SERVICE MANUAL
Contents
1. 25 TROUBLE SHOOTING PRINTER ERROR Check for the correct style of paper in the printer It must use Thermal paper 2 1 4 inch roll Check the paper tension bar located under the bottom of print head Tension Bar must be in the up position to allow it to feed paper thru Check for paper jam Check the cutting wheel on the printer head The wheel must be all the way to the right in the ready position Check the wiring from the relay board to the control board and the wires from the control to the printer Paper must be installed correctly It must come off the top of the roll with the treated side up as it passes thru the print head If the unit has two printers you might try to swap the two printers to help confirm the printer is not repairable Should the Printer causes the unit to have a power interruption while asking to print the label the issue will be with the Smart Chill Board and must be changed out with a version 1 12 or higher to correct the problem SYSTEM CONTROL ERROR The Box Temperature has exceeded 160 All fans compressors OVER TEMPERATURE and heaters turn off CONTACT SERVICE The Refrigeration Systems have failed to come on to cool the box The Cabinet Air Sensor could be bad and could be reading higher than 160 and will cause this Error message The power must be turned off and then back on to reset the control SYSTEM CONTROL ERROR Check all operation sensors Cabinet air se2. lt DC power distribution to controls Voltage Test Points SERVICE PROCEDURES RBC50 VI a IDENTIFY 2008 CURRENT vs PRE 2008 VI b SENSORS AND PROBES CONT b 2 Air amp Coil Sensor Locations RBC50 2008 Current Pre 2008 EVAP COIL SENSORS 2 3 CAB SENSOR 1 x 2 A 1 r L 2008 Current b 3 Sensor and Probe Troubleshooting All probes and sensors should return an Ohm reading of 32 7K Ohms at 32F or 0C Test by placing the sensor or probe tip in ice with a little bit of water and checking Ohm reading with an Ohm meter Temp F R Ohrms3 Temp C 5 99 9 K lt gt 20 52 VI b SENSORS AND PROBES 85 2 5 72 9 lt 2 had b 1 Air amp Coil Sensor Locations RBC50 pre 2008 e Air Sensor Green 45 53 7 K lt 9 47 Located in the return air of duct of the left or MS e maintenance system e Maintenance Coil Sensor Blue Located in the evaporator coil of the left or maintenance system e Blast Coil Sensor Yellow B Located in the coil of the evaporator coil of ac 19 9 2 the right or blast system Image available RBC50 POWER PACK REMOVAL pre 2008 c 1 RBC50 Power Pack Removal right or left side b 2 Air amp Coil Sensor Locations RBC50 2008 Current 1 Air Sensor Green p WARNING Disconnect the Loca
3. IV SMART CHILL CONTROL IV f SERVICE MENU NAVIGATION CONT All LED s should be illuminated Press any button to return to the SERVICE MENU IV g DIAGNOSTICS MENU 9 1 Accessing the Diagnostics Menu To access the Diagnostics Menu begin by accessing the Service Menu see section IV d page 5 From the Service Menu select SERVICE MENU to access the Diagnostics Menu EXIT REFR AIR DEF COIL p 4 PROBES ALARM FAN 4 PRINTER DISPLAY 4 DIAGNOSTIC MAXIMUM gt RUN CYCLES MINIMUM 4 SINCE DEF FAILURE 4 24 CYCLES CLEAR 7 9 2 Using the Diagnostics Menu The Diagnostics Menu consist of 5 available para meters to aid in the troubleshooting and diagnosis processes 1 MAXIMUM Maximum air temp recorded 2 MINIMUM Minimum air temp recorded 3 RUN CYCLES Total compressor run cycles 4 SINCE DEF Total compressor run cycles since the last defrost 5 FAILURE Any error codes the control has exper ienced for more information on error codes see pg 11 The value of each parameter will be displayed in the bottom left corner of the menu when selected To select a parameter press the corresponding button When selected a parameters value can be reset by pressing clear It is advisable to clear these parameters every time a unit is serviced so the next time service is needed the parameter values are va
4. 1 _ MULLION HTR CN2 1 1 POWER SUPPLY BOARD CNe 2 CN2 6 CN 2 1 wa J4 2 44 3 13 3 12 CONTROL BOARD VDD 112 J12 2 J13 4 SV J13 1 GND i 213 2 8 5W 4 13 5 GND MAINTENANCE yet DEFROST uten 1 BLAST CDM 11 3 MAIN COMP JL1 4 i gt 096 T 4 5 PLAST DEFROST 11 5 2CR s k MAEN DEFROST 111 6 n w ALARN J11 7 BSTCR 2 at PWR FAIL JL1 8 ED 4 T ET 4 J11 11 BSTCR 1 MAINTENANCE START i COMPRES SOR CAPACITUR AZA ne IRI TB 1 ihe MSTCR S 6e o0 ddl IFO GND YEL CVPP SVDC VPP 8 SVDC C WHT PRINTER 2 x TB 3 p 1 qm PRINTER TR 1 START COM TE S CAPACITOR VDD S DC GND GND GND CVPP SVDC VPP SVIC OREL WHT WHT Tr BLK o _ BR BR TB 1 BRL Ibe 1 WHT WHT o RN BR BR R 23 WIRE DIAGRAM RBC100 WARNING ELECTRICAL 4NT GROONDING CONNECTIONS MUST COMPLY WITH THE APPLICABLE PORTIONS OF THE NATIONAL ELECTRICAL m3 o N Th 3 CODE OTHER LOCAL ELECTRICAL TB 2 CODES 15 1 C FAN MOTOR 1 CNe 1 POWER SUPPLY BOARD CNe P CN2 6 CN2 1 Jt2 1 13 3 12v 12 2 13 4 Sv Ji2 3 13 1
5. PROBES ALARM FAN 4 PRINTER DISPLAY d 3 Access Service Menu Push Button To a access the service menu without using the control touchpad reference the following instructions IV d SERVICE MENU ACCESS CONT WARNING This procedure requires that the control box be open while the power is supplied to the unit Exercise extreme caution at all times CAUTION Electro static discharge will damage the control board Use an anti static grounding kit when servicing the computer control box 1 Remove thumb screws and control cover 2 Remove five phillips head screws from control mounting brackets to access the rear of the control 3 Disconnect power to the control by unplugging the 3 pin connector wire color red white black labeled J12 PWR ont board PROP mm m mm misi mn 2 2r 53 a zu mmm je m 222 Poma xa 5 Push and hold the TEST button then reconnect the 3 pin connector J12 PWR while still holding the TEST button Once power has been restored release the test button and check control display You should now have access to the SERVICE MENU See section IV f Service Menu Navigation for more information on th
6. DISPLAY 2 Printer harness 3 Printer mechanism printer board error 4 Printer power supply malfunction 5 Controller malfunction DISPLAY BLANK 1 Power supply to controller 2 Controller D21 on 3 Main power supply Should read 5v 12 amp 8 5v 4 Display harness 5 Display board malfunction 6 Controller malfunction ERR SHORT OR 1 Probe open OPEN 2 Temperature is normally displayed 3 Wire connections 4 Controller malfunction 5 Out of range actual temperature range 40 F to 200 F PRINTER DOES NOT PRINT 1 Controller malfunction TEST 2 Printer malfunction 3 Printer power supply board malfunction RECOGNIZABLE PRINTER DOES NOT 1 Printer out of paper message on display 3 Printer power supply malfunction NO RESPONSE FROM 1 Controller LED D21on 3 Check connection to control board PRODUCT NOT CHILLED 1 Product temperature probes not located ee 2 Correctly or sensor malfunction 3 System malfunction Refer to SYSTEM TROUBLESHOOTING 29 TROUBLE SHOOTING Continued CONDITIONS POSSIBLE SOLUTIONS PRODUCT FROZEN AT EDGES Product too thick in pans Too long of run time in Manual Chill Mode Surface protection option not selected Soft Chill Mode not used Controller malfunction I O board malfunction Power High voltage board 30 QUICK REFERENCE GUIDE SMART CHILL PROGRAMMING Service Menu Factory Menu Passwor
7. MAIN MENU 08 06 01 4HOLD PROD PRINT SETUP lt BACK 3 Select START the unit should now be in a defrost READY TO DEFROST REQUIRED IN XX MIN REMOVE FOOD 4 CANCEL J XX Number of minutes until next scheduled defrost gt DEFROSTING MAINT 50 F BLAST 49 F 00 10 05 PRINTING CONTROL DATA 1 Cycle Batch Data All batches run BY TEMP or using EASY START will be stored in memory At any time we can access this data and reprint Cycle Batch data using the following instructions 1 From the MAIN MENU select MORE MAIN MENU AIR 35 F 4BY TEMP BY PROD 4 TIME 08 05 01 2 Select Print MAIN MENU 08 06 01 4HOLD PROD 4DEFROST SETUPP Continued on next page V SMART CHILL CONTROL IV c PRINTING CONTROL DATA CONT 3 Select desired probe to retrieve data from 1 2 or 3 then select date and time of Cycle Batch PRINT CYCLE 4 03 08 40 gt RECORD gt PRINT gt 4MAIN MENU PRINT CYCLE lt 4PRB 1 RECORD gt 4MAIN MENU PRINT b 4 Select PRINT A full log of the selected Cycle Batch should print PRINT CYCLE 4 03 08 40 4 1 RECORD gt 4 MENU c 2 12 Hr Data Log The Smart Chill control records data from all inputs and outputs in five minute increments At any time this data can be retrieved in the form of a 12 Hr data log A 12 Hr
8. PIN 85 ENTER Note PRESET SUPERVISOR must be selected Continued on next page IV SMART CHILL CONTROL IV h FACTORY MENU ACCESS CONT 4 Press and release the TOP LEFT TOP RIGHT and BOTTOM RIGHT buttons all three simultaneously SELECT SUPERVISOR j PRESET SUPERVISOR PFT EENCET PIN 4CANCEL ENTER SmartChill 5 The display will advance to the FACTORY SETTINGS VERSION screen You now have access to the FACTORY MENU See section IV I Factory Menu Navigation for more information on the Factory Menu IV h 3 FACTORY MENU ACCESS Exercise extreme caution at all times CAUTION Electro static discharge will damage the control board Use an anti static grounding kit when servicing the computer control box 1 Remove thumb screws and control cover 2 Remove five phillips head screws from control mounting brackets to access the rear of the control 3 Disconnect power to the control by unplugging the 3 pin connector wire color red white black labeled J12 PWR on mother board fiz pie ete 5 4 Locate the push button labeled FACT on the control mother board mae Cie mm e am
9. aah 5 Push and hold the FACT button then reconnect the 3 pin connector J12 PWR while still holding the TEST button Once power has been restored release the test button and check control display You should now have access to the MENU See section 10 IV I Factory Menu Navigation for more information on the Factory Menu IV i NAVIGATING THE FACTORY MENU i 1 Reset and Serial Number Entry Upon accessing the Factory Menu you will be at the Reset and Serial Number Entry screen Here can reset all default settings by pressing the button labeled RESET After doing this you may need to re enter the serial number of the unit Note serial number is for reference only and is not critical to unit function FACTORY SETTINGS VERSION 2 11 S N T000000A00 4 RESET NEXT gt To enter the serial number use the to change the value of the current digit Press the to advance to the next digit For serial numbers with 5 digits between the T and the A leave the digit after the T at 0 Press NEXT to advance to the Printer Selection Screen i 2 Printer Selection The Printer Selection Screen allows you to turn on or off specified printers Depending on revision you options may differ slightly Most versions only allow the Label printer to be turned on or off Version 2 11 or higher will allow for both Label and Record Print
10. button in the first screen and then go thru until you get to the Security screen Press the Reset button again All settings will default to original settings RBC100 Use the button to the right of Machine Size to change from the 100 to the 50 and then press Exit In the next screen press the Yes button to save your changes Proceed to the Main Menu Go back into the 85 program and press the rest button for the second time Then go to the screen that shows the defrost time Use the down arrow to change the defrost button to 15 min Press the Back button to go back to the first screen in program 85 to enter the correct serial number this allows usage of the Blast Chill Communication software 28 TROUBLE SHOOTING Continued CONDITIONS POSSIBLE SOLUTIONS LOW SUCTION PRESSURE 1 Solenoid valve restricted 2 Restriction in drier 3 Loss of refrigerant 4 Poor air flow due to bad blower motor or iced up evaporator coil 5 Expansion valve blocked HIGH HEAD PRESSURE 1 Improper airflow across condenser 2 Extreme ambient conditions 3 Overcharge of refrigerant 4 Air in system WILL NOT DEFROST 1 Defrost heater malfunction 2 Wired wrong or faulty connection 3 Relay contacts open 4 Coil temperature sensor failure 5 Controller malfunction 6 board malfunction 7 Power High voltage board 8 Thermal fuse opened PRINTER ERROR ON 1 Paper not feeding correctly
11. 2 RED 15 Record Printer Power Port 1 RED 16 Record Printer Communication Port PTR 1 WHT 17 Label Printer Communication Port PTR 2 WHT CIS TU 9894488828858 395 r V CONTROL COMPONENTS V a COMPONENT IDENTIFICATION amp OPERATION CONT a 5 RBC50 Control Relay Box 2008 Current RBC50 Controls Relay Box Operation e House all control components except Smart Chill Control e House start components for compressor Ledger RS232 Communication Port Relay Board DC Power Supply Compressor Start Capacitor Compressor Run Capacitor Terminal Block 4 0 mF Run Capacitors For Blowers Compressor Start Relay Condenser Fan Motor Relay 1CR Compressor Relay 16 ojal 2CR Defrost Relay V CONTROL COMPONENTS V a COMPONENT IDENTIFICATION amp OPERATION a 6 Relay Board RBC50 2008 Current Relay Board Operation e Conditions and distributes DC power for the DC control components e Receives DC signals from Smart Chill control to energize 12VDC control relay coils LED indicators on board indicate which 12VDC output is energized e Jumper Pins adjacent to LED indicators to manually operate 12VDC outputs 18 Ledger 14VDC input High Fan 115vac output 12VDC outputs to control relays 12VDC output signal from Smart Chill LED indicators amp jumper pins
12. GND J13 2 8 Sv 139 5 GND LUV FAN 111 1 HIGH BLAST COMP J11 3 MAIN COMP 211 4 5 BLAST DEFROST 11 5 MAIN TEFROST 2311 6 ALARN 11 7 PWR FAIL 11 8 111 9 J2 Jt1 10 J11 11 J11i 12 J11 2 4 J15 6 PRINTER 1 PRINTER SDC 5 2 GND 5 3 GND 45 4 GND 5 5 VPP 8 5vIC CVPP 8 PRINTER 2 PRINTER vr 33 2 GND J3 3 GND J3 4 GND J3 5 VPP 8 vpm 8 5VIC 24 WIRE DIAGRAM RBC200 WARNING ELECTRICAL GRUURTING CONNECT ONS MUST COMPLY WITH THE APPLICABLE PORTIONS OF THE NATIONAL ELECTRICAL CODE AND OR OTHER LOCAL ELECTRICAL pa Brett E 1 6 WACHINE GND MULLION HTR TB 2 TB 2 CN2 1 CN2 1 POWER SUPPLY BOARD CN2 2 CN2 6 CNe 1 TB 2 EVAR CONTROL BOARD RED vhr sED BLK e BLU 40TM 2 AIR BLK AR p bom 7 E 2 BLK YEL GOTH H J13 8 8 5V THe PRODA BLK RN 2 RED V TB 2 LOW FAN E x HIGH FAN T bam M7 BLAST CDMP BLAST CONTROL MAIN COMP E VHT BLK AN GRN BLAST DEFROST H 30M V MAIN DEFROST H H TA TENANCE ALARM E 55 PRINTER 1 PWR FAIL E PRINTER H CIV C CN3 E SVDC ezg J lm Hera pri lt VPP 8 SVDC __ CVPP 8 SYDC PRINTER 2 rb PRINTER C Hl ANAN zz a GND 4 GRN CVPP 8 SVDC BR BR __ lt 8 SVDC
13. PRESSURE Q WATTS AMPS NT TYPE HIGH NT TYPE HIGH 370 60294 00 REV A SANITATION AW 03118 READING THE SERIAL TAG Serial The permanent ID of your Traulsen Model The model of your Traulsen Volts Voltage Hz Cycle PH Phase Total Current Maximum amp draw Minimum Circuit Minimum circuit required Lights z Light wattage Heaters Heater amperage Refrigerant Refrigerant type used Design Pressure operati charge High amp low side ng pressures and refrigerant Agency Labels z Designates agency listings SPECIFICATIONS a EQUIPMENT SPECIFICATIONS RBC50 RBC50 DIMENSIONS 2003 2007 2008 CURRENT RBC100 RBC200 RBC200RT Length Overall in 57 1 2 54 34 48 1 2 48 1 2 Depth Overall in 34 1 4 34 7 16 34 34 41 5 8 37 1 2 41 1 8 80 1 8 89 122 89 1 2 Height Overall in 1 Height shown to work top height over control is 53 b OPERATING DATA 50 50 DATA 2003 2007 2008 CURRENT RBC100 RBC200 RBC200RT H P 1 2HP__ 1HP 1 2 __3 4 __3 4 1 BTU 1350 4400 3880 3880 2 1 2 1 1 4 n a n a BTU 10 degree F evaporator 1350 n a 5460 18 700 18 700 Refrigerant R 404A R 404A R 404A 404 R 404A Full Load Amps 1 Self Contained Holding or Primary Compressor 2 Blast Chilling or Secondary Compressor 3 These may vary depending upon type of r
14. display both coil temperatures in real time DEFROST TEST If a coil temperature sensor is open the the temperature value will display no value or depending on revision will display OPEN were the temperature value is IV f SERVICE MENU NAVIGATION CONT normally displayed If a coil temperature sensor is shorted will be displayed were the temperature value is normally displayed DEFROST TEST 4 HEATER OFF BLAST OPEN MAINT Select BACK to return to the SERVICE MENU f 5 Evaporator Fan Test FAN Select FAN from the SERVICE MENU to access the evaporator fan test menu SERVICE EXITD REFR AIR DEF COIL 4 PROBES ALARM 4 PRINTER DISPLAY b ui EVAP FAN TEST 4 BACK N 2 Pressing the button next to FANS OFF will cycle the evaporator fans in the following order starting from the OFF position EVAP FAN TEST lt FANS _OFF BACK Press Once Low fan relay Press Twice High fan relay Press Three Times Return to all Off Select BACK to return to the SERVICE MENU f 6 Display Test DISPLAY Select DISPLAY from the SERVICE MENU to initiate a display LED test SERVICE EXITD REFR AIR DEF COIL p 4 PROBES ALARM FAN 4 PRINTER Continued on next page
15. in reverse order VII SERVICE PROCEDURES RBC100 VII a SENSORS AND PROBES a 1 Air amp Coil Sensor Locations RBC100 1 Air Sensor Green Mounted on return side of the evaporator coil 2 Maintenance Coil Sensor Blue Located in the top left of the evaporator coil 3 Blast Coil Sensor Yellow Located in the top right of the evaporator coil BLAST COIL SENSOR 3 MAINT COIL SENSOR 2 CAB SENSOR 1 a 2 Sensor and Probe Troubleshooting All probes and sensors should return an Ohm reading of 32 7K Ohms at 32F or OC Test by placing the sensor or probe tip in ice with a little bit of water and checking Ohm reading with an Ohm meter Temp F R Chms Temp C 5 99 9 K lt gt 20 5 35 2 K lt 2 17 77 72 9 K lt gt 15 0 357 30 1 K 2 17 26 1 lt gt 2 245 45 57 22 8 lt gt ri 50 19 9 IK 2 10 0 Ss 17 4 lt gt EE n 20 VII b ACCESS EVAPORATOR REFRIG SYS b 1 RBC100 Exploded View Right side air duct shelving Blower assembly Louver panel Evaporator housing cover Evaporator coil Condensing unit 5 2 Accessing Evaporator Sensors 1 Remove the right side shelving and air duct 1 2 Remove the blower assembly 2 3 Access sensors in the evaporator coil 4 Reinstall in reverse order b 3 Accessing The Evaporator Defrost Heater amp Thermal Fuse 1 Remove the
16. removal of product via the control the system returns to idle or the Main Menu a 5 Defrost Models RBC100 RBC200 and RBC200RT have electric defrost Models RBC50 have hot gas defrost On all units defrost is scheduled to occur every 3 hrs and terminates at a 5 coil temperature RBC100 RBC200 and RBC200RT have a max defrost duration 40 minutes while the RBC50 has a max defrost duration of 15 minutes defrost is initiated it cannot be overridden or terminated by any method other than meeting control parameters time or temperature The Smart Chill control WILL NOT initiate a defrost cycle during a chill cycle Rather it will flash DEF REQD in the top left portion of the display screen when a defrost is required during a chill cycle Once the chill cycle completes the unit will then initiate a defrost The Smart Chill control WILL initiate a defrost during a Hold mode For more information regarding additional operating modes and conditions please reference the Owner s Manual IV b Manual Defrost To initiate a manual defrost the system must be in idle and at the main menu Once a defrost is initiated it cannot be overridden and terminated by IV b MANUAL DEFROST CONT any method other than meeting control parameters time or temperature 1 From the MAIN MENU select f N MAIN MENU AIR 35 F 4BY TEMP BY PROD 4BY TIME 08 05 01 MORE J 2 Select DEFROST
17. 25 40 PSIG SUPERHEAT 7 31 DATA LOG DIAGNOSTICS Date and Time of this data record Control software version Example of Memory Dump Software Version 1 08 07 14 2003 06 00 Set Air 1 5 E2MNT 37 35 0 22 21 37 37 23 22 37 38 24 37 40 26 37 38 26 37 36 25 10 36 25 10 30 10 07 14 2003 06 00 Set Air E1BLS EZMNT 6 41 Prod2 Prod3 R 37 35 0 22 0 211037 I 0 37 I 0 371344 0 371344 3713e8 3813fc 401410 391424 371438 37144c 301460 4 26 20 18 18 8 Cuzrent mode operation Power Interruption Maintenance Mode Auto Chill or BY TEMP CHILLING Auto Soft Chill or BY TEMP SOFT CHILL Auto Freeze or BY TEMP FREEZING Manual Chill or BY TIME CHILLING Manual Soft Chill BY TIME SOFT CHILL Manual Freeze or BY TIME FREEZING Holding Chill after CHILLING completed Holding Chill after SOFT CHILL completed Holding Chill after FREEZING completed D Defrosting sv Unit in Service Mode FC Unit in Factory Mode T m m www HH O O O OC O C n t HH HHH C nj t HH HHH H H H tet den de de tet a 1115 0 121554 1615 8 2015 201520 291604 Set Is the current set point 1 Air for chilling freezing or maintenance mode 2 Coil for defrosting Air Always the cabinet air temperature 2 2 2 2 2 2 2 2 2 2 2 2 2 2 0 0 12 number if is 0 the output is off compressor if chilling freezing or heater if defrostin
18. 5 DIAGNOSTAIC ERRORS Printer Probe Power Interrupted Over Temp Def Heater Flash Memory PRODUCT DETECTED STARTING HOLDING MODE MAINTENANCE COIL IS ICED UP 5 emo ACER POSSIBLE SOLUTIONS Proceed in program 85 going thru the program to confirm the unit is set up to meet the requirements of the unit e g Set up for a RBC100 or RBC200 Check all Food probes that are selected at this time Check for moisture on top of the Food Probe Harness connections located in the ceiling and inside the box Check for proper sealing of the opening thru the Exterior top of the cabinet where the Food Probe Harness passes thru Check the wire connections on top of the Food Probe Harness for breaks in solder joints or corrosion on the joints No Food Probes were plugged into the sockets With the Food Probes not inserted into the sockets the Customer selects the By Temperature mode With the Food Probes plugged into the sockets amp inserted into the product all three food probes could have an open circuit Check to be sure the customer has Thermal Paper in the paper printer Check the version of the control a version 1 01 or 1 04 can allow this to occur if no paper is in the system Printer has had a problem either label or Record A Probe has stopped reading Power has been Interrupted Box temperature has exceeded 160 F Defrost Heaters did not make temp Either one or both Memory has b
19. CK to return to the previous screen i 5 Security Code Entry From here you can choose to exit and save your current settings or enter the security code to advance to the Machine Model Selection Screen ENTER SECURTIY CODE FOR NEXT SETTINGS lt 000000 4 EXIT ENTERD To exit the Factory Menu select EXIT To advance to the Machine Model Selection Screen enter the security code by using the to change the current digit Use the to advance to the next digit Select ENTER when the correct code has been entered The security code is the first 6 numerical digits in the serial number after the T reversed If the security code is entered incorrectly the following will be displayed INCORRECT CODE PLEASE CALL TRAULSEN FOR INFORMATION NEXT gt i 6 Select Machine Size When the correct security code is entered the screen will advance to the Machine Model Selection Screen MACH MODEL MACHINE SIZE 100 4 RESET EXIT 11 Selecting RESET will default the MACHINE SIZE to 100 To change the machine size select the IV i NAVIGATING THE FACTORY MENU CONT or next to MACHINE SIZE to switch between 50 100 and 200 When done select EXIT When exiting the Factory Menu you will be prompted to save any settings changes you may have made FACTORY SETTINGS DO YOU WISH TO SAVE THESE NEW SETTING
20. Defrost b Manual Defrost c Printing Control Data c 1 Cycle Batch Data c 2 12 Hr Data Log d SERVICE MENU ACCESS d 1 Introduction d 2 Access Service Menu 75 d 3 Access Service Menu Push Button f SERVICE MENU NAVIGATION f 1 Refrigeration Test REFR AIR f 2 Probe amp Alarm Test PROBES ALARM f 3 Printer s Test PRINTER f 4 Defrost Test DEF COIL f 5 Evaporator Fan Test FAN f 6 Display LED Test DISPLAY g DIAGNOSTICS MENU 9 1 Accessing the Diagnostics Menu g 2 Using the Diagnostics Menu h FACTORY MENU ACCESS h 1 Introduction h 2 Accessing the Factory Menu 85 h 3 Accessing the Factory Menu Push Button i NAVIGATING THE FACTORY MENU i 1Reset and Serial Number Entry i 2 Printer Selection i 3 Refrigeration Settings i 4 Defrost Settings i 5 Security Code Entry i 6 Machine Size Selection A 1 o 1 N 1 v o o N N Q N N ND N N NN N OC Vi Vil Vill IX XI XII XIII XIV XV j ERROR CODES j 1 Current Probe is Bad j 2 Chill Time Exceeded j 3 Defrost Sensor Failure j 4 No Product Probes j 5 Over Temperature j 6 Product Detected j 7 Air Temp Sensor Not Reading j 8 Record Printer Media j 9 Label Printer Media CONTROL COMPONENTS a COMPONENT IDENTIFICATION amp OPERATION a 1 Control Relay Box a 2 Relay Board a 3 Power Supply a 4
21. LING Maintenance Compressor Blast Compressor Energized anytime there is a call for cooling RBC100 models maintenance also controls cond fan motors Energized by a call for cooling during a Chill Cycle or in Holding mode RBC200 models every other cycle during the Idle mode RELAYS AND COLOR CODE Maintenance Compressor Relay CRI Coil Wire Yellow N O Terminal Yellow Blast Compressor Relay CR2 Coil Wire Orange N O Terminal Orange Defrost Relay CR3 Coil Wire White Purple N O Terminal Purple Blue on RBC200 Relay RBC200 only Coil Wire Grey 200 only Terminal Purple RBC200 only Low Fan Relay relay board Coil Wire N O Terminal Black TB4 High Fan Relay K2 on relay board Coil Wire N A N O Terminal Black TB4 NOTE Low fan speed is unused Both fan relays feed TB4 high speed What is 12hr Data Log Smart Chill control records its operation mode and sensor information every five minutes and stores this data in memory This data can be retrieved at any time for analysis Send data logs to Shaun Bishop via Fax 817 740 6757 or Email sbishop traulsen com for analysis How to Print Data Log START PRESS PRESS PRESS SELECT PRESS MAIN MENU MORE PRINT PRINT CYCLE START TIME FOR 12 DATA LOG PRINT Maintenance HI Ambient 30 covert to pressure LOW 25 40 PSIG SUPERHEAT 7 Blast Ambient 30 covert to pressure LOW
22. PRINTER MEDIA ERROR occurs anytime the Record Printer fails to print i 9 Label Printer Media Error p PRINTER ERROR LABEL PRINTER ERROR CHECK PRINTER MEDIA EXIT v LABEL PRINTER MEDIA ERROR occurs anytime the Record Printer fails to print V CONTROL COMPONENTS V a COMPONENT IDENTIFICATION amp OPERATION CONT a 1 Controls Relay Box Controls Relay Box Operation e House all control components except Smart Chill Control 13 Ledger Toggle Switch ON OFF Control Voltage Only RS232 Communication Port Relay Board DC Power Supply Terminal Board 4 0 mF Run Capacitors For Blowers 1CR Maintenance Compressor Relay 2CR Blast Compressor Relay 3CR Maintenance Defrost Relay 5 ojo 4CR Blast Defrost Relay RBC200 Only V CONTROL COMPONENTS V a COMPONENT IDENTIFICATION amp OPERATION Ledger CONT 1 14VDC input a 2 Relay Board 2 115vac Triac Outputs to Control Relays Relay Board Operation 3 High Fan Relay e Conditions and distributes DC power for the 4 Low Fan Relay DC control components 5 12VDC Triac gate signal from Smart Chill Receives DC signals from Smart Chill control 6 LED indicators amp Jumper and actuates Triacs to energize control relay 7 Pins DC power distribution to controls coils 8 Voltage test points LED indicators on board indicate which Triac is energized e Jump
23. S NO YES Select YES to save changes or NO to omit any changes made IV ERROR CODES j 1 Current Probe is Bad SYSTEM CONTROL ERROR CURRENT PROBE 15 BAD CHECK FOOD PROBES PLUGGED IN In the event a Food Probe error open or short during BY TEMP or EZ START cycle the control automatically switches to a BY TIME cycle The timer will begin to countdown from 90 minutes at which time the cycle will be complete A failure of one probe will force the entire batch into a BY TIME cycle and all recorded cycle data will be lost for that batch j 2 Chill Time Exceeded SYSTEM CONTROL ERROR CHILL TIME EXCEEDED CONTACT SERVICE EXIT In the event maximum chill time of 6hrs is exceeded the control switches to the holding mode Maximum allowable chill time to ensure safe product chilling according to HACCP standards is 6hrs j 3 Defrost Sensor Failure f gt SYSTEM CONTROL ERROR DEFROST FAILURE CONTACT SERVICE 2 Continued on next page SMART CHILL CONTROL IV j ERROR CODES CONT Defrost Sensor Failure occurs whenever a coil sensors fails open or short during a defrost cycle or if one or both coil sensors do not reach the 50F termination temperature before defrost times out j 4 No Product Probes f SYSTEM CONTROL ERROR NO PRODUCT PROBES CHECK FOOD PROBES USE BY TIME EXIT No Product Pro
24. Smart Chill Control Mother Board a 5 Control Relay Box RBC50 2008 Current a 6 Relay Board RBC50 2008 Current SERVICE PROCEDURES RBC50 a Indentify 2008 Current vs Pre 2008 b Sensors amp Probes b 1 Air amp Coil Sensor Locations RBC50 pre 2008 b 2 Air amp Coil Sensor Locations RBC50 2008 Current b 3 Sensor amp Probe Troubleshooting c RBC50 Power Pack Removal Pre 2008 d RBC50 Evaporator Access Pre 2008 RBC50 Evaporator Access 2008 Current SERVICE PROCEDURES RBC100 a Sensors amp Probes a 1 Air amp Coil Sensor Locations RBC100 a 2 Sensor amp Probe Troubleshooting b Access Evaporator Refrig Sys b 1 RBC100 Exploded View b 2 Accessing the Evaporator Sensors b 3 Access the Evaporator Defrost Heater amp Thermal Fuse b 4 Remove Refrigeration System SERVICE PROCEDURES RBC200 a Sensors amp Probes a 1 Air amp Coil Sensor Locations RBC200 a 2 Sensor amp Probe Troubleshooting b RBC200 Evaporator Access WIRE DIAGRAM RBC50 2008 CURRENT WIRE DIAGRAM RBC50 2003 2007 WIRE DIAGRAM RBC100 WIRE DIAGRAM RBC200 TROUBLESHOOTING QUICK REFERENCE GUIDE DATA LOG DIAGNOSTICS 11 11 11 11 12 12 12 12 12 12 12 13 13 13 14 15 16 17 18 19 19 19 19 19 19 19 20 20 20 20 20 20 20 20 20 20 21 21 21 21 21 21 22 23 24 25 26 30 31 32 GENERAL INFORMATION Il APPLICABLE MODELS This manual applies to the following Traulsen models RBC50 Undercou
25. Traulsen Refrigeration Instructions For The Installation Troubleshooting And Repair Of Traulsen Smartchill Equipped Blast Chiller Models 50 Ib Capacity Undercounter Models 100 Ib Capacity Reach In Models 200 Ib Capacity Roll In amp Roll Thru Models NOTICE This Manual is prepared for the use of trained Authorized Traulsen Service Agents and should not be used by those not properly qualified This manual is not intended to be all encompassing but is written to supplement the formal training on the job experience and other product knowledge acquired by Authorized Traulsen Service Agents Before proceeding with any work you should read in its entirety the repair procedure you wish to perform to determine if you have the necessary tools instruments and skills required to perform the procedure Procedures for which you do not have the necessary tools instruments and skills should be performed only by a trained Authorized Traulsen Service Agent Reproduction or other use of this Manual without the express written consent of Traulsen is prohibited TABLE OF CONTENTS TABLE OF CONTENTS GENERAL INFORMATION a Applicable Models b Introduction c Operation d Cleaning e Wiring Diagrams f Tool Requirements g The Serial Tag SPECIFICATIONS a Equipment Specifications b Operating Data c Installation SMART CHILL CONTROL a Sequence of Operation a 1 Control Revision Numbers a 2 System Idle a 3 Chill Cycle a 4 Holding a 5
26. a the control touch pad reference the following instructions 1 From the MAIN MENU select MORE MAIN MENU AIR 35 F 4 TEMP BY PRODP gt 4BY TIME 08 05 01 Continued on next page IV SMART CHILL CONTROL IV d SERVICE MENU ACCESS CONT 2 Select SET UP MAIN MENU HOLD PROD 4DEFROST lt BACK 08 06 01 PRINT 2 N 3 Change the PASSWORD PIN to 75 using the up or down arrow adjacent to PASSWORD PIN SELECT SUPERVISOR PRESET SUPERVISOR PASSWORD PIN 75 4CANCEL ENTERP Note PRESET SUPERVISOR must be selected 4 Press and release the TOP LEFT TOP RIGHT and BOTTOM RIGHT buttons all three simultaneously SELECT SUPERVISOR SUPERVISOR PASSWORD PIN 75 lt CANCEL SmartChill 5 The display will advance to the LAST DATE OF SERVICE screen From this screen you can update the service date by selecting UPDATE set the internal clock by selecting SET CLOCK see owner s manual for set clock instructions or Select NEXT to advance to the SERVICE MENU LAST DATE OF SERVICE UPDATE 4 SET CLOCK NEXT 6 You should now have access to the SERVICE MENU See section IV f Service Menu Navigation for more information on the Service Menu 4 SERVICE MENU EXIT 4 REFR AIR DEF COIL
27. bes occurs when a TEMP or EZ START cycle is selected but no probes are connected The unit will return to idle 1 5 Over Temperature SYSTEM CONTROL ERROR OVER TEMPERATURE CONTACT SERVICE TURN OFF UNPLUG UNIT M In the event the cabinet air temperature reaches 160F for 10 minutes or more the control will shut down all relays and lock out until power to the unit is cycled This is to guard against possible damage caused by a complete refrigeration failure j 6 Product Detected PRODUCT DETECTED STARTING HOLD MODE CHECK FOOD PROBES Product Detected occurs when food probe rises 40 above cabinet temp for more than 10 minutes indicating someone has introduced hot product into the chill but failed forgot to start a chill cycle The unit automatically switches to a refrigeration holding mode 1 7 Air Temp Sensor Not Reading AIR TEMP SENSOR NOT READING CONTACT SERVICE TURN OFF UNPLUG UNIT In the event the cabinet air temperature sensor opens or shorts the control will trigger the AIR TEMP SENSOR alarm shut down all relays and lock out until 12 IV ERROR CODES CONT the power the unit is cycled The defective sensor must be repaired or the alarm will reoccur on power up i 8 Record Printer Media Error PRINTER ERROR RECORD PRINTER ERROR CHECK PRINTER MEDIA N RECORD
28. d Pin 75 Press Top Left Top Right Bottom Right Password Pin 85 Press Top Left Top Right Bottom Right ERROR CODES Current Food Probe is Bad Food Probe open or shorted during chill cycle Food probes amp connections Chill Time Exceeded Maximum 6hr chill time exceeded 77755 v sys funcion EEEE Y Product type amp capacity Defrost Sensor Failure A Coil Sensor is open or shorted OR defrost did not reach 50F Defrost function E C No Product Probes All product probes open or shorted Food probes and connections Over Temperature Ait temp has been above 160F for ten minutes or more no Refrig Sys function feftigeration 1 Air sensor value Product Detected Triggered by a 40F difference between air temp and probe temp Food probes Air sensor values for 10 minutes v Operator is using equipment properly did not start cycle when Hec Air Temp Sensor Ait Sensor open or shorted Air Sensor and connections Printer Error Printer did not print properly Printer function see printer service manual Idle Main Menu Air Temp 40F 37F Blast Chill or EZ Start Temp 10F Product Target Temp 37F p 8 p Defrost Every 3hrs 50F termination temp Will not initiate a defrost during a chill cycle Holding Once a Chill Cycle completes unit automatically goes to holding mode 40 37F COMPRESSOR CYC
29. data log is a useful tool when troubleshooting intermittent errors or when all other avenues have been exhausted You may analyze the data yourself using the reference on page 33 Data Log Diagnostics Explanation or you may contact Traulsen Technical Support and we will analyze it for you Ph 800 825 8220 Fax 817 740 6737 To print a data log follow the instructions below 1 From the MAIN MENU select MORE MAIN MENU AIR 35 F 4BY TEMP BY PROD 4BY TIME 08 05 01 MORE P 2 Select Print MAIN MENU 08 06 01 4HOLD PROD 4DEFROST SETUP BACK IV c PRINTING CONTROL DATA CONT 3 Select PRINT CYCLE will change to PRINT DATA 4 03 08 40 gt 4PRB 1 RECORD MAIN MENU PRINT P 4 Select appropriate date and time to begin the 12 Hr log PRINT DATA 4 30 08 00 12 HOUR LOG b MENU PRINT b 5 Select PRINT a 12 Hr log should begin to print via the record printer PRINT DATA lt 4 03 08 00 gt 12 HOUR LOG b marn MENU 3 IV d SERVICE MENU ACCESS d 1 Introduction The service menu can be used to assist in troubleshooting a Blast Chiller There are two ways to access the service menu see d 2 amp d 3 Once the service menu has been accessed all relay outputs should de energize A technician may then cycle components individually for troubleshooting purposes gt 4 2 Access Service Menu 75 To access the Service Menu vi
30. e Service Menu IV f SERVICE MENU NAVIGATION f 1 Refrigeration Test REFR AIR Select REFR AIR from the SERVICE MENU to access the refrigeration test menu SERVICE EXITD PENT DEF COIL p PROBES ALARM 4 PRINTER DISPLAY IV SMART CHILL CONTROL IV f SERVICE MENU NAVIGATION CONT Pressing the button next SOLENOID will cycle refrigeration in the following order starting from the OFF position REFRIGERATION TEST 4 SOLENOID OFF CABINET TEMP 37F BACK gt Press Once Maintenance compressor only Press Twice Maintenance compressor and Low Fan NOTE Low Fan relay energizes High Speed on Blower s Press Three Times Maintenance compressor Blast Compressor and High Fan Press Four Times Return to all OFF Select BACK to return to the SERVICE MENU and you may select EXIT from the SERVICE MENU to return to the MAIN MENU Selecting COMP USAGE will advance the display to the CLEANED CONDENSER COIL screen REFRIGERATION TEST SOLENOID OFF CABINET TEMP 37F 4 COMP USAGE BACK CLEAN CONDENSER COIL 24 DAYS amp 20 HRS SINCE LAST CLEANING 4 CLEANED BACK S 7 The CLEAN CONDENSER screen gives value in hours and minutes of the maintenance compressors run time This can be reset to 0 by
31. een reset manually V1 08 or earlier Check Food Probes Air temp has exceeded 70F for 10 minutes An assumption has been made that product is in the box turn on holding cycle Check the Maintenance compressor for proper cycling on and off This may be caused by the contacts on the relay sticking closed Check to see if the customer did not clear all of the probes upon completion and then starting next batch This will result in the unit not being allowed to go into a defrost cycle until the coils ice up Go thru the steps to remove all products and allow the unit to go into a defrost cycle Should the Maintenance Compressor not shut off look on top of unit to see if the contacts might be stuck closed If the relay is functioning correctly you will need to go to the evaporator and check the two coil sensors They should not be reading high temperature as this will result in the compressor running excessively long and freezing the evaporator up The refrigeration system could be causing the coil to ice up if not functioning correctly 27 TROUBLE SHOOTING Continued CONDITIONS CORROSION OCCURING ON CONTROL BOARD UNIT TRIPS A GROUND FAULT BREAKER RBC200 NOT HOLDING TEMP IN IDLE MODE 50 FOOD PROBE HARNESS 50 SMART CHILL CONTROL 1 2 1 POSSIBLE SOLUTIONS Use a Food Grade Silicone and with all power off to the unit spread a light coating of the silicone on all exposed c
32. emote condensing 9 3 per unit 13 3 REFRIGERATION SYSTEM INSTALLATION All Traulsen blast chillers with the exception of model 50 require the use of a floor drain or floor mounted condensate evaporator for condensate removal Refer to Section Ill h of the blast chill owner s manual for more information Remote refrigeration installation requirements apply only to models RBC200 and RBC200RT A remote con densing unit operating on R 404A refrigerant is re quired for Blast Chill operation on these models The remote condensing unit s should be capable of pro viding 18 700 BTU hr 10 F suction and 90 ambi ent at the evaporator coils of the Blast Chill section 4 HP air cooled and 3 HP water cooled remote con densing units are available from Traulsen as an op tional accessory but please note that these are rated for use only within a 25 foot radius of the cabinet 15 2 15 2 REF N SYSTEM INSTALLATION CONT Actual capacity of the remote condensing unit and line sizing will depend on the length and layout of the con necting piping from the remote condensing unit to the Blast Chill unit These utilize a 1 2 liquid and 1 1 8 suction lines Proper line sizing should be defined by a qualified refrigeration engineer or technician The low pressure cut out of the remote condensing unit should be adjusted to obtain an evaporator coil temperature NO LOWER THAN 150F If the lengt
33. er Pins adjacent to LED indicators to manually operate Triacs 14 V CONTROL COMPONENTS V a COMPONENT IDENTIFICATION amp OPERATION Ledger CONT 115vac input a 3 DC Power Supply 14 15VDC output RA Q N DC Power Supply Operation Output adjustment pot 115vac input primary 4amp 250vac glass fuse 14 15VDC output secondary 15 V COMPONENT IDENTIFICATION amp OPERATION CONT V CONTROL COMPONENTS a 4 Smart Chill Control Mother Board Mother Board Operation Performs all control logic Send Receives information to from printers Receives input from Food Probes and Air and Coil Sensors Send Receives information from Smart Chill touch pad and display Sends 12VDC signal to activate Triacs on Relay Board Push button override to Service and Factory Menus C a3 2 3 OO a 5 16 Ledger 1 Display Power 2 Ribbon Cable to Touch Pad 3 Expansion Port For Optional NAFEM Daughter Board 4 Factory Menu Push Button 5 Service Menu Push Button 6 Program Port Unused in Field 7 Real Time Clock Battery 8 Food Probe Inputs 9 System Sensor Inputs 10 5VDC amp 12VDC Control Power Input 11 12VDC Control Outputs 12 RS232 Communication Port 13 8 5VDC Printer Power Input 14 Label Printer Power Port PTR
34. ers to be toggled on or off To turn a printer on or off select button to the left or right of the printer you wish to edit YES to activate printer NO to deactivate printer RECORD PRINTER YES VLABELPRINTER NO BACK NEXT Press NEXT to advance to the Refrigeration Settings Screen or BACK to return to the previous screen i 3 Refrigeration Settings The Refrigeration Settings Screen allows you to adjust the following settings Blast or chilling temperature differential e Holding or maintenance temperature differential e Compressor Anti Short cycle To adjust any of these settings use the up or down arrows next to the appropriate parameter v BLASTING DIFF 4 F v HOLDING DIFF 3 Y ANTI SHORT 1 1 Press NEXT to advance to the Defrost Settings Screen or BACK to return to the previous screen SMART CHILL CONTROL IV i NAVIGATING THE FACTORY MENU CONT i 4 Defrost Settings The Defrost Settings Screen allows you to adjust the following settings e Defrost Duration minutes e Defrost Termination Temp degrees F e Defrost Frequency hours To adjust any of these settings use the up or down arrows next to the appropriate parameter y DEFROST TIME 40 v DEFR TEMP 50 y DEFR INTVL 3 4 BACK NEXT gt Press NEXT to advance to the Security Code Entry Screen or BA
35. est print for the printer selected The test print will include a system diagnostic as shown below SOFTWARE VERSION 2 11 RUN CYCLES 5 CYCLES SINCE DEF 5 CYCLES MAXIMUM AIR 78F MINIMUM AIR FAILURES PRINTER YES PROBE NO INTERRUPTED NO CONTROL NO OVER TEMP NO SYSTEM FAIL NO DEFR HEAT YES FLASH MEM NO Continued on next page IV SMART CHILL CONTROL IV f SERVICE MENU NAVIGATION CONT Upon completion on a successful print the control will display SUCCESS or ERROR if the print is unsuccessful PRINTER TEST 4 RECORD SUCCESS 4 LABEL ERROR BACK Select BACK to return to the SERVICE MENU f 4 Defrost Test DEF COIL Select DEF COIL from SERVICE MENU to access the defrost test menu SERVICE EXITD 4 REFR AIR 4 PROBES ALARM FAN b PRINTER DISPLAY b DEFROST TEST HEATER OFF BLAST 37F MAINT 32F BACK 7 Pressing the button next HEATER OFF will cycle the defrost heaters in following order starting from the OFF position DEFROST TEST 4 HEATER OFF BLAST 37F MAINT 32F BACK b Press Once Blast Coil Heaters Press Twice Maintenance Coil Heaters Press Three Times Both Coil Heaters Press Four Times Return to all Off Note RBC50 will only cycle BOTH due to hot gas defrost vs electric on RBC100 amp RBC200 The defrost test menu will also
36. g 294 number is the Evaporator temperature 371974 381988 43199 421950 4119 4 Last four digits are the address of the data memory This may be removed at a future date Product probe information 1 digit letter for probe status Idle or not in use Selected Chilling soft chilling or freezing Done reached target temp or time expired Removed 294 digit 0 4 minutes of offset for start time 3 4 digit probe temperature 32
37. h of the connecting piping is 40 feet or less the condens ing unit low pressure cut out settings will be approxi mately 15 2 PSIG cut out and 25 3 PSIG cut in For more information please contact the factory 800 825 8220 IV SMART CHILL CONTROL IV a SEQUENCE OF OPERATION a 1 Control Revision Numbers There are multiple versions of the Smart Chill Control V1 08 V2 11 Largely troubleshooting on all versions will be the same a 2 System Idle The Smart Chill control is meant to maintain a median operating temperature of 37F 40F when in idle no active batches During this time only the Maintenance or holding system is active with the exception of the RBC200 which runs the Blast system ever other cycle Anytime the display shows to be at the Main Menu the system is in idle a 3 Chill Cycle When a standard chill cycle or batch is started the unit will maintain a median temperature of 10F 14F until all product is chilled to 37F if using food probes or until preset time is complete During this time both the Maintenance and Blast systems will be active a 4 Holding Once all product reach 37F or below or the preset time is completed the unit will begin what is called a Holding mode During Holding the unit will again maintain 37F 40F but both systems continue to operate because of the known product load Once the operator removes the product and acknowledges the
38. isk broom Care must be taken not to damage the condenser coil fins For more information please refer to section IV a IV c of the Blast Chill Owner s Manual ll e WIRING DIAGRAMS Refer to the wiring diagrams on pages 20 thru 22 for any service work performed on the unit Should you require another copy please contact Traulsen Service at 800 825 8220 and provide the model and serial number of the unit involved ll f TOOL REQUIREMENTS For most jobs a standard set of hand tools a VOM with AC current tester electrically conductive field service grounding kit along with a temperature tester or thermometer are adequate However in some cases the following additional tools may be required as well II f TOO L REQUIREMENTS CONT Refrigeration Reclaiming Equipment Acetylene Torch Nitrogen Bottle With Gauges Refrigeration Gauge Manifold Dial a Charge Valve Core Removal Kit Vacuum Pump g THE SERIAL TAG The serial tag is a permanently affixed sticker on which is recorded vital electrical and refrigeration data about your Traulsen product as well as the model and serial number This tag is located at the front top corner on the right interior wall on all blast ch iller models An example is shown below SERIAL VOLTS TOTAL CUR MINIMUM CI FORT WORTH TX RENT RCUIT AMPS AMPS MAXIMUM OVER CURRENT PROTECTION LIGHTS HEATERS REFRIGERA DESIGN PRESSURE REFRIGERA DESIGN
39. lid and useful When selecting FAILURE press the bottom left button to scroll though all error codes If none is displayed then no error codes have been recorded since last cleared To return to the SERVICE MENU select DIAGNO STIC IV f DIAGNOSTIC MENU CONT DIAGNOSTIC NARI gt RUN CYCLES MINIMUMp SINCE DEF FAILURE 24 CYCLES CLEARDP SY SERVICEMENU EXITD REFR AIR DEF COIL PROBES ALARM FAN gt PRINTER DISPLAY b Select EXIT to return to the MAIN MENU IV h FACTORY MENU ACCESS h 1 Introduction The Factory Menu is used to set up basic equipment parameters such as printer function temperature differentials defrosts schedule machine size and machine serial number There are two ways to access the Factory Menu see h 2 amp h 3 Once the service menu has been accessed all relay outputs should de energize h 2 Access the Factory Menu 85 To access the Fervice Menu via the control touch pad reference the following instructions 1 From the MAIN MENU select MORE MENU AIR 35 F 4BY TEMP BY PRODR 4BY TIME 08 05 01 EO 2 Select SET UP MAIN MENU 08 06 01 4HOLD PROD PRINTP DEFROST SETUPP BACK 3 Change the PASSWORD to 85 using the up or down arrow adjacent to PASSWORD PIN SELECT SUPERVISOR PRESET SUPERVISOR
40. louver panel assembly 3 2 Remove the evaporator housing cover 4 3 Access defrost heater thermal fuse 4 Reinstall in reverse order lt 4 5 S S Vil SERVICE PROCEDURES RBC100 ACCESS EVAPORATOR REFRIG SYS CONT b 4 Remove Refrigeration System ky A WARNING Disconnect the y electrical power to the machine and 3 follow lockout tagout procedures There may be multiple circuits Be sure all circuits are disconnected E NOTE See b 1 RBC100 Exploded View for Reference 1 2 3 4 a 1 Air 1 Remove the right side shelving and air duct 1 Remove the blower assembly 2 Remove all sensors from evaporator coil Remove 2 phillips head screws from the rear evaporator flange that secure the evaporator to the cabinet frame Remove the louver panel assembly 3 Remove the evaporator housing cover 4 ACCESS EVAPORATOR REFRIG SYS CONT 12 13 Remove defrost heater Remove 2 phillips head screws from the front evaporator flange that secure the evaporator to the cabinet frame Remove rear condenser access panel Disconnect wiring to condensing unit Remove two 72 bolts one in front one in back securing the condenser skid in place Remove refrigeration system being sure to support the evaporator coil Reinstall in reverse order Vill SERVICE PROCEDURES RBC200 SENSORS AND PROBES amp Coil Sens
41. nor Maintenance coil CHILL TIME HAS sensor and Blast Chill coil sensor EXCEEDED 6 HOURS Check the refrigeration systems for proper operation The lack of either refrigeration system will cause the chill time to run longer Check the blower motors for proper operation Observe the Blower Motor housing amp blower wheels for any deformation Check the operation of the unit If the control was in a By Temp or By Time mode for more than six hours the unit will shut down and the only way to make it come back on is to turn off the power and then restart the unit SYSTEM CONTROL ERROR Both Defrost Sensors did not achieve defrost termination DEFROST SENSOR FAILURE temperature 50 Go to program 75 until you reach the Def coil button Press this button and observe the temperature of both sensors If one or both read strange or open circuit the bad sensor should be changed out Check the Thermal fuse located near the evaporator coil If it is open the heater will not come on to raise the temperature past the termination point Go to program 85 see manual amp scroll thru until you see the defrost time The length of defrost should be set to 40 min 26 TROUBLE SHOOTING Continued CONDITIONS SYSTEM CONTROL ERROR DEFROST SENSOR FAILURE Continued SYSTEM CONTROL ERROR CURRENT PROBE IS BAD SYSTEM CONTROL ERROR NO PRODUCT PROBES CHECK THE FOOD PROBES CONTROL IS STUCK IN THE FIRST SCREEN MENU 7
42. nter Blast Chiller Models RBC100 Reach In Blast Chiller Models RBC200 Roll In Blast Chiller Models RBC200RT Roll Thru Blast Chiller Models PLEASE NOTE This manual refers to the above mod els built after June 2003 equipped with the Smart Chill control For information regarding models built prior to that date please contact the factory In addition models UBC50 RBC400 and RBC400RT are not covered by the procedures listed in this manual Please contact the factory for more information Il b INTRODUCTION Blast Chillers are food processing refrigerators de signed for rapid chilling of product from 135 F to 37 F in approximately 90 minutes for reheating and or serving at a later time These models aid in preserving food quality texture and nutritional value in addition to enhancing food safety All of the information illustrations specifications contained within this manual are based on the latest product information available at the time of printing c OPERATION Refer to the instructions contained in the Owner s Manual form number TR35850 for specific operating instructions Il d CLEANING Detailed cleaning instructions are included with each unit however special care MUST be given to the condenser coil s These must be cleaned WEEKLY This surface must be kept free of dirt and grease for proper system operation This can be done with a vacuum cleaner using a brush attachment or a stiff brush or wh
43. onnections Look for high humid conditions Go to the relay box and with the power off to the unit pull all of the wires off of terminal 1 and reinstall them one at a time Once you force the breaker to trip this will tell you which component has failed The temperature must be equal from top to bottom in cabinet The remote condenser will come on every other cycle on Control Versions 1 12 and later Should the Food Probes fail to read any temperature you will need to check them for breaks in the wires or separation of the insulation Look at the Sockets in the ceiling of the box were the Food Probes plug into for any broken pieces Pull the Socket Plate down to inspect the top of the sockets for broken wires or corrosion Should the Harness be bad it will have to be replaced To replace the Harness you will have to replace to complete top due to the harness being foamed into the top at the time of manufacture You will have to pull the Control Panel and disconnect the Food Probe Harness in the back ductwork Remove the Stainless Steel Work top Remove the top that contains the Food Probe Harness and install the new one in its place Reinstall all of the parts to normal working positions the 50 it has been found that the Defrost Time setting can possibly be set to 40 min Should this be true of the unit you are working on you will need to go into program 85 and navigate thru the settings to press the Reset
44. or Locations RBC200 Air Sensor Green Mounted on the return side of the maintenance evaporator coil Maintenance Coil Sensor Blue Located towards the top of the maintenance evaporator coil Blast Coil Sensor Yellow Located towards the top of the second blast evaporator coil a 2 Sensor and Probe Troubleshooting All probes and sensors should return an Ohm reading of 32 7K Ohms at 32F or OC Test by placing the sensor or probe tip in ice with a little bit of water and checking Ohm reading with an Ohm meter 35 2 K lt 2 VIII b 1 RBC200 EVAPORATOR ACCESS Remove right side air screen 21 Vill a SENSORS AND PROBES CONT CAB SENSOR 1 MAINT COIL SENSOR 2 BLAST COIL SENSOR 3 IX WIRE DIAGRAMS RBC50 2008 CURRENT CABINET AIR DISPLAY COIL 1 COIL 2 IDISPLAY IMULTICONDUCTORS BLACK POWER gue BLOWER PURPLE DEFROST RELAY SOLENOID VALVE PURPLE 2 3 E gt COND FAN MOTORS COMPRESSOR RELAY POTENTIAL START RELAY COMP YELLOW START CAP COMPRESSOR ORANGE PERIMETER HEAT ORANGE SPARE PERIMETER HEATER NEAN 72400 22 X WIRE DIAGRAM RBC50 2003 2007 No WARNING Lic ELECTRICAL AND GRUUNDING CONNECTIONS MACHINE MUST COMPLY WITH THE APPLICAILE GND PORTIONS OF THE NATIONAL ELECTRICAL JL RENAN CODE AND OR OTHER LOCAL ELECTRICAL Lic CONDENSATE HTR MACHINE
45. selecting CLEANED COIL Select BACK to return to the REFRIGERATION TEST menu f 2 Probe Alarm Test PROBES ALARM Select PROBES ALARMS from the SERVICE MENU to access the product probe and audible alarm test menu SERVICE MENU EXIT REFR AIR DEF COIL p FAN 4 DISPLAY IV f SERVICE MENU NAVIGATION CONT PRODUCT PROBE TEMPS 145F 44F 3 244F ALARM OFF BACK Product probes 1 2 amp 3 will be displayed in real time If a probe is shorted will be displayed next to the probe number If a product probe is open or dis connected nothing will be displayed next to the probe number PRODUCT PROBE TEMPS 1 Seed 244F 4 ALARM OFF BACK gt Pressing the button next to ALARM OFF will activate the audible alarm test Pressing the button next to ALARM ON will deactivate the audible alarm test Select BACK to return to the SERVICE MENU f 3 Printer s Test PRINTER Select PRINTER from the SERVICE MENU to access the printer s test menu SERVICE EXITD 4 REFR AIR DEF COIL p PROBES ALARM FAN b DISPLAY b N 7 PRINTER TEST 4 RECORD READY lt LABEL READY BACK b Note If no Label printer present LABEL READY will not be displayed Pressing the button next to RECORD READY or LABEL READY will run a t
46. ted in the evaporator housing in the electrical power to the machine and return air stream 73 follow lockout tagout procedures lt There may be multiple circuits Be Maintenance Coil Sensor Blue SS Located in the top center of the evaporator i sure all circuits are disconnected coil Blast Coil Sensor Blue 1 Remove louver assembly Located in the top center of the evaporator 2 Disconnect power and mullion heater plugs from chassis bottom right 3 Remove 4 Phillips head screws securing the power pack to the cabinet frame 4 Remove tray slides from interior wall of unit 5 Remove return air grill located at the bottom of interior and interior supply plenum located at top back of interior 6 Remove return and supply air duct 7 Disconnect all wiring between the power pack assembly and the control tower 8 Pull power pack out from the front 9 Reinstall in reverse order coil 19 SERVICE PROCEDURES RBC50 VI d RBC50 EVAPORATOR ACCESS pre 2008 1 Locate access panel at rear of left or right power pack assembly 2 Remove access panel 3 Remove evaporator housing cover 4 Reinstall in reverse order RBC50 EVAPORATOR 55 2008 Current 1 Remove screws on the left and right side holding the stainless steel work top in place 2 Use knife to score seal around insulated top 3 Remove screws from top holding insulated top in place 4 Remove insulated top 5 Reinstall
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