughs Food cooked in advance and stored must be cooled quickly to minimise bacterial growth Rapid chilling enables the food core temperature to pass through the temperature danger zone 70 to 3 in the shortest time Within the 70 to 3 temperature range the bacteria population will double every 10 minutes The product can then be stored prior to use for up to 5 days in a storage refrigerator at a temperature below 3 C without loss or deteroration in colour texture and flavour The new Foster Modular Blast Chiller s are designed to meet this need with the large scale operator in mind Both oven and chilling trolleys can be acomodated in both roll in and roll through configuration This minimises double handling and decreases the food processing time The Blast Chiller has been designed with caterers in mind provi
21. N NO 05 NO 05 NO 05 NO 05 R404A R404A TCAE No2 TCAE No2 Electrical Supply 230 1 50 230 1 50 230 1 50 230 1 50 230 1 50 230 1 50 Nominal Amps 12 1 2 2 84 2 84 2 84 2 84 Maximum Amps 6 9 6 9 13 9 13 9 13 9 13 9 Max Amps During Defrost 3200 3200 3200 3200 3200 3200 Mains Supply 16 16 16 16 16 16 Chilling Capacity 75kg 75kg 75kg 75kg 150kg 150kg Freezing Capacity 15kg 15kg 15kg 15kg 30kg 30kg 1 OPERATING INSTRUCTIONS FOR THE Mk4 MICROPROCESSOR 1 1 INTRODUCTION The cabinet and counter Blast Chiller Controller is a drop in replacement for the Mk2 Mk3 and Mk Blast Chiller Controller It is a microprocessor based temperature controller which may be fully programmed to perform process operations for various Chilling Freezing applications The Controller performs many functions including Automatic Defrost Initiation amp Full Alarm Warning The display Fascia panel and microprocessor control board forms a single integral unit from here to referred to as the Controller 1 2 GENERAL SYSTEM OPERATION The Controller applies proportional control of the refrigeration system components in order to maintain an integral air temperature necessary to cause rapid Chilling and Freezing Upon completion of the Chill or Freeze phase determined through product temperature measurement or a programmed time period the internal air temperature will rise and be maintained to Hold the product in a chilled or frozen state 1 3 CONTROLLER F
22. Probe Temperature during a Food Temperature Control Programme or Air Temperature during a Time Control Programme Time Display Normally indicates Elapsed Cooling Time during a Food Temperature Control programme or Remaining Cooling Time during a Time Control Programme Programme Display Normally indicates current selected programme Food Temperature Indicator Illuminated amber if the temperature of the stored product falls outside preset alarm limits Extinguished when the stored product temperature falls back within alarm limits The Controller calculates the temperature of the stored product during the Hold Phase through monitoring internal air temperature Overtemperature Indicator Flashes red in the event of the internal temperature exceeding the preset Overtemperature Alarm Setting The Controller Alarm output will also go high Compressor Run Indicator Illuminated green while the compressor will cycle on and off to maintain the desired internal air temperature Compressor will stop if the door is left open for longer than one minute Evaporator Fan Run Indicator Illuminated green while the evaporator fans are running Evaporator fans will stop if the door is opened Food Temperature Control Indicator Illuminated green if a Food Temperature Control Programme is selected Time Control Indicator Illuminated green if a Time Control Programme is selected Hold Indicator Illuminated green during the Hold Phase Run Indicator Indi
23. Screw Terminals PRB1 Air Probe 2 Screw Terminals PRB2 Evaporator Probe 2 Screw Terminals PRB3 Safety Probe 2 Screw Terminals PRB4 Food Probe 2 2 Screw Terminals PRB5 Food Probe 3 2 Screw Terminals PRB6 Door Switch 2 Screw Terminals DOORSW Blast Chiller Controller Terminal Arrangement 2206200000200 PRB1 2 PRB3 PRB4 PRB5 PRB6 DOORSW Figure 3 Connections to rear of Controller DISPLAY FASCIA PANEL Display Fascia Panel see Fig 4 Page 19 Construction Fitting of the fascia panel to the Counter or Cabinet sheet metal unit cover is by means of a screw and boss fitting Ratings An O ring provides sealing between the cover and Fascia panel The front of th Fascia Panel has a protection classification of IP54 and the material used is a fire retardent and self extinguishing Symbols and Indicators The displays on the fascia panel consist of a smoked seven diget seven segment dispay together with the following indicators and symbols Illuminated Indicators These appear adjacent to the three diget seven segment display Condensing unit LED illuminated green when Condensing Unit outpus high Evaporator Fans LED illuminated green when Evaporator Fan output is high Food Temperature LED illuminated amber when Calculated Stored Product Temp is outside the preset High and Low Food Temperature Alarm Settings 11 and 12 respectively Overtemperature LED flashing red in the event of the Alarm Interna
24. again 2 2 3 ADDITIONAL FEATURES Surface Protection To minimise surface damage to delicate products the surface protection function raises the air temperature during the latter part of the Cooling Phase The air temperature during the Cooling Phase while Surface Protection is active rises to 2 Under a Cooling Time Control Program Surface Protection becomes active after 7096 of the pre set cooling time has elapsed Under a Food Temperature Control Program Surface Protection becomes active when 5 measured by the Food Probe is reached Surface Protection cannot be selected if the program setting Food temperature Cooling temperature or Holding Air temperature are below 15 Cooling Program Extension During the Hold Phase following a Cooling Time Program the Controller can be caused to re enter the Cooling Phase for a further ten minutes Program Extension can be initiated by holding down the SET key and pressing the TIME key Capacity Control The function of the Capacity Control output is to reduce the refrigeration capacity of the condensing unit during periods when the required internal air temperature is above a set value Capacity Control is achieved by unloading one cylinder of a multi cylinder compressor by means of a solenoid valve disabling a condenser fan on systems having multiple condenser and by means of a contactor The Capacity Control output will be made when the set internal air temperature during the Coolin
25. controller is switched on the test routine will be initiated On the display fascia panel each segment of the display and each LED indicator will illuminate in turn Any faulty display output can be identified during this test routine Pressing the fascia panel keys will perform the tests detailed below Note the display will illuminate randomly during these tests unless stated otherwise 1 If the key on the fascia panel is pressed r1 will be displayed in the right hand window of the display fascia panel and Defrost Output will go high If the key on the fascia panel is pressed r2 will be displayed in the right hand window of the display fascia panel and the Evaporator Fan Output will go high If the SET key on the fascia panel is pressed one of the following codes will be displayed in the right hand window of the display fascia panel 17 2 6 5 Self Tests Passed FL1 Food Probe Fail FL2 Air Probe Fail FL3 Evaporator Probe Fail FL4 Safety Probe Fail FL5 Software Fail If the 94 key on the fascia panel is pressed the Software Version and Issue e g will be displayed in the right hand window of the display fascia panel If the 99 key on the fascia panel is pressed will be displayed in the right hand window of the display fascia panel and the Condensing Unit Output will go high If the key on the fascia panel is pressed r4 will be displayed in the right hand window of the display fascia panel and the A
26. fans will also re start The Temp Display will now revert to showing air temperature Defrosting may be manually initiated while the controller is in standby before starting a programme or during the Hold Phase by holding down the key and pressing the Fo key See Operation Flowchart 2 2 1 ALARM FUNCTIONS The Food Temperature and Hold Alarms may be cancelled by operation of the fascia panel Alarm Mute Key The internal Overtemperature Alarm can only be cancelled by resetting the Controller or removing the cause of the alarm Hold Alarm The Controller alarm output will sound on entry to the Hold Phase to inidicate completion of the Chill Phase The Hold Alarm will sound for a period of two minutes Alternatively the Hold Alarm may be muted by operation of the Food Temperature The Controller calculates the temperature of the stored product during the Hold Phase through monitoring internal air temperature Should the calculated stored product fall outside the preset alarm limits the Food Temperature LED will illuminate amber and the alarm will sound Should the stored product fall back within the limits the Food Temperature LED will extinguish and the alarm will cease The Food Temperature Alarm may be temporarily cancelled by operation of the key This will mute the alarm for a period of ten minutes If after the ten minute period the calculated food temperature is still outside the preset alarm limits the alarm will sound
27. of events will occur The fascia panel displays Cooling Time and Air Temperature The refrigeration cycle begins and the Evaporator Fan output remains high throughout the cycle except if the door is opened The Cooling Time displayed on the fascia panel will decrement from the programmed value If internal air temperature is higher than the pre set Air Temperature the Condensing Unit output goes high When the internal air temperature pulls down to the pre set Air Temperature the Condensing Unit output goes low If the internal air temperature then rises above the pre set Air Temperature plus the Differential the Condensing Unit goes High The Cooling time continues until the displayed time increments to zero The end of cycle alarm sounds and the Unit enters the Hold phase Hold LED illuminated Hold Phase With the evaporator fan output still high the condensing unit output falls low until the internal air temperature rises to the pre set Hold Temperature plus the Hold Temperature Differential The Condensing Unit output goes high until the internal air temperature pulls down to the pre set Hold Temperature The Hold Phase continues until the programme is stopped by operation of the Start stop button End of Cycle Alarm The Controller alarm output will go high on entry to the Hold Phase to indicate completion of the Cooling Phase The Hold Alarm will stay high for the period Hold alarm Duration Alternatively the Hold Alarm may be mut
28. panel all outputs are in low state Sleep Standby Button Depressed The Controller switches on fascia panel indicates programme time and internal air temperature Any one of the stored programs may be selected by pressing the programme button Programme settings may be altered by following the User Setting Procedure Start Stop Button Depressed The selected Controller programme is initiated Cooling Phase If the selected programme is a Food Temperature Control programme the following sequence of events will occur The fascia panel displays Cooling Time set to zero and product Temperature measured by the Food Probe The refrigeration cycle begins and the Evaporator Fan output remains high throughout the cycle except if the door is opened The Cooling Time displayed in the fascia panel will increment from zero If internal air temperature is higher than the pre set Air Temperature the Condensing Unit output goes high When the internal air temperature pulls down to the pre set Air Temperature the Condensing Unit output goes low The Cooling Phase continues until the pre set Product Temperature is reached The end of cycle alarm sounds and the Unit enters the Hold phase Hold LED illuminated The displayed Cooling Time stops incrementing and holds the displayed value The Temperature Display changes to indicate Internal Air Temperature If the selected programme is a Cooling Time Control programme the following sequence
29. switching single phase mains supply to Hot gas solenoid or Electric heaters Contact rating 250Vac 10A External Alarm Relay output switching single phase mains supply to alarm activated when chill phase is completed when calculated food temperature is outside preset limits during hold phase and in the event of an internal overtemperature Contact rating 250Vac 10A Display Fascia Seven segment display seven digets Normally indicating cabinet air or product temperature and cooling time To display parameter values during controller programming Status indication during defrost Indicator LED s representing correct control phase selected programme and status of refrigeration component outputs ELECTRICAL CONNECTIONS For connections to rear of controllers See Figure 2 below Supply 1 Live L1 1 Neutral N1 1 Earth E Figure 2 Connections to rear of controller Condenser 1 Live C Food Probe 2 Screw Terminals PRB1 Air Probe 2 Screw Terminals PRB2 Evaporator Probe 2 Screw Terminals PRB3 Safety Probe 2 Screw Terminals PRB4 Door Switch 2 Screw Terminals DOORSW Evaporator Fans 2 Live F Defrost 2 Live D 4 i 0 a 1 PRB2 PRB3 DOORSW Alarm 1 Live AL FID D N Common Neutral 5 Neutral s 8 AIR TEMP PROBE INPUT COIL TEMP PROBE INPUT OVERTEMP PROBE INPUT 8 FOOD TEMP
30. the ten minute period the calculated Food Temperature is still outside the preset High and Low Food Temperature Alarm Settings the alarm output will return to a high state Internal Overtemperature Alarm Should the internal temperature rise above the parameter Overtemperature Alarm setting 14 possibly due to a defrost heater malfunction the Overtemperature Alarm LED will flash red and the alarm output will go high Also at this point all other outputs will fall low condensing unit evaporator fan motors and defrost The controller will remain in an Overtemperature Alarm state until the cause is removed i e until the internal temperature falls below the parameter Overtemperature Alarm Setting 14 or power is disconnected from the controller No longer applies to models fitted with the 56Kohm resistor Programme Settings Cooling Time Mins Duration of Cooling Phase for a Cooling Time Control Programme f set to zero the controller automatically assumes a Food Temperature Control Programme Food Temperature C Desired Food Temperature at completion of the Cooling Phase Required when a Food Temperature Control Programme is selected Measured by the Food Probe inserted into the product to be cooled Cooling Air Temp Counter or Cabinet internal air temperature during the Cooling Phase Hold Air Temp Counter or Cabinet internal air temperature during the Hold Phase Surface Protection On Off Selects
31. to be adjusted up or down to allow for systems tolerances This provides a higher level of temperature accurancy Graph Print Out Low Point The service graph print out has a range of 60 C This parameter sets a low point of the graph example of P24 is set to 10 C the graph will show the temperature time between 50 C to 10 C The graph function is intended to assist the Service Operation Settings and testing Date Time Settings P25 P26 P27 P28 P29 These values are used in the Real Time Clock RTC the times and dates are printed with temperature data from the print log under normal circumstances the controller will be pre programmed with the correct Time and Date GMT or BST No account is taken for international time zones therefore some adjustments may be necessary The controller is fitted with a PCB battery which will retain time date setting if the electrical supply is removed isolated once set 12 CONTROLLER MODEL SELECTION 1 12 1 The controller holds the Standard Operating Settings for 16 0 to 15 inclusive Blast Chiller and Blast Freezer models both integral and remote To select the appropriate models Bit Switches are used The Bit Switches are a series of 4 two position switches see below situated on the back of the controller PCB and which can be accessed with the rear cover removed Bit Switch 1 2 3 4 OFF All Buttons to the Bottom Value 0 1 12 2 Using binary Notation values between 0 and 15 can b
32. 00 low until the Fan Delay Temperature 22 P Surface Protection Food measured by the evaporator probe Temperature is reached No longer applies to Under a Food Temperature models fitted with the 5 1Kohm Control programme the measured resistor Fan Delay is by time only 0 20 to 20 Food Temperature at which the 11 P High Food Temperature Alarm C Air Temperature Set Point rises to Value to be added to High Point of the value Surface Protection Hold Operating Range Hold Set Temperature 20 5 10 to 30 Point plus hold Differential 5 1 to 20 23 P Surface Protection Limit C 12 Low Food Temperature Alarm If the programmed Food Value to be subtracted from Low Temperature under a Food Point of Hold Operating Range temperature Control Hold Set Point 5 1 to 20 progamme Air Temperature or Hold Temperature are above this 13 P Hold Alarm Duration mins value the Surface Protection Maximum duration of Hold Alarm 2 0 to 999 function cannot be selected 15 5 to 15 19 display or readout Displays P F 1 Food Probe Displays P F 2 Air Probe Displays P F 3 Evaporator Probe Displays P F 4 Safety Cutout Evap Fans not working Compressor not working Evaporator iced up 2 74 CONTROLLER FAULT FINDING Before any checks are made to controller operation and the rear cover of the controller is removed power MUST BE disconnected from the cabinet counter Compressor and or
33. 1 Blast Chiller Introduction 3 2 Controller Introduction 3 8 Controller The Display 34 Chiller Operation 3 5 Controller Operating Instructions 3 6 Chiller Programming 37 Chill Cycle Setting 3 8 Failure Situations 3 9 Test Outputs 3 10 Parameter Settings 3 11 Installation Instruction 3 12 Installation Instruction Diagrams 3 13 Probes Positions 24 25 25 25 25 25 26 27 28 28 29 29 29 29 31 31 32 33 33 34 34 34 35 35 36 37 38 38 39 39 40 40 41 41 42 42 43 44 45 45 45 45 46 47 48 49 50 50 50 51 52 52 54 55 Cabinet Blast Chiller Freezer Technical Data 91 0L ve 0S 007 sed 10H 1 2082 suub oovz sse 49g OL 02 69 09 1 POON Zorrervo suub 0091 01 02 404 8 01 l 908 Ot 09 1 seoiH POON zeevervo 46006 vvoru 01 dog 6y OL 02 vv 09 1 seoiH POON zevvzrvo suub 0091 __ 4989 64 OL l 908 09 1 oez seoiH OON 26672 suub 0061 20045 g 0L 4989 9L zv 056 seoiH 2992 suubooS vvord 02 l 226 6 056 seoiH 708 1 560002 vvoru OL el 40 6 09 1 POON zevvzrvo
34. 76 once more The unit will now begin cooling The Run LED will illuminate as will the Alarm LED 8 if selected The Compressor LED 19 and Fan LED 18 will illuminate If it is an Air Control Cycle the timer display 17 will decrement If itis a Probe Control Cycle then the timer display 17 will increment The Surface Protection facility LED 10 will also flash see par 3 5 3 below Atthe completion of the chill cycle the controller will switch to the hold mode The hold LED 23 will illuminate and the Alarm LED 8 will flash If selected the audible alarm will sound and may be cancelled by pressing the Alarm button A The alarm LED 7 will remain on constantly to indicate that the alarm has been acknowledged The unit may be left in this mode for as long as is required The unit will automatically defrost at a preset period Hold Mode can be terminated by pressing the Start Stop button The Controller will prepare to repeat the same cycle Note During the hold phase the hold temperature value controls the air temperature even if a probe control programme has been selected Door opening During the Chilling cycle opening the coldroom door will cause the internal fans to stop This does not stop the timer in display 17 if the door remains open for a period greater than 30 seconds the compresor is also stopped Surface Protection The surface protection LED 10 will be flashing to indicate that this is available The effect of this is to li
35. Air Temperature 10 EN Air Temperature 10 Period 90 mins RM Brobe Temperature 2 Hold Temperature 2 DN n Hold Temperature 2 3 3 CONTROLLER THE DISPLAY FOSTER THE DISPLAY DIAGRAM 1 2 o On Off Turns the control system functions on or off When Off standby node the FOSTER logo is illuminated and three bars are present in display 17 to indicate that power is still supplied to the chiller unit When On the selected rogram is displ 3 Run LED Green Indicates a program is running 76 6 Program Button Displays pre programmed values used to select programmes and f 7 A Alarm Button Selects alarm facility during cycle start and mutes audible alarm 8 Alarm LED Yellow Flashes when the alarm facility is offered during the cycle start Displays constantly following the mute of the audible alarm to indicate that the alarm 10 Surface Protection LED Yellow Flashes when surface protection is available Constant when surface protection has been selected c H 11 Decrement Button t rement variou rameters 2 13 Function Button Only operational on units having more than one mode 6 if the unit is a chiller only this button does not function 7777 7 7 7 0 M Def B 15 Product Internal LED s Gree
36. D LED S Time Display 4 green seven segment LED s show time left to run in Timed mode 0000 in Food Temperature mode and shows Time Elapsed in Hold mode time since end of cycle 8888 88 Temperature Display 3 green seven segment LED s show Air Temperature during Timed and Hold modes via Air Probe Shows Product Temperature in Food Probe Mode via Food Probe By use of Increment Button the display will show the temperature of the Probe not controlling the cycle Food Probe Temperature LED Illuminates green during Product Cooling cycle used in conjunction with Temperature Display e Air Temperature LED green during Timed Cycle Hold Cycle used in conjunction with Time Display and Temperature Display Hold Function LED Illuminated green to show when unit is in Hold Mode Hard Chill Programme LED Illuminates green in conjunction with Programme LED s programme B or to show that the selected programme is set as Hard Chill Program Soft Chill Programme LED llluminates green in conjunction with Programme LED s programme B or to show that the selected programme is set as a Soft Chill Program Programme A Illuminated green when Programme A is selected Programme B Illuminated green when Programme B is selected Programme C Illuminated green when Programme is selected Start Running L
37. ED Illuminated green when the unit is in Timed Product or Hold Modes In conjunction with the Start Stop Button End of Cycle LED Illuminated red when the End of Cycle Alarm has sounded and the Mute Button has been depressed It is extinguished when the unit is stopped by pressing the Start Stop Button Defrost Indication LED Illuminated red to Defrost in Operation automatic or manual Condensing Unit Run LED Illuminated green when Condensing Unit output is high Evaporator Fan Run LED Illuminated green when Evaporator Fan output is high 1 5 1 5 1 1 5 2 1 5 3 Mk4 BLAST CHILLER CONTROLLER OUTLINE OPERATING GUIDE Foster Part Number 00 554481 Controller Operation Basic Functions Sleep Standby Mode Program Chill Freeze Program Start Stop Green LED illuminates during Program and Hold Modes End of Cycle Alarm Mute Button x Red LED illuminates once audible End of Cycle alarm has been muted Print Data Press once to print data Press and Hold for 3 seconds to clear memory Controller Operation User Setting Procedure A Change Program Program changes from gt C and Appropriate Program LED s illuminate Change Program Parameters Press and Hold for 3 seconds Minutes display flashes increment minutes value save parameter value em Hours display flashes increment hours value
38. Evaporator fan s not working Check operation of door switch es Door switches are of reed switch type which should be closed circuit when door is closed with switch adjacent to the magnet and open circuit when door is open with switch away from the magnet Check switch operation by connecting a circuit tester across the switch outputs when switch is disconnected from the controller board Probe Fault PF1 PF2 or PF4 A probe fault occurs when the controller is unable to read the temperature probe First check the integrity of the probe connections to the controller board Check the resistance of the temperature probe with the probe disconnected from the controller board using an ohm meter The temperature probes used are of the thermistor type which change in resistance when subjected to a change in temperature As temperature is seen to rise the resistance of the probe should fall 8 8 PUT 000000 FID D FOOD TEMP PROBE INPUT 3 DOOR SWITCH INPUT COIL TEMP PROBE INPUT g OVERTEMP PROBE INPUT 8 AIR TEMP PROBE NOTE 1 HTR DRAINLINE HTR amp MULLION HTR TO BE CONNECTED TO EVAPORATOR FAN OUTPUT NOTE2 ris TA Y HEATER TO BE CONNECTED TO DEFROST LIVE INPUT EARTH INPUT COMPRESSOR OUTPUT EVAP FAN OUTPUTS DEFROST OUTPUTS NEUTRAL INPUT ALARM OUTPUT NEUTRAL OUTPUTS Check power supply for correct
39. ICROPROCESSOR UP TO MAY 2000 Food Temp Control Indicator Compressor Run Time Control Indicator Evaporator Fan Run Hold Indicator Time Display Temp Display Programme Indicators Food Temperature Amber Outside Alarm Settings Over Temperature Flashing Red Overtemp Alarm 950009 roster sr 9 Sleep On Key Defrost Key Start Stop Key Key Alarm Mute Key Figure 1 Controller Front Panel Product Code F15247077 2 1 24 4 2 1 2 a DISPLAY FASCIA PANEL Construction Fitting of the fascia panel to the Counter or Cabinet sheet metal unit cover is by means of a screw and boss fixing Ratings An 0 ring provides sealing between the Counter Cabinet unit cover and fascia panel The front of the fascia panel has protection classification of IP54 and the material used is fire retardant and self extinguishing Symbols and Indicators The displays on the fascia panel consist of a smoked seven digit seven segment display together with the following indicators and symbols Illuminated Indicators These appear to the three digit seven segment display Condensing Unit LED illuminated green when Condensing Unit outputs high Evaporator Fans cf LED illuminated green when Evaporator Fan output is high Food Temperature A LED illuminated amber when Calculated Stored Product Temp is outside the preset High and Low Food Temperature Alarm settings 11 and 12 respectively
40. Modular Blast Chillers Freezers Page SECTION 3 1 Modular Blast Chillers amp Freezers 1 Operating Instructions for the Mk4 Microprocessor May 2000 1 1 Introduction 1 2 General System Operation 1 3 Controller Front Panel 1 4 Indicating Displays and LED s Procedure for modifying modular blast chiller ELM ELM Controller 15 4 Blast Chiller Controller Outline Operating Guide 1 6 Operation 17 Error Annunciation 18 Hard or Soft Chilling 1 9 User Programme Settings 1 10 Programme Setting and Control Parameter Adjustment 1 11 Service Parameters 1 12 Controller Model Selection 1 13 Electrical Connections 1 14 Resistance Values SECTION 3 2 Modular Blast Chillers amp Freezers 2 Operating Instructions for the Mk2 amp 3 Microprocessor Feb 1997 to May 2000 21 User Operation Guidelines 2 2 Temperature Controller Operation 2 3 Operation Flow Chart 2 4 Programme Setting Flow Chart 2 5 Using the Blast Chiller Freezer 2 6 Standard Controller Programme Settings 27 Electrical Connections 2 8 Display Fascia Panel 2 9 Operation 2 10 Surrroundings and Eternal Influences 2 11 Program Settings and Control Parameter Adjustments 212 Program and Control Parameters Settings 213 Error Annunciation and Fault Finding 2 14 Controller Detail 2 15 Food Probe Detail SECTION 3 3 Modular Blast Chillers amp Freezers 3 Operating Instructions for the Mk1 Microprocessor Up to February 1997 3
41. ND EXTERNAL INFLUENCES INPUTS Food Temp Probe Senses counter cabinet product temperature Negative temperature resistance coefficient thermistor probe Air Temp Probe Senses counter cabinet internal air temperature Negative temperature resistance coefficient thermistor probe Evap Temp Probe Senses temperature at the evaporator coil required to terminate defrost No longer fitted on models produced after September 1998 replaced by 5 1Kohm resistor Defrost terminates on time only Safety probe Senses temperature adjacent to the evaporator coil in order to detect a internal overtemperature No longer fitted on models produced after July 1998 replaced by 56Kohm resistor Door Switch Voltage free contacts open circuit when door is open causing evaporator fan output to fall low and condensing unit output to fall low after a period of one minute Display Fascia Used to switch On Off the controller Initiate or terminate a chill or freeze programme Programme in operating parameters Manually initiate a defrost Cancel all alarm outputs OUTPUTS Condensing Unit Relay output switching single phase mains supply to condensing unit compressor and condensor fan Contact rating 250Vac 10A Evaporator Fan Relay output switching single phase mains supply to evaporator fan Also in parallel with the evaporator fan are connected the mullion and vaporiser tray heaters Contact rating 250Vac 10A Defrost Relay output
42. PROBE INPUT NOTE 1 VAP DRAINLINE HTR amp MULLION HTR TO BE CONNECTED TO EVAPORATOR FAN OUTPUT NOTE2 m js Y HEATER TO BE CONNECTED TO DEFROST UTPUT LIVE INPUT EARTH INPUT COMPRESSOR OUTPUT EVAP FAN OUTPUTS DEFROST OUTPUTS NEUTRAL INPUT ALARM OUTPUT NEUTRAL OUTPUTS 4 In this section the behaviour of the controller is described in the form of a list of events event response list with regard to the counter cabinet refrigeration components Where outputs are stated to be in a high or low state a low state indicates controller board relay output contacts to be open and a high state indicates the relay contacts to be closed Refrigeration and Defrost Power Connected to Counter or Cabinet The controller is in a sleep mode seven bars are displayed on the fascia panel all outputs are in a low state 1 Key Depressed The controller switches on fascia panel indicates programme time and internal air temperature Any one of three stored programmes may be selected Programme settings may also be altered 76 Key Depressed The selected controller programme is initiated Cooling Phase If the selected programme is a Food Temperature Control Programme the folllowing sequence of events will occur See list of Control Parameters section 6 3 The fascia panel displays Cooling Time set to zero and Food Temp measured by Food Probe The refrigeration cy
43. RONT PANEL The controller display is made up of the following components Sleep Standby Button Switches the Controller from the sleep mode where seven bars are illuminated in the Display Windows to standby mode where the unit runs x Start Stop Button gt Used to start and stop the Blast Chilling Freezing Cycle Alarm Mute Button Silences the End of Cycle alarm at the end of the Chilling Freezing Cycle x Print Button A dual function button If pressed and released the contents of the print log will be output to the printer If pressed and held for a period of three seconds the print log is cleared accompanied by an audible confirm chirp Programme Button N A dual function button If pressed and released the programme will change from A to B B to C and C to A If pressed and held for a ae period of three seconds the Controller enters the Setting Mode for a selected programme Increment Button A dual function button Primarily used when in the User and Service programming modes to change values Can also be used when gt gt the unit is running to show Food Air temperature Whilst the button is pressed a Time Cycle or Hold Mode the temperature display will show Food Probe temperature Whilst button is pressed in a Food Probe Cycle the temperature display show Air temperature e Manual Defrost Button Used to manually start Defrost when the unit is in Standby or Hold mode 1 4 INDICATING DISPLAYS AN
44. Surface Protection function which raises the Air Temperature during the latter part of the Chill Phase Surface Protection can only be selected if the Programme Settings Food Chill Air and Hold Air Temperature are above the value Surface Protection Limit 23 ERROR ANNUNCIATION Should a temperature probe failure occur the controller will indicate the fault by flashing on the fascia panel PF1 PF2 PF3 or PF4 PF1 If a food probe fault occurs during a Food Temperature Control programme the Condensing Unit Output will fall low If a food probe fault occurs during a Cooling Time Control programme the Controller will continue to operate normally PF2 If an air probe fault occurs during either a Food Temperature or Cooling Time Control Programme the condensing unit output will fall low PF3 If an evaporator probe fault occurs the parameter Defrost Termination Temperature 4 is ignored and defrosts are caused to terminate only after the period Defrost Termination Time 5 has elapsed No longer applies to models fitted with the 5 1Kohm resistor defrost is terminated by time only PF4 If a safety fault occurs all controller outputs will fall low The overtemperature alarm will not sound No longer applies to models fitted with the 56 Kohm resistor Additional Features Surface Protection To minimise surface damage to delicate products the Surface Protection function raises the Air Temperature during the latter part of the Cooling Ph
45. Time Temp key Pressing the SET key again causes the green Air Control Cooling LED to illuminate and the Air Temperature may be altered using the Time Temp key Cooling Time Control Programme Cooling Time set above zero Pressing the SET key will cause the green Air Control LED to illuminate and the Air Temperature may be altered using the Time Temp key Pressing again the SET key will cause the green Hold LED to illuminate and the Hold Temperature may be altered using the Time Temp key Pressing again the SET key will cause SP Surface Protection to be displayed in the left hand window of the fascia panel Surface Protection can be selected using the Time Temp key and On or Off is displayed in the right hand window of the fascia panel display Pressing again the SET key will save the programme settings and the fascia panel display will flash for five seconds indicating storage of programme settings The green Programming LED will extinguish and the controller will exit the programming sequence Control Parameters Are accessed while the controller is in the sleep state with seven bars displayed in the fascia panel While holding down the SET key pressing the key will cause the fascia panel to display the Control Parameter number in the left hand window and the Control Parameter value in the right hand window The value may be altered within its limits by operation if
46. WPULSE 5 Defrost Type ELEC 6 Defrost Time DEFTIME 7 Defrost Frequency DEFFREQ 8 Defrost Term Temp DEFTTEMP 9 Drain Time 2 DRAINTIME 10 Fan Delay Time 5 FANDELTIME 11 Fan Delay Temp FANDELTEMP 12 Recovery Time RECTIME 13 Compressor Rest Time COMPRESTTIME 14 Probe Failure PROBEFAIL 15 Manual Program Extension MANTIME 16 Surface Protection Timed SURPROTTIME 17 Surface Protection Chill SURPROTPROB 18 Surface Protection Thaw SURPROTTHAW 19 Uncontrolled Mode Chill UNCONCHILL 20 Uncontrolled Mode Freeze UCONFREEZE 21 Uncontrolled Mode Thaw UCONTHAW 22 Product Alarm Max Chill MAXCHILL 23 Product Alarm Min Chill MINCHILL 24 Product Alarm Max Freeze MAXFREEZE 25 Product Alarm Min Freeze MINFREEZE 26 Product Alarm Max Thaw MAXTHAW 27 Product Alarm Min Thaw MINTHAW 28 Overtemp Alarm Max OVETEMPMAX 29 Alarm Delay Period ALARMDELAY 30 Air Filter Time Constant FILCONST 0z0ff 1 2 Off if Chill Thaw if Freeze 51 3 11 INSTALLATION INSTRUCTIONS Coldroom Evaporator Module The coldroom is a standard Foster product The following Notes and Diagrams are guidelines for room erection NOTE Prior to securing the evaporator module must be supported when the fan door is opened as it will overbalance and fall forward 3 11 1 When installing door jamb thread the door switch lead through the evaporator module e Fit Control Panel The control panel is fitted through obround slots This is to allow future r
47. a list of the parameters that may be adjusted by the user in the programmes A B or C Cooling Time Control Programme Hrs Mins Duration of Cooling Phase for a Cooling Time Control Programme If set to zero the Controller automatically assumes a Food Temperature Control Programme Food temperature Control Programme C Desired Food Temperature at completion of the Cooling Phase Required when a Food Temperature Control Programme is selected Measured by the Food Probe inserted into the product to be cooled Cooling Air Temperature Counter or Cabinet internal air temperature during the Cooling Phase Hold Air Temperature C Counter or cabinet internal air temperature during the Hold Phase Cooling Type Hard or Soft Chill Selects cooling type function which in Soft Chill raises the Air Temperature during the latter part of the Chill Phase Soft Chill can only be selected if the Programme Settings Food Chill Air amp Hold Air Temperature are above the value of the Soft Chill Limit Printer Sample Rate Selects the inteval between Air or Food temperature samples being recorded during the Cooling Cycle and Hold Mode PROGRAMME SETTING AND CONTROL PARAMETER ADJUSTMENT The user can tailor the Programme Settings to suit the particular product to be cooled Settings can be saved in up to three programmes stored by the controller A B or C The Controller is pre set with three typical programmes Ch
48. all outputs in a low state Sleep Standby Button Depressed The Controller switches on fascia panel indicates programme time and internal air temperature Any one of the stored programs may be selected by pressing the programme button Programme settings may be altered by following the User Setting Procedure Start Stop Button Depressed The selected Controller programme is initiated Cooling Phase If the selected programme is a Food Temperature Control programme the following sequence of events will occur The fascia panel displays Cooling Time set to zero and product Temperature measured by the Food Probe The refrigeration cycle begins and the Evaporator Fan output remains high throughout the cycle except if the door is opened The Cooling Time displayed in the fascia panel will increment from zero If internal air temperature is higher than the pre set Air Temperature the Condensing Unit output goes high When the internal air temperature pulls down to the pre set Air Temperature the Condensing Unit output goes low The Cooling Phase continues until the pre set Product Temperature is reached The end of cycle alarm sounds and the Unit enters the Hold phase Hold LED illuminated The displayed Cooling Time stops incrementing and holds the displayed value The Temperature Display changes to indicate Internal Air Temperature If the selected programme is a Cooling Time Control programme the following sequence of even
49. an the preset Air Temp plus Chill Temperature Differential 1 the Condensing Unit output goes high When the internal air temperature pulls down to the preset Air Temperature the Condensing Unit output goes low This Chill Phase continues until the displayed time decrements to zero Hold Phase The Hold Alarm output goes high to indicate completion of the Chill Phase With the evaporator fan output still high the condensing unit output falls low until the internal air temperature rises to the preset Hold Temperature plus Hold Temperature Differential 2 The condensing unit output goes high until the internal air temperature pulls down to the preset Hold Temperature The Hold Phase continues until the program is stopped by operation of the start stop key SURROUNDINGS AND EXTERNAL INFLUENCES Inputs Food Temp Probe 1 Senses stored product temperature Used for control Negative temperature resistance coefficient thermistor probe Air Temp Probe Senses internal air temperature Negative temperature resistance coefficient thermistor probe Evap Temp Probe Senses temperature at the evaporator coil required to terminate defrost Negative temperature resistance coefficient thermistor probe Safety Probe Senses temperature at the evaporator coil in order to detect an internal overtemperature High temperature Negative temperature resistance coefficient thermistor probe Food Temp Probe 2 Senses stored product temperature Optional us
50. ase The Air Temperature during the Cooling Phase while Surface Protection is active rises to the value of Surface Protection Temperature 20 Under a Cooling Time Control Programme Surface Protection Time 21 of the preset Cooling Time has elapsed Under a Food Temperature Control Programme Surface Protection becomes active when the value Surface Protection Food Temperature 22 measured by the Food Probe is reached Surface Protection can only be selected if the Programme Settings Food Temperature Cooling Air Temperature and Hold Air Temperature are above the value Surface Protection Limit 23 Cooling Programme Extension During the Hold Phase following a Cooling Time Control Programme the controller can be caused to re enter the Cooling Phase for a further ten minutes Programme Extension can be initiated by holding down the SET key and pressing the key Self Test Function It is possible to cause the controller to enter a test routine during which the display outputs relay outputs inputs software and software version may be checked With power disconnected from the counter or cabinet a jumper must be connected across the 2 Test Pins positioned adjacent to the Door Switch screw terminal input of the controller printed circuit board All four temperature probes food air evaporator and safety and the door switch must be disconnected from the controller When power is re connected to the counter or cabinet and the
51. can tailor the Programme Settings to suit the particular product to be cooled Settings can be saved in up to ten programmes stored by the controller A to J inclusive The Controller is pre set with three typical programmes Programme D to J are unprogrammed Chill Programme P15 z 0 ProgrammeA Programme B Programme C Time 1 Hr 30 min 0 00 Hrs 1 Hr 30 min Food Temperature Probe NA 3 Air Temperature Probe 10 10 10 Hold Temperature 3 3 3 Chill Mode HARD HARD SOFT Print Sample Rate 3 3 3 Chill Freeze and Freeze Programme P15 z 1 Programme A Programme B Programme C Time 3Hr 0 00 Hrs 1 Hr 30 min Food Temperature Probe NA 21 Air Temperature Probe 30 30 10 Hold Temperature 21 21 3 Chill Mode HARD HARD SOFT Print Sample Rate 3 3 3 Control Parameters alter the characteristics of the chilling or freezing process They should not be adjusted without a good understanding of the operation of the Controller If no button is pressed for a period of two minutes the controller will revert to the standby mode without saving any of the modified settings SERVICE PARAMETERS Itis strongly advised that before adjusting any Service Parameter a thorough understanding of theBlast Chiller operating principles are obtained Service Parameters are accessed the following way Putthe control panel into the Sleep Mode Press the Programme butto
52. cator above 20 key illuminated green while a programme is initiated Programme Indicator Indicator above the SET key illuminated green during Controller programming Hold Alarm Indicator Indicator above the key illuminated green after Hold Alarm is muted 2 1 2 FASCIA KEYS Sleep On Key 6 Switches the Controller bewteen sleep and states Start Stop Key 76 Initiates or terminates a selected cooling programme Set Key SET Used to enter programming sequence and acknowledge programme settings Time Temp Key A Used to alter time and temperature values during the programming sequence During a Time Control Programme used to view temperature of Food Probe s During a Food Temperature control Programme used to view Air Temperature and temperature of additional Food Probes During a Defrost used to view Evaporator Temperature i Ad Defrost Key 9 Hold down this key and press the 76 key to manually initiate a defrost Alarm Mute Key gt Used to mute the audible Hold Alarm permanently or the Food Temperature Alarm for a period of ten minutes 34 Internal Overtemperature Alarm Should the internal temperature of the coldroom rise above 80 possibly due to a defrost heater malfunction the Product Overtemperature Alarm LED will flash red and the alarm will sound Also at this point all other outputs will fall low Air Temp condensing control The Controller will remain in this state
53. cle begins and the Evaporator output remains high throughout the cycle The Cooling Time displayed in the fascia panel will increment from zero If internal air temp is higher than the preset Air Temperature Differential 1 the Condensing Unit output goes high When the internal air temperature pulls down to the preset Air Temperature the Condensing Unit output goes low This Cooling Phase continues until the preset Foot Temperature is reached The displayed Cooling Time stops incrementing and holds the displayed value duration of Cooling Phase Or if the selected programme is a Cooling Time Control Programme the following sequence of events occurs The fascia panel displays Cooling Time and Air Temperature The refrigeration cycle begins and the Evaporator output remains high throughout the cycle The Cooling Time displayed on the fascia panel will increment from zero The Cooling Time displayed on the fascia panel will decrement from the programmed value If internal air temperature is higher than the preset Air Temperature plus Cooling Temperature Differential 1 the Condensing Unit output goes high When the internal air temperature pulls down to the preset Air Temperature the Condensing Unit output goes low This Cooling Phase continues until the displayed time decrements to zero 16 2 4 6 2 4 7 2 4 8 2 4 9 2 5 2 5 1 2 5 2 Hold Phase The Hold alarm output goes high to indicate completion of the Cooling Phase With the e
54. covery periods the evaporator coil temperature measured by the Evaporator Probe may be viewed by pressing the 94 key The refrigeration cycle will now recommence with internal air temperature displayed on the fascia Alarm Functions The Food temperature and Hold alarms be cancelled by operation of the fascia panel alarm mute button The internal overtemperature alarm can only be cancelled by removing power from the controller Hold Alarm The controller alarm output will go high on entry to the Hold Phase to indicate completion of the Cooling Phase The Hold Alarm Duration 13 Alternatively the Hold Alarm may be permanently muted by operation of the fascia panel fX key Food Temperature The controller will calculate the temperature of the stored product during the Hold Phase through monitoring internal air temperature Should the calculated stored product temperature fall outside the parameters High Food Temperature Alarm and Low Food Temperature Alarm 11 and 12 respectively the Food Temperature LED will illuminate amber and the alarm output will go high Should the stored product temperature fall back within the High and Low Food Temperature Alarm parameters the Food Temperature LED will extinguish and the alarm output will return to a low state The Food Temperature Alarm if in a high state may be temporarily cancelled by operation of the fascia panel P key This will cause the alarm output to fall low for aperiod of ten minutes If after
55. ding a flexible chilling unit with easy to use controls and improved accress for cleaning and maintenance CONTROLLER INTRODUCTION The purpose of the Blast Chiller is to reduce the temperature of cooked product within a pre determined time period The complex nature of food products means that the optimum chilling process will vary with differing food types The Blast Chiller control system has been designed to give the user an interface that is both easy to use and can chill the product to their specification quickly and efficiently To achieve this the control system has been configured to provide the facility for ten user definable chill programmes which remian resident in the control System at all times In programming the control system within each of the ten programmes the user can select one of two chilling methods namely control of the chilling operation by time or secondly by the food core temperature using the food probe Once the chilling method has been selected the user defines the temperature and time constraints to finish the program This information is saved against the relevant program number and simply called up and initiated by the operator as required A facility new to this control system is Surface Protection To minimise the effects of surface damage on delicate products Surface Protection limits the temperature of the latter part of the chill cycle to 2 The manual has been written to encompass all aspects of the co
56. ds indicating storage of program settings The green Programming LED will extinguish and the Controller will exit the programming mode 1 11 3 Control Parameters Are accessed while the Controller is in the sleep state with nine bars displayed on the fascia panel While holding down the SET key pressing the I O key will cause the fascia panel to display the Control Parameter number in the left hand window and the Control Parameter value in the centre window The control parameter may be altered within its limits by operation of the Time Temp key Pressing the SET key causes the display to advance to the next Control Parameter e To exit and save the new Control Parameter values the Start Stop key must be pressed The Controller reverts to the on state e To exit without saving the new Control Parameter values the 1 0 key must be pressed The Controller reverts to the sleep state 2 12 PROGRAM AND CONTROL PARAMETER SETTINGS 2 12 1 Program Settings e Chill Time Mins Duration of Chill Phase for a Chill Time Control Program If set to zero the Controller automatically assumes a Food Temperature Control Program e Food Temperature C Desired Food Temperature at completion of the Chill Phase Required when a Food Temperature Control Program is selected Measured by the Food Probe inserted into the product to be cooled e Chill Air Temp Cold Room internal Air Temperature during the Cooling Pha
57. e obtained 20 The Bit pattern settings to access these are as follows 6 7 8 9 10 11 12 13 14 15 1 12 3 By setting the bit switches to the appropriate positions various Operating Parameters are selected If setting 12 15 inclusive are selected the unit will not function as these are not currently pre programmed A full breakdown of the Pre set Values is shown on the next page Should any programme need to be changed the User Programme Setting Procedure on page 7 must be followed Should any parameters require changing the Service Parameter Setting Procedure on pages 10 amp 11 must be followed 11 1 12 4 Controller Model Selection Table or FBC BF BC F FBC FBC These settings Denomination BC BF FBC F R R ata not tised BIT Switch Settings 0 1 2 3 4 5 6 7 8 9 10 11 12 18 14 15 Cooling Temperature P1 Differential 3 3 3 3 3 3 3 3 3 3 3 3 Hold Temperature P2 Differential C 3 3 3 3 3 3 3 3 3 3 3 3 p3 Compressor Rest ss oe Time mins Defrost Termination 5 20 20 20 20 20 20 20 20 20 20 20 Temperature Defrost Termination P5 Time mins 6 6 6 6 6 6 12 12 12 12 12 12 P6 Number of Defrosts 6 6 6 6 6 6 6 6 6 6 6 6 per day Defro
58. e pp save parameter value 3 Probe Temp flashes adjust Food Temp value save parameter value 2 Air Temp flashes adjust Air Temp value save parameter value Y Temp flashes adjust Hold Temp value save parameter value sns Select Hard Soft Chill toggle Chill mode save parameter value an A X and exit setting mode B Set Print Sample Rate increment sample rate save parameter value 6 Initiate Manual Defrost Standby Hold Mode Red LED illuminates during defrost Only when Hours Minutes parameter values set to 00 00 1 5 3 Displays and Indications Probe Temp LED Air Temp LED Hold Function LED Program i Display 27 Compressor LED Evap Fan LED Hard Chill LED E gt Soft Chill LED 8888 Time Display Temp Display 1 6 2 1 6 3 1 6 4 1 6 5 1 6 6 1 6 7 1 6 8 1 7 OPERATION In this section the behaviour of the Controller is described in the form of a list of events with regard to the system refrigeration components Where outputs are stated to be in a high or low state a low state indicates the board relay output contacts to be open circuit and high state indicates the relay to be closed and hence live Power Connected to Unit The Controller is in a sleep mode seven bars are displayed on the fascia panel
59. ed by operation of the fascia Mute button However the Hold LED above the Mute button will illuminate Defrost Automatic or Manually Initiated The time period to the first defrost is calculated from the start of the Cooling Programme If the Defrost interval is every 4 hours but the Cooling Cycle is 6 hours the Defrost will be postponed until the Unit enters Hold Mode Defrosts will occur automatically in the Hold Mode The evaporator fan output falls low Depending on Defrost Type either a Hot Gas Type 1 or Electric Heater Type 0 Defrost will be initiated and the Time Display will continue to display Time Elapsed The temperature display will show the temperature measured by the Food Probe The RED LED will illuminate Alternatively a Defrost can be initiated in the Standby or Hold modes To initiate a Manual Defrost press the Defrost button once and defrost will commence Defrost will be the same as in automatic mode ERROR ANNUNCIATION Should temperature probe failure occur the controller will indicate the fault by flashing on the fasica panel PF1 PF2 or PF3 in the temperature display window It is important to note that on Probes 1 and 2 Probe Fault occurs if a resistance corresponding to above 60 or below 60 C See page 13 for resistance values against temperature Indicates Food Probe failure If a food probe fault occurs during a Food Temperature Control Programme the Condensing Unit output goes low If a
60. ed for indication only Negative temperature resistance coefficient thermistor probe Food Temp Probe 3 Senses stored product temperature Optional used for indication only Negative temperature resistance coefficient thermistor probe Door Switch Voltage free contacts open circuit when door is open causing evaporator fan output to fall low and condensing unit output to fall low after a period of one minute Display Fascia Used to switch On Off the Controller Initiate or terminate a Chill or Freeze program Program in operating parameters Manually initiate a defrost Cancel all alarm outputs Outputs Condensing Unit Relay output switching single phase mains supply to condensing unit compressor and condenser fan Contact 250 Va c 10 A Evaporator Fan Relay output switching single phase mains supply to evaporator fans Also in parallel with the evaporator fans are connected the mullion and vaporiser tray heaters Contact rating 250 Va c 10 A Capacity Control Relay output switching single phase mains supply to condenser fan contactor or condensing unit unloading solenoid Contact rating 250 Va c 10 A Defrost Relay output switching single phase mains supply to hot gas solenoid or electric heaters Contact rating 250 Va c 10 A External Alarm Relay output switching single phase mains supply to alarm activated when chill phase is completed when calculated food temperature is outside preset limits during Hold Phase and
61. emoval of the door if required e The control panel is designed to be approx 40mm higher than the roof of the coldroom with cables entering the rear of the panel e The evaporator modules are supplied with 2 liquid line and 1 outlet 3 11 2 Bumper Bars Standard 1 2m x 1 2m rooms will be pre drilled and rivnutted ready for the bumper bars On larger rooms bumper bars will be fitted site These will require M5 rivnuts rivnut tool required or Self tapping screws 3 11 3 Door Switch Wiring e The fan door operates a plunger style switch It is wired using contacts 1 and 3 e The coldroom door switch is a magnetic reed switch It is a double pole device with two switches wired in parallel as added security e The door switches must be wired in series 3 12 INSTALLATION INSTRUCTION DIAGRAMS 3 12 1 Stage 1 Assemble Plastic U Channel in required position and screw down if required Stage 2 Position Wall and Corner Panels in U Channel and lock together in the following sequence 1102 302 4103 504 52 3 12 2 sjeued 0 sjeueg x20 1004 pue 0 jeued 400 01 100q Ajquiassy ue4 pejquiesse parjddns 11 90 6 8 5 9 9jON Uonisod quer 1004 ebelis siu ye sjaued 1001 490 JOU uonisod sjaued pejquiesse J9M01 19
62. eratur t Point ri to the value Surf Protection Temperature 2 10 to P Surface Protection Limit If the programmed Food Temperature under a Food Temperature Control Program Air Temperature or Hold Temperature are above this value the Surface Protection function P Capacity Control Limit The output is high during the Chill or Hold Phase if th t point i ve this valu 15t ERROR ANNUNCIATION AND FAULT FINDING Error Annunciation Should a temperature probe failure occur the controller will indicate the fault by flashing PF followed by the probe number The Controller may be fitted with up to three food probes an air probe an evaporator coil probe and an overtemperature safety probe The first food probe is used for control and must be fitted The second and third food probes are used for indication only and need not be fitted Probe fault will not occur if Food Probe 2 or Food probe 3 if damaged or disconnected Probe failures are shown on the fascia panel as follows Food Temperature Probe 1 fault Air Temperature Probe fault Evaporator Temperature Probe fault Safety Temperature Probe fault PF1 Probe Fault If a probe fault occurs during a Food Temperature Control Program the Condensing unit Output will fall low If a food probe fault occurs during a Chill Time Control program the Controller will continue to operate normally PF2 If an air probe fault occurs during either a Food temperature or Chill Time Contro
63. erminal rail Connect controller terminal interconnecting loom terminals Red and White cores to terminals 37 amp 38 and Probe 1 on the controller 2 Connect the Air probe to terminals 39 amp 40 on the Control panel terminal rail Connect controller terminal rail interconnecting loom terminbals Yellow and Blue cores to terminals 39 amp 40 and probe 2 on the controller 3 Connect the Coil probe to terminals 41 amp 42 on the control panel terminal rail Connect controller terminal rail interconnecting loom terminals Black amp Grey cores to terminals 41 amp 42 and probe 3 on the controller 26 1 5 Mk4 MODULAR BLAST CHILLER CONTROLLER OUTLINE OPERATING GUIDE Foster Part Number 00 554482 1 5 1 Controller Operation Basic Functions Sleep Standby Mode Program Chill Freeze Program Start Stop Green LED illuminates during Program and Hold Modes End of Cycle Alarm Mute Button v Red LED illuminates once audible End of Cycle alarm has been muted Print Data Press once to print data Press and Hold for seconds to clear memory 1 5 2 Controller Operation Enhanced Functions Change Program c P Program changes from A B B C etc until J A Selected Program is Displayed Change Program Parameters Press and Hold for 3 seconds Minutes display flashes adjust minutes value p save parameter value ae A Hours display flashes adjust hours valu
64. ernal air temperature will rise and be maintained to Hold the product in a chilled or frozen state 1 3 CONTROLLER FRONT PANEL The controller display is made up of the following components Sleep Standby Button Switches the Controller from the sleep mode where seven bars are illuminated in the Display Windows to standby mode where the unit runs Start Stop Button 2 Used to start and stop the Blast Chilling Freezing Cycle Alarm Mute Button Silences the End of Cycle alarm at the end of the Chilling Freezing Cycle Print Button y A dual function button If pressed and released the contents of the print log will be output to the printer If pressed and held for a period of three seconds the print log is cleared accompanied by an audible confirm chirp Programme Button CA A dual function button If pressed and released the programme will change from A to B B to C through to J and back to A If pressed and held for a period of three seconds the Controller enters the Setting Mode for a selected programme Increment Button A dual function button Primarily used when in the User and Service programming modes to change values Can also be used when 42 the unit is running to show Food Air temperature Whilst the button is pressed a Time Cycle or Hold Mode the temperature display will show Food Probe temperature Whilst button is pressed in a Food Probe Cycle the temperature display show Air Temperature
65. ese are not currently pre programmed A full breakdown of the Pre set Values is shown on the next page Should any programme need to be changed the User Programme Setting Procedure on page 27 must be followed Should any parameters require changing the Service Parameter Setting Procedure on pages 29 amp 30 must be followed 31 1 12 4 Controller Model Selection Table Ope BC BF BC F FBC FBF FBC 3 Denomination Settings 6 to 15 are not used R R R R R F R Switch Settings 0 1 2 3 4 5 Cooling Temperature E Differential 3 3 3 3 Hold Temperature Differential 1 3 3 3 Compressor Rest 9 0 0 9 0 P4 Defrost Termination 20 20 20 20 20 20 Temperature p5 Defrost Termination 43 49 49 42 12 42 Time mins P6 Number of Defrosts 6 6 6 6 6 6 per day Defrost Type ET 0 1 hot gas 9 0 0 2 P8 Drain Down Time 5 5 5 5 5 5 mins P9 Fan Delay Time 1 1 1 1 1 1 mins Fan Delay FID Temperature C 0 0 0 0 Cabinet P11 ID Number 1 1 1 1 1 1 P12 Prnt Qut Language P13 Hold Alarm 2 2 2 2 2 2 Duration mins P14 Display Offset 0 0 0 0 0 0 P15 Chill 0 Freeze 1 0 1 1 0 1 1 Select Max Chill Cooling P16 Set Point 10 10 10 10 10 10 Min Chill Cooling _ _ 17 Set Point 15 15
66. eze e Foods having low thermal conductivity or high heat capcity will in general take longer to chill freeze e Lids or covers on food containers will cause chilling freezing times to increase by at least 1096 e reducing the depth of the food will reduce the chilling freezing time e Increased spacing betwen each container will reduce the chilling freezing time 2 6 STANDARD CONTROLLER PROGRAMME SETTINGS 2 6 1 Blast Chiller Cooling Food Probe Cooling Air Hold Air Surface Time Temp Temp Temp Protection Programme 1 1 hr 30 mins N A 10 3 2 0 hr 0 mins 3 10 3 3 1 hr 30 mins N A 10 3 ON Programme 4 UNPROGRAMMED Programme 10 2 6 2 Blast Freezer Cooling Food Probe Cooling Air Hold Air Surface Time Temp Temp Temp Protection Programme 1 1 hr 30 mins N A 35 21 2 3 hr 0 mins N A 35 21 OFF Programme 3 4 hr 30 mins N A 35 21 OFF Programme 4 UNPROGRAMMED Programme 10 38 2 7 2 71 2 8 2 8 1 2 8 2 2 8 3 2 8 4 a ELECTRICAL CONNECTIONS Electrical Connections For connections to rear of Controllers see Fig 3 below and page 29 Supply 1 Live L1 1 Neutral N1 1 Earth E Condenser 1 Live C Evaporator Fans 2 Live F Capcity Control 1 Live CAP Defrost 2 Live D Alarm 1 Live AL Common Neutral 7 Neutral N Food Probe 1 2
67. g or Hold Phase is above the value of the Capacity Control Limit on parameter No P24 35 2 3 OPERATION FLOWCHART Controller switched on Time Display shows Cooling Time Temp Display shows Air Temp Programme Display shows Selected Programmme Correct Programme Yes Select programme by holding SET key and Programme number 1 10 pressing 1 key indicated To initiate programme press 76 key Controller enters the Cooling phase of selected programme Automatic defrosting may occur Yes Door Open No Evaporator Fan stops and Compressor stops after 1 minute Surface Protection Selected Air temperature rises during latter part of Cooling Phase When preset Cooling Time has elapsed or Food Temp is reached Controller enters Hold phase Hold alarm sounds Mute Hold Alarm No Press E key Hold Alarm Indicator illuminates Programme Extension Required No 9 Hold SET and press 7 key Only available after Controller will re enter Colling Time control Programme Phase for a further 10 minutes Manual Defrost Required No Hold key and press the 76 key To terminate programme press 7 key 36 2 4 PROGRAMME SETTING FLOWCHART Controller switched on Time Display shows Cooling Time Temp Display shows Air Temp Correct Programme Yes Select programme by holding SET key and pressing 21 key Programming I
68. he unit from running However depending of the nature of the fault the operation of the unit may not be correct and the chill cycle may need to be restarted Failure Disconnection or severing of a Probe will show as a PF symbol in display 24 Overtemperature Fans if the fans overheat the individual fan thermal overload will cut out the motor to prevent accidential damage Heaters should the internal temperature exceed a preset value due to heater control failure the overtemperature probe will cause a shut down of the blast chiller Should this fail to operate a safety stat will terminate all electical supply TEST OUTPUTS Test Outputs This mode allows the installer or service engineer to activate any of the relays for commisioning or testing Ensure that the display is off Three bars will be displayed in 17 Press and hold the increment Decrement and Function buttons together VA E and then press the On Off button Display will show Display 25 shows the currently selected relay output and display 24 shows the state fo that relay On or Off Select the required relay by pressing the Function button Switch the relay on or off by pressing the Increment or Decrement buttons respectively V There are seven relays five on the Tuscan and two on the auxilliary relay board These are allocated as follows No Description Neon 1 Compressor 1 1 High Speed Fan Low Speed Fan Defrost Alarm Compressor 2 Heat NOOR WP
69. he unit is in the hold mode the unit will defrost automatically 48 3 6 CHILLER PROGRAMMING SWITCHON 79 CORRECT NO PROGRAM FOR CHANGE 2 PRESS FID HOLD USE OR PRESS AND HOLD TO CHANGE PROGRAM NO T amp 4 AND SIMBETANEOUSLY PRESS FOR 5 SECONDS a E ILLUMINATES 7 TMERDIPLAY __ FASHES __ REQUIRE ZERO USING OR AIR OR PROBE NTROL s SET CHILL TIME SELECT PROBE TEMP USING OR USING OR press PRESS P AIR LED AIR LED ILLUMINATES ILLUMINATES SELECT AIR TEMP SELECT AIR TEMP USING OR USING OR PRESS press HOLD LED AUN KG HOLD LED ILLUMINATES ILLUMINATES SELECT HOLD TEMP SELECT HOLD TEMP USING OR USING OR press IP PROBE LED ILLUMINATES PRESS P T 7 q 372 DISPLAY SCROLLS DISPLAY SCROLLS THROUGH SELECTED THROUGH SELECTED TEMPERATURES TEMPERATURES ae Eum Lope HOLD START AND PRESS TO SAVE PROGRAM DISPLAY WILL FLASH FOR FIVE SECONDS WHILST SAVING PROGRAM PROGRAM LED FLASHES CHANGE CURRENT OR FURTHER PROGRAM YES PRESS PROGRAM BUTTON PROGRAM NO HOLD DOWN FLASHES SELECT PROGRAM NO press RETURN TO OPERATION MODE 49 3 7 3 7 1 3 7 2 3 7 3 b 3 74 3 7 6 377 3 8 CHILL CYCLE SETTING This section covers programming the blast chiller Setting is accessed by simultaneously pressing three buttons to prevent tampering or accidentia
70. hm Resistor fitted 20 0 to 50 Point Active when Blast Chiller AS Operation is selected 5 P Defrost Termination Time Mins parameter 15 0 15 Maximum defrost time duration 8 0 to 60 18 F Maximum Freeze Cooling Set Point 6 P Number of Defrosts per Day Maximum allowable Freeze Determines duration between Temperature Set Point Active automatic defrosts 6 0 to 24 when Freezer Operation is selected 7 P Defrost Type 1 0 parameter 15 1 10 Hot Gas 1 or Electric 0 19 F Minimum Freeze Cooling Set Point C determines whether both the Minimum allowable Freeze defrost and condensing unit Temperature Set Point Active outputs it the defrost output alone when Freezer Operation is selected goes high when a defrost is initiated 1 0101 parameter 15 1 35 8 Drain Down Time mins 20 Surface Protection Temperature C Time period after defrost for which Air Temperature Set Point during the Defrost and Condensing unit Cooling Phase when Surface outputs remain low 5 0 to 24 Protection is active 2 5 to 25 9 P Fan Delay Time Mins 21 P Surface Protection Time After drain down period time for Under a Cooling Time Control which Evaporator Fan output Programme the percentage of remains low 1 0 to 20 Cooling Time after which the Air 10 Fan delay Temperature Temperature Set Point rises to After drain down period the value Surface Protection Evaporator Fan output remains Temperature 20 70 0 to 1
71. ill Programme P15 z 0 ProgrammeA Programme B Programme C Time 1 Hr 30 min 0 00 Hrs 1 Hr 30 min Food Temperature Probe NA 3 Air Temperature Probe 10 C 10 C 10 C Hold Temperature 3 C 3 C 3 C Chill Mode HARD HARD SOFT Print Sample Rate 3 3 3 Chill Freeze and Freeze Programme P15 1 ProgrammeA Programme B Programme C Time 3 Hr 0 00 Hrs 1 Hr 30 min Food Temperature Probe NA 21 Air Temperature Probe 30 30 10 Hold Temperature 21 21 3 Chill Mode HARD HARD SOFT Print Sample Rate 3 3 3 Control Parameters alter the characteristics of the chilling or freezing process They should not be adjusted without a good understanding of the operation of the Controller If no button is pressed for a period of two minutes the controller will revert to the standby mode without saving any of the modified settings 1 11 SERVICE PARAMETERS 1 11 1 Itis strongly advised that before adjusting any Service Parameter a thorough understanding of the Blast Chiller operating principles are obtained Service Parameters are accessed in the following way Put the control panel into the Sleep Mode Press the Programme button and hold while pressing the Increment button The Controller is now in the Service Parameter settings release both buttons To save a value press the Programme button change a value press the Increment button till you get the desired value
72. in the event of an internal overtemperature Contact rating 250 Va c 10 A Display Fascia Seven segment display nine digits Normally indicating cabinet air or product temperature amp cooling time To display parameter values during controller programming Status indicatin during defrost Indicator LEDs representing current control phase selected program and status of rerigeration component outputs 40 2 11 PROGRAM SETTING AND CONTROL PARAMETER ADJUSTMENT 2 11 1 The user can tailor the Program Settings to suit the particular product to be chilled Settings can be saved in up to ten programs stored by the controller P01 PO2 P10 Control parameters alter the characteristics of the chilling or freezing process The Control Parameters should not be adjusted without detailed knowledge of the operation of the Controller During the programming of either Program Settings or Control Parameters if no key is pressed for a period of two minutes the Controller will exit the particular programming mode without saving any modified settings or parameters 2 11 2 Program Setting While the Controller is switched on with Chill Time and Food Temperature or Air Temperature displayed on the fascia panel the required stored program can be selected While holding down the SET key pressing the Time Temp key will change the selected program indicated in the right hand fascia window by the green LEDs P01 P02 or P10 e To enter the progra
73. int plus Hold Differential 1102 12 P Low Food Temperature Alarm Value t ubtracted from Low Point of Hol rating ran Hol t Point 1102 41 14 15 16 17 18 19 20 21 22 23 24 2 13 2 13 1 1 2 213 2 2 13 3 2 13 4 2 13 5 2 13 6 2 13 7 Description ttin Limit P Hold Alarm Duration Mins Maximum duration of Hold Alarm 2 01 Internal overtemperature Alarm Setting gt to 12 P Chill Freeze Select UO F Maximum Chill Set Point C Maximum allowable Chill Temperature Set Point Active when Chiller Operation is selected F Minimum Chill Set Point Minimum allowable Chill Temperature Set Point Active when Blast Chiller Operation is selected F Maximum Freeze Cooling Set Point Maximum allowable Freeze Temperature Set Point Active when Freeze Operation is selected F Minimum Freeze Cooling Set Point C Minimum allowable Freeze Temperature Set Point Active when Freeze Operation is selected P Surface Protection Temperature C Air Temperatur t Point during Chill Ph when Surf Protection Temperature 2 25 1 Surface Protection Time Under a Chill Time Control program the percentage of Chill Time after which the Air Temperature t Point ri to the value Surface Protection Temperature 2 7 to 1 Surface Protection Food Temperature Under a Food Temperature Control program the measured Food Temperature at which the Air temp
74. ion A manual defrost can be started by holding down the Defrost key and then pressing the Stop Start button at the same time Check output on rear of controller marked D Check that Hot Gas Solenoid valve is operating Check termination time and temperature settings on controller parameters Resistance Values For Probes 1 2 and 3 Food Air and Evaporator Probe fault occurs if a resistance correcponding to above 60 approximate values is detected See following temperature resistance values 60 656 ohms 10 34480hms 20 C 121000hms 30 1679 ohms 0 5107 ohms 30 19455 ohms 20 2381 ohms 10 7754 ohms 60 100181 ohms 20 WIRING DIAGRAM 2 8 8 9 01 498 Ol 49 0298 Ol 29 101 9 H3Z33Hd H3TIIHO 15 18 90 00 0 5 00 ON 0634 1 4 H31S04 1578 ec cpm cl 009705 oa 1508430 NOILdIHOS3G A3H 86 2 01 7991 Q3AOW3H 38OHd 1102 SO 86 6 72 7851 93 HOLSISSY 90 18 3108 335 HOLS WS 30059 38088 53000 3 0003 M3TIOMINOO 8
75. l program the condensing unit output will fall low PF3 If an evaporator probe fault occurs the parameter defrost Termination Temperature 4 is ignored amp defrosts are caused to terminate only after the period Defrost Termination Time 5 has elapsed If a safety probe fault occurs all Blast Chiller Controller ouputs will fall low the overtemp alarm will not sound Fault Finding Before any checks are made to controller operation and the rear cover of the controller is removed power MUST BE disconnected from the Cold Room Compressor and or Evaporator Fan s not working Check operation of door switch es Door switches are of reed switch type which should be closed circuit when door is closed with switch adjacent to the magnet and open circuit when door is open with switch away from the magnet Check switch operation by connecting a circuit tester across the switch outputs when switch is disconnected from the Controller board Probe Fault PF1 PF2 or PF4 A probe fault occurs when the controller is unable to read the temperature probe Firstly check the integrity of the probe connections to the controller board Check the resistance of the temperature probe with the probe disconnected from the controller board using an ohm meter The temperature probes used are of the thermistor type which change in resistance when subjected to a change in temperature As temperature is seen to rise the resistance of the probe sho
76. l programming changes This sequence is as follows Select the program for change ref 3 5 1 Hold down the decrement increment buttons and simultaneously press the program button until the Program LED illuminates The controller is now in programming mode The Timer display will flash NOTE no changes are made during a programming operation for 2 minutes the controller will reset itself automatically for normal _ Set the Timer For Air Temperature Control use the increment decrement buttons VA to select the desired chill time For Probe Temperature Control set the Timer display to zero using the increment decrement buttons For Air Temperature Control Press the Program button The Air Control LED 22 will illuminate and the air temperature will flash Using the increment decrement buttons V select the Air temperature required for chilling Press the Program button the Hold LED 23 will illuminate and the hold temperature will flash Using the increment decrement buttons V select the Hold temperature Press the Program button La the Temperature Display will alternatively flash between the Air Temperature and the Hold Temperature showing the selected values Go to 3 7 6 For Probe Temperature Control Press the IRE button P The Probe Control LED 21 will illuminate and the Probe Temperature will flash Using the increment decrement buttons select the desired probe te
77. l temperature exceeding the preset Overtemperature Alarm Setting 14 Food Control Chill LED Illuminated green prior to and during the Cooling Phase of a Food Temperature Control Program Time Control Chill LED illuminated green prior to and during the Cooling Phase of a Cooling Time Control Program Hold LED illuminated green during the Hold Phase Programme number display displays current programme number Run LED illuminated green during program operation Programming LED illuminated during programing procedure Hold Alarm LED illuminated green after Hold Alarm is muted Key Symbols Switches the Controller between Sleep and on states 76 Starts or stops a selected Controller Program SET Used to enter programming sequence and acknowledge program settings Used to alter time or temperature values during programming sequence Used in conjunction with the 76 key to indicate a manual defrost Will mute the audible Hold Alarm permanently or the Food Temperature Alarm for a period of ten minutes 39 2 9 2 9 1 2 9 2 2 9 3 2 9 4 2 9 5 2 10 2 10 1 2 10 2 OPERATION In this section the behaviour of the Controller is described in the form of a list of events Event response list with regard to the cold room refrigeration components Refrigeration and Defrost Power Connected to Cold Room The Controller is in a sleep mode three bars are displayed on the fascia panel all outputs are in a low state
78. larm Output will go high exit the test routine power must be disconnected from the Counter or Cabinet and the jumper removed from the Test Pins on the controller printed circuit board If the 94 key on the fascia panel is pressed the Software Version and Issue e g will be displayed in the right hand window of the display fascia panel If the 5 key on the fascia panel is pressed will be displayed in the right hand window of the display fascia panel and the Condensing Unit Output will go high If the X key on the fascia panel is pressed r4 will be displayed in the right hand window of the display fascia panel and the Alarm Output will go high To exit the test routine power must be disconnected from the Counter or Cabinet and the jumper removed from the Test Pins on the controller printed circuit board PROGRAMME SETTING AND CONTROL PARAMETER ADJUSTMENT Table 2 Programme Settings The user can tailor the Programme Settings to suit the particular product to be cooled Settings can be saved in up to three programmes stored by the controller P1 P2 and P3 The controller is preset with three typical Chill programmes Chill Programme P15 2 0 Programme 1 Programme 2 Programme 3 Time 1Hr 30min 0 00 Hrs 1Hr 30min Probe Temp NA 3 10 10 10 Hold Temp 3 C 3 C 3 C SP OFF OFF ON Chill Freeze Programme P15 1 Programme 1 Programme 2 Programme 3 Time 3Hr 0 00 Hrs 1Hr 30
79. ler Freezer room e Alkaline based cleaning agents bleach solvents and cleaners containing abrasives will damage the surfaces of the room and must be avoided e A solution of warm water and mild detergent is recommended followed by rinsing and drying 2 5 2 Good Practice Guidelines e Hot products exceeding 70 should not be placed in the Blast Chiller Freezer A good indication is when steam has stopped rising e Pre chilling the unit will reduce the chilling freezing time e Allow meat poultry cuts to rest after cooking and before chilling freezing e Do not fill containers to a depth of over 50mm 2 e Do not overload the mobile trolley leave a 50mm 2 gap between each container e Always ensure the food probe is cleaned with a sanitised wipe before use e Preferably decant sauces and soups out of cooking pots and into shallow Gastronorm containers before chilling e Do not place lids or covers over food products during chilling freezing 2 5 8 Factors Affecting Speed of Chilling Freezing e Reducing the temperature within the Blast Chiller Freezer will speed up the chilling freezing process However when Blast Chilling care should be taken not to freeze the stored product e Container shape and weight will affect chilling freezing time In general increasing the surface area and reducing the weight of the container will reduce the chilling freezing time e Foods of low density and evenly distributed will in general take less time to chill fre
80. lue Soft Chill Temperature 10 to 23 P Soft Chill Limit C If the programmed Food Temperature under a Food Temperature Control Frogr mme is above the Air Temperature or Hold Temperature th ft Chill function cannot 15 5 10 1 24 Graph Print Low Point 10 30 to 30 25 P Year 00 00 to 99 26 P Months 01 01 to 12 27 P Date 01 01 to 31 28 P Time Hours 00 00 to 23 29 P Time Minutes 00 00 to 59 30 P Three Probe Software 0 Not Active 1 Active Three Probe software Se selects whether the optional probe numbers 2 and 3 are active and allows temperature t to 1 LLimit 0 15 to 5 30 1 11 3 1 12 2 Service Parameters Additional Information Display Offset P14 Allows the display temperature and hence operating temperature to be adjusted up or down to allow for Systems tolerances This provides a higher level of temperature accurancy Graph Print Out Low Point The service graph print out has a range of 60 C This parameter sets a low point of the graph example of P24 is set to 10 C the graph will show the temperature time between 50 C to 10 C The graph function is intended to assist the Service Operation Settings and testing Date Time Settings P25 P26 P27 P28 P29 These values are used in the Real Time Clock the times and dates are printed with temperature data from the print log Under normal circumstances the controller will be pre programmed with the correc
81. min Probe Temp NA 21 C NA Air Temp 30 C 30 C 10 C Hold Temp 21 C 21 C 3 C SP OFF OFF ON Control Parameters alter the characteristics of the chilling and freezing control process The Control parameters should not be adjusted without detailed knowledge of the operation of the controller During the programming of either Programme Settings or Control Parameters if no key is pressed for a period of two minutes the controller will exit the particular programming mode without saving any modified settings or parameters Programme Setting While the controller is switched on with Cooling Time and Food Temperature or Air Temperature displayed on the fascia panel the required stored programme can be selected While holding down the SET key pressing the Time Temp key will change the selected programme indicated by the green LEDs P1 P2 or P3 To enter the programming sequence the SET key must be depressed for five seconds until the green programming LED is illuminated The Cooling Time minutes display will flash and the minutes value may be altered using the Time Temp key Pressing the SET key again will cause the Cooling Time hours display to flash which may be altered using Time Temp key Food Temperature Control Programme Cooling Time set to zero Pressing the SET key will cause the green Food Control Cooling LED to illuminate and the Food temperature may be altered using the
82. mit the air temperature to 2 for the final one third of an air control program or when the probe temperature reaches 5 for a probe control program If the program time has passed the two thirds mark or if the probe temperature is below 5 then this option will cease to be available Display of Programmed Current Values At any time the pre defined temperature values can be seen by pressing the program button When the unit is running the temperature in the display is indicated by the illumination of LED s 21 22 amp 23 When in air temperature control the decrement button displays the current probe temperature Probe LED 21 is lit When in probe temperature control the decrement button displays the current temperature air control LED 22 is lit Both in air and probe temperature control the coil temperature can be viewed by pressing the increment button LED s 21 22 amp 23 are extinguished Manual Program Extension At the end of the chill cycle further chilling is required simultaneously press and hold the function button and program button for a period of 5 seconds This will extend the chill cycle by 10 minutes The hold LED 23 will flash during this period Manual Defrost The manual defrost facility is only available when the unit is in the On condition but not running To initiate a manual defrost press and hold the Manual Defrost button 2 p and press Start Stop 76 Automatic Defrost When t
83. mming sequence the SET key must be depressed for five seconds until the green programming LED is illuminated The Chill Time minutes display will flash and the minutes value may be altered using the Time Temp key e Pressing the SET key again will cause the Chill Time hours display to flash which may be altered using Time Temp key e Food Temperature Control Program Chill Time set to zero Pressing the SET key will cause the green Food Control Chill LED to illuminate and the Food Temperature may be altered using the Time Temp key Pressing the SET key again causes the green Air Control Cooling LED to illuminate and the Air Temperature may be altered using the Time Temp key e Chill Time Control Program Chill Time set above zero Pressing the SET key will cause the green Air Control Cooling LED to illuminate and the Air Temperature may be altered using the Time Temp key e Pressing again the SET key will cause the green Hold LED to illuminate and the Hold Temperature may be altered using the Time Temp key e Pressing again the SET key will cause SP Surface Protection to be displayed in the left hand window of the fascia panel Surface Protection can be selected using the Time Temp key and On or Off is displayed in the right hand window of the fascia panel display e Pressing again the SET key will save the program settings and the fascia panel display will flash for five secon
84. mperature Press the Program button the Air Control LED 22 will illuminate and the Air Temperature will flash Using the increment decrement buttons V select the internal Air Temperature during chilling Press the Progam button the hold LED will illuminate and the hold temperature will flash Using the increment decrement buttons V select the desired Hold Temperature Press the Program button the temperature display 24 will alternate between probe air and hold temperature showing the selected values To save the selected values press and hold the Start Stop button 76 and press the Program button All displays will flash for 5 seconds If the current program has been incorrectly entered or programming of further channels is desired press the Program button the Program number will flash display 25 Using the increment decrement buttons V select the Program number to be changed Press the Program button The Timer display will flash Continue from 3 7 3 To exit the programming mode hold down the increment decrement buttons VA and press the Program button FAILURE SITUATIONS Power Failure In the event of a power failure the unit will stop functioning On resupply the unit will resume from its condition at the point of failure If the failure causes the product to deviate from its desired temperature control limits products alarms will be activated Probe Failure In general this will not stop t
85. n Red Green LED Safe operation Constant Red LED Product overtemp 7 Infra Red Link W 17 Timer Display Incremental in Probe Control Decremental in Air Control Sars in standby mode 2727272000 SSS SSS 3 4 CHILLER OPERATION SWITCHON CORRECT PROGRAM PRESS Po HOLD USE OR TO CHANGE PROG NO PRESS START STOP PROGRAM LED FLASHES ALARM YES REQUIRED PRESS AND HOLD ALARM AND PRESS START STOP 9 START STOP SURFACE PROTECTION REQ PRESS SURFACE PROTECTION ae PMU CYCLE EXTENSION REQ i amp SIMULTANEOUSLY FOR 5 SECONDS AIR CHILL LED ILLUMINATES AND HOLD LED FLASHES SM DURING EXTENDED CYCLE UNIT MOVES INTO L HOLDMODE __ PRESS START STOP O TO STOP UNIT ANOTHER SWITCH OFF CHILL CYCLE REQ 47 3 5 2 3 5 8 e 3 5 5 CONTROLLER OPERATING INSTRUCTIONS Program Selection To select the programme number Switch the unit on using the On Off button Press and hold the program button Use the Decrement Increment buttons to select the required program number Running the Chill Cycle Press the Start Stop Button 76 Both the Run LED 3 and Alarm LED 8 will flash If an end of cycle audible alarm is required press and hold the Alarm button A and press the Start Stop button 76 otherwise press the Start Stop button
86. n and hold while pressing the Increment button The Controller is now in the Service Parameter settings release both buttons To save a value press the Programme button To change a value press the Increment button till you get the desired value To exit and save the new Control Parameter values the Start Stop button must be pressed The controller reverts to the on condition If any other buttons are pressed the changed values will not be held If not buttons are pressed for two minutes whilst in the Service Parameter Setting Mode the controller will revert to the Sleep State without saving any of the changes 29 1 11 2 Control Parameters Fixed or Programmable F or P N Eor P Descripti Settings Limits 1 P Cooling Temperature Differential C lin t Point ling Temperature Differential High point of the coolin ration range 110 1 2 Hold D Differential al C 3 P Compressor Rest Time Mins Minimum Tim tween successive r ration to 1 4 P Defrost Termination Temperature NOT USED 5 P Defrost Termination Time Mins Maximum defrost time duration t 6 P Number of Defrosts Per Day 4 7 Defrost Type 1 0 Hot Gas 1 or Electric 0 determines whether both the defrost and condensing unit outputs or the 8 P Drain Down Time Mins Time period after defrost for which the Defrost and Condensing 9 P Fan Delay Time Mi
87. ndicator illuminates and Time Display minutes value flashes Hold SET key for five seconds Time Temp Food Temp or cooling Time Control Set Cooling Time minutes to zero using 2 key Set Cooling Time minutes using key Press SET key Set Cooling Time hours using key Time display hours value falshes Press SET key Set Cooling Time hours to zero using A key Press SET key Set Food Temp using key Press SET key Set Cooling Temp air using key Press SET key Set Hold Temp air using key Press SET key Switch on off Surface Protection using key Press SET key 37 Programme Display shows Selected Programmme Programme number 1 10 indicated Time Display hours value flashes Temp Display Food Temp value flashes Temp Display Cooling Temp Air value flashes Temp Display Hold Temp Air value flashes Temp Display shows SP and Time Display shows on off Display flash as new programme settings are stored Time Display shows preset Cooling Time and Temp Display shows actual air temp Programming indicator extinguishes 2 5 USING THE BLAST CHILLER FREEZER 2 5 1 Cleaning and Maintenance e High Pressure washers may damage the seal between coldroom panels and possibly create electrical hazards and must not be used to clean the exterior or interior of the Blast Chil
88. ns Tim ri fter Drain Down Time for which Evaporator Fan output remains low 1 0102 10 Fan Delay Temperature NOT USED 11 P Cabinet Identification Number t the number print ut at the h f the Print Log to identify th ntroller inet 1 010 2 12 Print Out Language Determines the Language Printed when Downloading t the Print Log English 1 Danish 2 Dutch 3 French 4 zltali Spanish 7zSwedish to 7 13 P Hold Alarm Duration Mins 14 P Display Allows th lay temperature t justed up or down to allow for system tolerances 15 to 1 15 P Chill Freeze Select 1 0 16 F Maximum Chill Cooling Set Point Maximum allowable Chill Temperature Set Point 17 F Minimum Chill Cooling Set Point E Minimum allowable Chill Temperature Set Point Active when Chiller ration i lected rameter 152 1 18 F Maximum Freeze Cooling Set Point Maximum allowable Freeze Temperature Set Point Active when Freez ration i lect rameter 15 1 1 19 F Minimum Freeze Cooling Set Point Minimum allowable Freeze Temperature Set Point Active when Freeze Operation is selected parameter 15 1 35 20 Chill Temperature 21 Soft Chill Time 96 Under a Cooling Time Control Program the percentage of Cooling Time after which the 22 P Soft Chill Food Temperature C Under a Food Temperature Control Program the measured Food Temperature at which the Air Temperatur t Point ri to the va
89. ntrol system It opens with a brief illustration of how the Blast Chiller is designed to operate and follows with an indepth explanation of operating programming and testing the controller Blast Chiller Operation To give a full understanding of how the Blast Chiller operates the chill cycle has been broken into three phases This is explained below and on the following graphs Phase 1 Uncontrolled Chill This is the uncontrolled chill phase To achieve maximum heat transfer from the product in the early part of the chill cycle the unit cools down as rapidly as possible to approximately 15 C Phase 2 Controlled Chilling The Air temperature now cycles around the pre defined air temperature this will be affected by Surface Protection if selected This will continue until a Under temperature control the predefined chill period has elapsed b Under probe temperature control the predefined product core temperature has been reached Phase 3 Hold Once the probe temperature has been reached for a probe control program or when the time reaches zero for a timed air control program the controller will enter the hold mode AIR TEMPERATURE CONTROL PROBE TEMPERATURE CONTROL Air Temperature 10 Air Temperature 10 hill Period 90 mins ET Probe Temperature 2 E cdi 2 eT 122 4010 Temperature 2 SAR TEMPERATURE CONTROL PROBE TEMPERATURE CONTROL With Surface Protection With Surface Protection
90. ood Probe number 1 2 or 3 when the three probe software is selected and the Increment Button is pressed during a Cooling cycle or Hold mode Start Running LED Illuminated green when the unit is in Timed Product or Hold Modes In conjunction with the Start Stop Button End of Cycle LED Illuminated red when the End of Cycle Alarm has sounded and the Mute Button has been depressed It is extinguished when the unit is stopped by pressing the Start Stop Button Defrost Indication LED Illuminated red to Defrost in Operation automatic or manual Condensing Unit Run LED Illuminated green when Condensing Unit output is high Evaporator Fan Run LED Illuminated green when Evaporator Fan output is high 25 PROCEDURE FOR MODIFYING MODULAR BLAST CHILLER FROM ELM MK3 3A ELM CONTROLLER TO SUIT MK4 ELM CONTROLLER controller is interchangeable with theMk3 3A controller but care will need to be taken when connecting as the terminals on the Mk 4 controller are arranged differently but marked in the same way with the exception of the Capacity control which is marked as Whereas previously it was marked as Cap The probes are arranged differently with the exception of the over temp probe which is not required with the Mk4 control system For wiring detail consult Sheet 4 of Wiring Diagram 00 838137 00 07 and follow the instructions below Connect Food probe to terminals 378 38 on the Control panel t
91. peration of the fascia Mute button However the Hold LED above the Mute button will illuminate Defrost Automatic or Manually Initiated The time period to the first defrost is calculated from the start of the Cooling Programme If the Defrost interval is every 4 hours but the Cooling Cycle is 6 hours the Defrost will be postponed until the Unit enters Hold Mode Defrosts will occur automatically in the Hold Mode The evaporator fan output falls low Depending on Defrost Type either a Hot Gas Type 1 or Electric Heater Type 0 Defrost will be initiated and the Time Display will continue to display Time Elapsed The temperature display will show the temperature measured by the Food Probe The RED LED will illuminate Alternatively a Defrost can be initiated in the Standby or Hold modes To initiate a Manual Defrost press the Defrost button once and defrost will commence Defrost will be the same as in automatic mode ERROR ANNUNCIATION Should temperature probe failure occur the controller will indicate the fault by flashing on the fasica panel PF1 PF2 PF3 PF4 or PF5 in the temperature display window It is important to note that on Probes 1 and 2 Probe Fault occurs if a resistance corresponding to above 60 C or below 60 C See page 33 for resistance values against temperature 1 Indicates Food Probe failure If a food probe fault occurs during a Food Temperature Control Programme the Condensing Unit output goe
92. red by the Food Probe is reached Soft Chilling can only be selected if the Programme Settings Food Temperature Cooling Air Temperature and Hold Air Temperature are set above the value of the Surface Protection Limit USER PROGRAMME SETTINGS The following is a list of the parameters that may be adjusted by the user in the programmes A to J Cooling Time Control Programme Hrs Mins Duration of Cooling Phase for a Cooling Time Control Programme If set to zero the Controller automatically assumes a Food Temperature Control Programme Food Temperature Control Programme C Desired Food Temperature at completion of the Cooling Phase Required when a Food Temperature Control Programme is selected Measured by the Food Probe inserted into the product to be cooled Cooling Air Temperature Internal air temperature during the Cooling Phase Hold Air Temperature C Internal air temperature during the Hold Phase Cooling Type Hard or Soft Chill Selects cooling type function which in Soft Chill raises the Air Temperature during the latter part of the Chill Phase Soft Chill can only be selected if the Programme Settings Food Chill Air amp Hold Air Temperature are above the value of the Soft Chill Limit Printer Sample Rate Selects the inteval between Air or Food temperature samples being recorded during the Cooling Cycle and Hold Mode PROGRAMME SETTING AND CONTROL PARAMETER ADJUSTMENT The user
93. s low If a Food Probe fault occurs during a Cooling Time Programme the Controller will continue to operate normally PF2 Indicates Air Probe Failure If an Air Probe fault occurs during either a Food Temperature or Cooling Time Control Programme the Condensing Unit output goes low Indicates Evaporator Coil Failure A probe is not fitted however in its place a 5 1 Kohm resistor is fitted If this fails it will not effect the cooling cycle as the defrost will terminate using the time setting 4 amp PF5 Indicates Food Probe 2 amp 3 Failures respectively Displayed only in standby mode this fault will only register if the probe software is activated Theres is no effect on unit operation or programming 28 1 8 1 9 1 9 1 1 9 2 1 9 3 1 9 4 1 9 5 1 9 6 1 10 ll HARD OR SOFT CHILL Hard Soft Chilling is used to minimise surface damage to delicate products The Soft Chill function raises the Air Temperature during the latter part of the Cooling Phase The Air Temperature during the Cooling Phase while Soft Chill is selected rises to the value of the Soft Chill Set Parameter temperature Under a Cooling Time Control Programme the Soft Chill level becomes active after the percentage value of the Soft Chill Set Time relative to the pre set Cooling Time has lapsed Under a Food Temperature Control Programme the Soft Chill becomes active when the Soft Chill Food Temperature measu
94. se e Hold Air Temperature Cold Room internal Air Temperature during the Hold Phase e Surface Protection On Off Selects Surface Protection function which raises the Air Temperature during the latter part of the Chill Phase Surface Protection can only be selected if the program Settings Food Chill Air amp Hold Air Temperature are above the value Surface Protection 23 2 12 2 Control parameters Fixed ot Programmable F or P No EorP Description ttin Limit 1 P Cooling Temperature Differential hill Set Point Chill Temperature Differential High point of Chill rating range 1101 2 Hold Temperature Differential Hol t Point Hold Temperature Differential High point of Hol rating range 1101 3 P Compressor Rest Time Mins Minimum Tim tween su iv r ration to 1 4 P Defrost Termination Temperature C Evaporator Pr Temperature at which defrost terminat to 5 Defrost Termination Time Mins Maximum defrost time duration 1 t 6 P Number of Defrosts Per Day Determin uration between automati frost 4 0 to 24 7 P Defrost Type 1 0 Hot Gas 1 or Electric 0 determines whether both the defrost and condensing unit outputs or the defrost output 10 P Fan Delay Temperature C After Drain down period Evaporator Fan output remains low until the Fan Delay Temperature measur the evaporator probe is reach 5 10 to 1 11 P High Food Temperature Alarm C Valu to High Point of Hol rating Range Hol t Po
95. set to 3 C the capacity control output will be active thereby reducing the refrigeration system capacity depending on wring It would be more usual for the for the capacity control only to become active in the Hold mode when the hold temperature would be set for 3 C The capacity control is active if the above conditions are met in the Timed chill or Hold modes It is not used for freezer applications CONTROLLER MODEL SELECTION The controller holds the Standard Operating Settings for 16 0 to 15 inclusive Blast Chiller and Blast Freezer models both integral and remote to select the appropriate models Bit Switches are used The Bit Switches are a series of 4 two position switches see below situated on the back of the controller PCB and which can be accessed with the rear cover removed Bit Switch 1 2 3 4 ON OFF All Buttons to the Bottom Value 0 Using binary Notation values between 0 and 15 can be obtained The Bit pattern settings to access these are as follows 11 13 14 15 1 12 3 By setting the bit switches to the appropriate positions various Operating Parameters are selected If setting 6 15 inclusive are selected the unit will not function as th
96. st Type P7 0 elec 1 gas 1 1 1 1 1 0 0 0 0 0 0 i see e mins P9 Delay qiie 1 350 362 mins P10 Fan Delay olololololo lo ololololo Temperature C Cabinet P11 ID Number 1 1 1 1 1 1 1 1 1 1 1 1 P12 Print Qut 0 0 Language Hold Alarm P13 Duration mins e 2 5 e 2 2 P14 Display Offset 0 010 0 0 0 010 0 0 0 0 Chill 0 Freeze 1 P15 Select 0 1 1 0 1 1 0 1 1 0 1 1 Max Chill Cooling P16 Set Point C 10 10 10 10 10 10 10 10 10 10 10 10 Min Chill Cooling FUN _ _ PESE P17 Set Point C 15 15 15 15 15 15 15 15 15 15 15 15 Max Freeze Cooling P18 Set Point 10 10 10 10 10 10 10 10 10 10 10 10 Min Freeze Cooling _ E 3 _ _ _ 4 19 Set Point 35 35 35 35 35 35 35 35 35 35 35 35 Soft Chill P20 Temperature C 2 2 2 2 2 2 2 2 2 2 2 2 P21 Soft s nme 70 70 70 70 70 70 70 70 70 70 70 Soft Chill Food P22 Temperature C 5 5 5 5 5 5 5 5 5 5 5 5 p23 Soft ye Limit 45 15 45 45 45 15 15 15 15 15 15 15 Graph Print Out P24 Low Point 10 10 10 10 10 10 10 10 10 10 10 10 P25 Year 00 00 00 00 00 00 00 00 00 00 00 00 P26 Month 01 01 01 01 01 01 01 01 01 01 01 01 27 Date 01 01 01 01 01 01 01 O1
97. t Time and Date GMT or BST No account is taken for international time zones therefore some adjustments may be necessary The controller is fitted with a PCB battery which will retain time date setting if the electrical supply is removed isolated once set Three Probe Software Allows the three probe temperatures to be displayed The two additional probes probes 2 and 3 are for information only and do not perform any control function When is set to 0 pressing the increment button will cause the temperature display to show either Air or Food probe temperatures When P30 is set to 1 pressing the increment button will cause the temperature display to show Food Probe 1 temperature when in a timed chill or hold mode When pressed during a Food probe cycle the programme display will show 2 along with the temperature received by that probe for 3 seconds displayed in the temperature display The programme display will then show 3 followed by temperature measured by Probe 3 in the temperature display for the same time period of 3 seconds On completion the temperature will return to showing the probe 1 temperature Capacity Control The function controls the condensing unit or evaporator fans during periods when the required internal air temperature is above the value set for the Capacity Control in the Service Parameters 31 In basic terms if the capacity control value is set to O C default value and in a Timed Chill mode the air temperature is
98. the Time Temp key Pressing the SET key causes the display to advance to the next Control Parameter To exit and save the new Control Parameter values the Start Stop key must be pressed The controller reverts to the on state To exit without saving the new Control Parameter values the key must be pressed The controller reverts to the sleep state 18 2 6 3 Fixed or programmable or P Setting Setting No ForP Description Limits No ForP Description Limits 1 P Cooling temperature Differential 14 P Internal Overtemperature Cooling Set Point Cooling Temp Alarm Setting Differential High point of Cooling Not used if 5 1Kohm operating range 3 1 to 10 Resistor fitted 80 450 to 120 2 P Hold Temperature Differential 15 P Chill Freeze Select 1 0 Hold Set Point Hold Temp Freeze 1 or Chill 0 Configures Differential Hold point of Hold operation as a Chiller or Freeze 0 0 to 1 operating range 3 1 to 10 3 16 F Maximum Chill Cooling Set Point 3 P Compressor Rest Time Mins Maximum allowable Chill Minimum Time between sucessive temperature Set Point Active compressor operations 0 0 to 10 when Chiller Operation is selected 15 0 10 4 Defrost Termination Temp Evaporator probe temperature 17 F Minimum Chill Cooling Set Point at which defrost terminates Minimum allowable Chill Set Temp Not used if 5 1Ko
99. ts will occur The fascia panel displays Cooling Time and Air Temperature The refrigeration cycle begins and the Evaporator Fan output remains high throughout the cycle except if the door is opened The Cooling Time displayed on the fascia panel will decrement from the programmed value If internal air temperature is higher than the pre set Air Temperature the Condensing Unit output goes high When the internal air temperature pulls down to the pre set Air Temperature the Condensing Unit output goes low If the internal air temperature then rises above the pre set Air Temperature plus the Differential the Condensing Unit goes High The Cooling time continues until the displayed time increments to zero The end of cycle alarm sounds and the Unit enters the Hold phase Hold LED illuminated Hold Phase With the evaporator fan output still high the condensing unit output falls low until the internal air temperature rises to the pre set Hold Temperature plus the Hold Temperature Differential The Condensing Unit output goes high until the internal air temperature pulls down to the pre set Hold Temperature The Hold Phase continues until the programme is stopped by operation of the Start stop button End of Cycle Alarm The Controller alarm output will go high on entry to the Hold Phase to indicate completion of the Cooling Phase The Hold Alarm will stay high for the period Hold alarm Duration Alternatively the Hold Alarm may be muted by o
100. uld fall For probes 1 2 and 3 Food Air and Coil Probe Fault occurs if a resistance corresponding to above 60 or below 60 approximate values is detected See the following temperature resistance values 60 656 ohms 10 3448 ohms 20 12100 ohms 30 1679 ohms 0 5107 ohms 30 19455 ohms 20 2381 ohms 10 7754 ohms 60 100181 ohms For probes 4 Overtemp Probe Fault occurs if a resistance corresponding to above 204 or below 30 approximate values is detected See the following temperature resistance values 204 589 ohms 100 6786 ohms 40 53248 ohms 160 1465 ohms 80 12552 ohms 20 124936 ohms 120 3886 ohms 60 24871 ohms 3 280542 ohms Note The Controller ignores the Overtemp Probe below an evaporator coil temperature of 25 C measured by the Evaporator Probe 42 2 14 CONTROLLER DETAIL Wav G3 LO3NNOO LON G3 LO93NNOO LON ALIOVdVO G3LO93NNOO LON L WHLNAN DOOR SWITCH probe 6 FOOD 3 COMMON PROBE 5 FOOD 2 PROBE 4 SAFETY COMMON O QO OO O LO 1O 10 CV CN CN CN LO LO T LL LL LL LL LL 2 9 E 29o2EP 2 Stos OLLON 43 2 15 FOOD PROBE DETAIL FOOD PROBE LEAD FAN
101. vaporator fan output still high the condensing unit output falls low until the Cabinet or Counter internal air temperature rises to the preset Hold Temperature plus Hold Temperature Differential 2 The Condensing unit output goes high until the internal air temperature pulls down to the preset Hold Temperature The Hold Phase continues until the programme is stopped by operation of the start stop key Time Period Elapsed Between Automatic Defrost or Manually Initiated Defrost The time period to the first defrost is calculated from the beginning of the cycle The evaporator fan output falls low depending on parameter Defrost Type 7 either a Hot Gas Defrost Type 1 or Electric Heater Defrost Type 0 defrost will be initiated and dEF will be displayed on the fascia panel Hot Gas Defrost output goes high operating a solenoid valve and Condensing Unit output goes high Electric Defrost output goes high operating an electric heater and Condensing Unit output goes low When Defrost Termination Temperature 4 is reached or Defrost Termination Time 5 has elapsed the Defrost and Condensing Unit outputs goes low for the Drain Down Period 8 The fascia panel will now display REC and the refrigeration cycle restarts however the Evaporator Fan output will not go high until the Fan Delay Period 9 has elapsed or the Fan Delay Temperature 10 has been reached Terminates on time if 5 1 kohm resistor is fitted During the defrost and re
102. voltage Check connections onto L1 N1 8 E Check that Food Probe is connected correctly onto PRB1 Check for damage to Food Probe Check resistance of Food Probe Change Food Probe if probe is open circuit or damaged Check Air Probe connections onto PRB2 Check position of Air Probe Check resistance of Probe Change Probe if resistance is incorrect or Probe open circuit Tego Check Evaporator Probe connections on PRB3 Check resistance of Probe Check position of Probe Change Probe is resistance is incorrect or Probe open circuit Check that Probe is the correct position Check resistance of Probe Change Probe if resistance is incorrect or Probe open circuit Check operation of cabinet after resetting Check temperature cutout on Defrost Mode OLN If fans not working and LEDs illuminated on front panel check connections on rear of controller marked F Check connections for door switch Check to see of door switch is operating Switch contacts should be closed when door is closed If LED is illuminated on front panel check output on rear of controller marked 2 Check power going to compressor wiring 3 Check door switch is operating Switch contacts should be closed when door is closed Enquire as to when last manual defrost was initiated 2 Check defrost cycle by initiating manual defrost via front fascia operat

FOSTER BLast Chiller Service Manual

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