ETL Blast chiller Service Manual
Contents
1. 39 3 4 3 How to replace cabinet evaporator or needle probe 40 3 4 4 How to replace evaporator motor fans 42 9 5 HOW LO REPLACE THE DOOR SWITG P 42 3 5 1 GBF15 11S smallest self contained unit 42 3 5 2 Units from GBC30SG to GBF171 132S 43 3 6 REPLACE THE PRESSURE SWITCH 43 3 7 HOW REPLACE THE DOOR FRAME HEATER 44 3 8 HOW REPLACE 45 3 9 HOW TO REPLACE THE KEY BOARD u u 46 4 5 VACUUM AND CHARGE PROCEDURE 4 1 INSTRUCTION FOR VACUUM AND CHARGE 4 1 1 Self contained units 4 1 2 Remote units eere 4 1 3 Vacuum and charge recommendations SCHEMES AND WIRING DIAGRAMS 5 1 SCHEME OF 5 5 2 WIRING DIAGRAM SINGLE PHASE UNITS SELF 5 3 WIRING DIAGRAM 3 PHASE UNITS HOT GAS DEFROST SELF CONTAINED 5 4 WIRING DIAGRAM 3 PHASE2. ELECTRICAL Boa x Md HHO TIH S VINO SES 53 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy HOW TO READ THE MODEL NUMBER This manual applies to all the models in the table below The models can be identified as follows 6 15 115 15 tS 6863056 30 NOFREEZNG 50 756 30 47 50 GBF4265G 4 S 75 30 47 SP GBFA4260P 44 SP 6835 39 NOFREZNG GB3924 39 4 25 O GBF52 378 52 37 8 85 6 64 6500 775 77 5 68 45 46 243 500 6 242 20908 22 209 S 608 98 NOFREZNG GBF amp 65 8 _ 66 S GBFi43 108 133 10 650 GBC2S 112 NOFREZING S 68512778 142 77 8 6 171 13258 141 142 8 GBFA4038R 440 38 GBF837727R 97 77 R Maximum amount of food pounds that can be chilled within 90 minutes Maximum amount of food pounds that be frozen within 270 minutes 5 SELF CONTAINED G GASTRONORM PZPASTRY R REMOTE UNIT 54 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy DATA CHART TABLE lt lt x lt gt Br 2 P 2 ci lt 9 gt 5 m amp a 0 Qo lt O O a lt 0 o o t x CE N Q u gt lt r E olo tc tc LL 7 A A
3. ELECTRICAL 111 eS SS ier zie 30011 5b 3 4315 c S E di 21514 frk MH MS SWITCH PORTA MAGNETICO MAGNETIC DOOR SWITCH VENTOLA EVAPORATORE EY APORATOR FAN TENTOLA CONDENS ATORE CONDENSER FAN MOTOR RP DOORFRAMEHEATER SOLENOID VALVE FU GS GENERAL POWER 10 83 51 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy PHASE units hot gas defrost self contained 5 3 Wiring diagram 3 Nid SNO TIIdS VCOHNOS E dd zad HOLM qHOLVSNSONOO 1 ZA HOLO NY THOIVHOdWVAS ddd Loodad vINOS HOLLMSHOOTOLLENOWED HOIDAS SWI AYTA TYGE LA dd TANT PTT FON WHO THAN 50 JASOA ATVACIONTIOS 4004 di Rev Date 2012 06 21 ELECTRICAL d EM 1 11144 56 Draft ETL Blast chiller Service Manual PHASE units no active defrost remote units 5 4 Wiring diagram 3 TOLOM NYA da Shadow 1 5 SOLVAY AT OLVACdTAd CIOLNZXA HOLMS O IL VILUOd HALIM S sil AVT YE JAMOA TRANS Ad warren amy ad wood dA
4. input active with contact closed 1 1 NC input active with contact open 9 min O microportinputalamdelay O Hev Date 2012 06 21 Blast chiller Service Manual Draft copy high pressure input contact type P40 1 10 NA input active with contact closed 1 1 NC input active with contact open high pressure input alarm delay low pressure input contact type P42 0 NA input active with contact closed 1 NC input active with contact open P43 min 0 lowpressure inputalarmdelay 0 compressor thermal protection input contact type 0 NA input active with contact closed 1 NC input active with contact open min 0 thermal protection input alarm delay 0 Ca a NN P46 min 5 UV light on duration duration of cabinet sterilisation 5 GROUP NEEDLE PROBE HEATING P47 needle probe heating end temperature with reference to the needle probe P48 5 15 maximum duration of needle probe heating 15 a n P49 41 the temperature below which the door elements switched on with reference to the cabinet probe P49 differential GROUP 5 J gt condenser fan activity in the absence of the P51 1 condenser probe P61 0 1 0 in parallel with compressor 1 the temperature below which the condenser fan 15 switched off in the presence of the condenser probe P61 1 and on condition th
5. 71 49 0 108 17912 087 22060 Hz 3Ph 9 1 R404A 71 331 174 71 490 1081179 12 08 220460 9 1 R404A 71 331 174 56 0 23 6 409 12 08 220V 60Hzi3Ph 19 3 R404A 71 206 CO NIN AE VERSION 208 220 60 Hz 1Ph ALSO AVAILABLE Un Un Hev Date 2012 06 21
6. Both shocking freezers and blast chiller units come with a frame heater to prevent frost on the gasket external border line The heater could be either 115V or 220V rated depending on the unit Three phase units come with a 220V rated heater to be connected among two mains Heater cable runs around the frame under a plastic strip cover Cable end terminals go through the bottom cabinet panel toward the electric box 18 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy Length 7 8 feets Resistance 1 4 Current 80 mAmps Length heated part 6 5 feets Resistance 2 4 kO Current 90 mAmps 2 5 MAIN BOARD Every unit has a main board to supply electrical components In the remote units this board is located in the condensing unit The board has 10 outputs 10 relays as shown in the scheme at the following page The relays work as indicated in the below reference table RELAIS RELATED COMPONENT PUMP DOWN VALVE EVAPORATOR FAN MOTOR CONTACTOR COIL DEFROST VALVE UV LAMP HEATED NEEDLE PROBE HEATED NEEDLE PROBE OL 7 Each load is continuously connected to L1 or neutral L2 is and off by the dedicated relay 2 5 1 Checking relay outputs When a component is not running it may be useful to understand if the related relay output is working properly The relays should cut in and off according to the logic sequences of the controller To check an outp
7. Start date amp hour Time cabinet and needle probe temperatures each capture line Type of cycle legend Tab 3 Time soft chilling P1 99 Programmed cycle 10 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 1 4 3 How to replace the paper roll a Push on the printer front panel the cover will open allowing the paper roll to be accessed Remove the printer roller by pulling it from one side Fit the new paper roll and place the paper between the rollers Reset roller and printer cover 11 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 2 TROUBLESHOOTING If from a first inspection there isn t any chance to fix the problem a deeper troubleshooting may be necessary The unit may need to be dismounted and some electrical mechanical parts to be checked 5 The blast chiller units are equipped with Negative Temperature Coefficient thermistor sensors briefly Room and evaporator probes have the same exterior structure needle probe has a different sensor element Both probes are anyway NTC type and have the same resistance Vs Temperature chart ROOM EVAPORATOR PROBE TYPE NTC PROBE BULB PROBE MEASURING NTC NEEDLE PROBE TYPES 12 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 2 1 1 Checking probes When a probe alarm occurs it means that something is wrong with the sensor reading
8. ES z 0 T Oo O 5 TT I J O O cc GBFI5 118 100 115V 60 Hz 1Ph 5 1 20 20 gt D O gt gt gt OD NJN RIR GBC3088 100 115v 60 Hz 1Ph 12 GBF30 178G 100 115V 60 H2 1Ph 12 0 R404 EX 2 N CO AJ K 2 JJ T ER CO CO CO CO CO CO CO CO 2 GBF44 268G 100 115V 60 Hz 1Ph 15 GBF30 17SP 100 115 60 Hz 1Ph 12 0 GBFA4 268P 100 115V 60 H2 1Ph 15 GBC39S 100 115V 60 Hz 1Ph 15 5 JJ T O gt CO N K E JJ T O gt N 4 JJ T ER gt AJ K 9 245 100 115V 60 Hz 1Ph 15 5 GBF52 375 208 220V 60 Hz 1Ph 10 5 R404A GBF61 4M4S 208 220V 60 H2 1Ph 11 0 R404A 490 10 8 17 312 08 220460 9 1 R404A 35 331 174 56 0 23 6 402112 08 220460 192 R404A 71 331 174 88 888 71 490 108 17912 087 220 60 23 91 R404A 71 331 174 GBF88 665 71 49 0 108 179 12 08 220V 60 Hz 3Ph 91 R404A 71 331 174 8 143 1108 172 56 0 236 40 9 12 087 220460 Hz 3Ph 193 04 71 331 174 88 1128
9. The parameter that needs to be configured is P71 set it at 1 to enable RS485 2 printer port Furthermore ensure that P76 1 P7522 and 74 2 An On Off LED shows the printer device status red 1 By pressing the Feed key is possible to output blank paper both during On or Off status 1 4 1 Printing alarm list To print the alarm list the controller must be in Off mode The beginning procedure is the same than checking the alarm list press the program key for 5 seconds J If the printer communication has been enabled the first label shown is Prt print the alarm list press again the program key Hl To exit from the printing label press up down keys the alarm list will be only shown on the displayed Maximum number of alarm filed is 10 Printed codes are as shown in the Tab 1 Alarm duration maximum minimum temperature date amp hour alarm number and alarm code are shown Hev Date 2012 06 21 Blast chiller Service Manual Draft copy 1 4 2 Printing cycle data Thanks to the HACCP printer of course is also possible to print the data history related to performed freezing chilling cycle If the printer is On and if a cycle is started printing of data starts automatically with the cycle The data capture frequency is specified by the parameter P72 print interval min e g if P72 is set to 1 the device will print each minute providing Type of cycle first line above date
10. reference to the cabinet probe 2 4 5 P6 P7 and P8 differential 2 set temperature chill end temperature with reference to the needle probe set temperature freeze end temperature with reference to the needle probe temperature at which the hard chill switches from the 46 first step to the second with reference to the needle 46 probe temperature above which it is not possible to start a set temperature operational cycle with reference to the needle probe needle probe and cabinet temperature gap for verification of correct needle probe insertion 0 the test will not be performed duration of the second test to check correct needle probe insertion see also P14 maximum set temperature chill duration also timed chill duration maximum set temperature freeze duration also 270 timed freeze duration 45 first hard timed chill step duration COMPRESSOR PROTECTIONS compressor delay from device power on from restoration of power minimum elapsed time period between two consecutive compressor start up operations minimum compressor shut down time DEFROSTING g 7 T Co N 7 10 11 12 13 14 15 5 16 3 17 18 19 min m P20 In P21 min GROUP Hev Date 2012 06 21 Blast chiller Service Manual Draft copy defrost type 0 electric defrost on relay P22 hot gas defrost compressor and relay on
11. with reference to the cabinet probe 0 no alarm NEN temperature below which the minimum temperature alarm is activated during post freezing storage with relation to P8 i e P8 P66 with reference to the cabinet probe 0 no alarm mr ESSO 62 P63 GROUP E 1 65 temperature above which the maximum temperature alarm is activated during post freezing storage with relation to P8 i e P8 P67 with reference to the 2 alarm enable printing t print interval HACCP alarm list deletion 1 YES P67 P tt P70 GROUP P71 P7 P73 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy Baudrate 0 2400 1 4800 2 9600 3 19200 Bit polarity O no polarity 1 2 odd 1 JjBoadaddes 1 1 3 3 Temperature probes displaying A quick mode to check directly the probe values is by provided by the controller During OFF mode keep pressed together for 5 seconds needle probe and down arrow keys Labels Pr1 Pr2 and Pr3 can be scrolled through up down keys Tab 2 LABEL RELATED PROBE cabinet probe needle probe evaporator probe A very useful information is provided by checking the evaporator probe especially when there are troubles in reaching the cabinet set point i e 40 T and the evaporator coil is supposed to be starved or short of gas When cabinet temperatur
12. 2 air evaporator fan on defrost end temperature with reference to the evaporator probe 10 maximum defrost duration defrost interval during storage see also P26 0 intermittent defrosting will never be activated only the first will be activated 24 ill mi P25 min I I 27 defrosting at start of chilling and freezing i P28 min 2 2 resetting of compressor protections at start of P29 defrosting only if P22 1 YES elapsed time between the defrost request and P30 switching on the compressor only if P22 1 and providing that the compressor is off when the defrost is requested see P31 7 8 also elapsed time between the defrost request and P31 activation of the solenoid valve only if P22 1 and on condition that the compressor is off when defrosting is requested see also P30 temperature above which the evaporator fan is P32 37 switched off during storage with reference to the 37 evaporator probe P33 2 2 evaporator fan activity during defrosting only if P22 P34 0 or 1 0 on 1 off 3 evaporator stop time after dripping temperature above which the evaporator fan is P35 in 3 poe i switched off with reference to the cabinet probe effect caused by activation of microport input on evaporator fan i 0 no effect 1 the evaporator fan will be switched off GROUP DIGITALINPU microport input contact type P38 1 10
13. Remote units have a separate condensing unit built in a dedicate case To access the condensing unit just unscrew the top metal cover and operate inside the box TOP COVER CONDENSING BOX 3 4 HOW TO ACCESS EVAPORATOR ASSY All the units self contained as well as remote are equipped with one evaporator assembly made by An evaporator coil battery One or more evaporator fans depending on the unit s size A TX valve in some case M O P A probe sensor positioned on the evaporator output defrost probe A hinged cover panel holding motor fans and finger guards A probe sensor placed on the hinged panel in the cabinet area regulation probe FOD O O O o 3 4 1 Evaporator assy description EVAPORATOR ASSY BIGGER UNITS ee PANEL 38 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy DEFROST LINE TX BULB EVAPORATOR FEEDING LINE EQUALIZATION CIRCUIT TX VALVE BULB EVAPORATOR CAPILLARY OUTPUT LIQUID LINE TX VALVE DEFROST PROBE CABLE DEFROST PROBE BULB 3 4 2 How to access to the evaporator Remove the screws which fix the hinged panel to the evaporator shoulders and open the panel Eventually lift the panel up and remove it 39 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 3 4 3 How to replace cabinet evaporator or needle probe a Cabinet probe is covered by a metal grid and is fitted in plastic tie Remove both t
14. UNITS NO ACTIVE DEFROST REMOTE UNITS HOW TO READ THE MODEL NUMBER DATA CHART TABLE Blast chiller Service Manual Draft copy 1 BASIC SERVICE INSTRUCTION The controller provides alarm and failure codes to shortly identify roots of problems and go investigating directly the concerned parts Furthermore a service submenu allows technicians to check rapidly all the sensors scrolling room needle evaporator temperatures 1 1 ALARM FAILURE LIST Tab 1 CODE Doesn t allow to run any cycle If a cycle is running it is forced to stop EVAPORATOR PROBE FAILURE During storage evaporator fans are Cut out Er3 NEEDLE PROBE FAILURE Doesn t allow to run a needle probe set temperature cycle If a needle probe cycle is running it is forced to Stop HP HIGH DISCHARGE PRESSURE Doesn t allow to run any cycle If a LOW SUCTION PRESSURE cycle 15 running compressor evaporator and condenser fans are Cut out d r IS OPEN FOR MORE THAN Compressor and condenser fan are cut out Evaporator fan are cut in out according to parameter P37 CONNECTION FAILURE Res POWER FAILURE DURING The cycle starts again as soon as RUNNING OF CYCLE power is restored The message Res blinks to indicate the cycle has been resumed Although the controller board is equipped with one additional dedicated input for low pressure switch pressure switch device installed in this
15. password will shown first The controller doesn t need actually any password to configure the parameters By pressing the up arrow key the parameter list can be accessed directly first parameter is PO Scroll the parameter by pressing Up down keys Select a parameter by pressing the time key Change the value by up down keys Press again time key to save and go back to the list 1 3 2 Parameter list factory setting The following table shows parameter factory settings for both Blast chiler units GBC and shock freezer GBF Note Selecting a freezing cycle on a GBC unit will anyway run a normal chilling cycle cabinet at 4f needle probe end cycle tempe rature at 37 F P fo unit of temperature measurement ER 0 F Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 4 cabinet probe offset 4 evaporator probe offset needle probe offset MAIN CONTROLLER operational setpoint during the second hard chill 0 Co PO GROUP U K ER step also operational setpoint during normal chilling with reference to the cabinet probe operational setpoint during freezing with reference to _ 4 the cabinet probe operational setpoint during the first hard chill step A with reference to the cabinet probe operational setpoint during post chill storage with reference to the cabinet probe operational setpoint during post freeze storage with
16. tap must be closed to prevent refrigerant loss Regarding low pressure side a simple self closing Schroeder connection 44 SAE is used 43 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 3 7 HOW TO REPLACE THE DOOR FRAME HEATER Frame heater might become interrupted or shorted Before replacing the heater make sure the problem is with the heater itself and it s not in another place for example missing supply Cable features above help in troubleshooting To replace the cable a Insert a slice in the edges by softly hammering on it Place the slice plump line with respect to the frame Lift the slice up and lever on the strip c Run the slice left and right to remove the strip for all the strips d Fit the new heater cable under all the strips follow the provided path Re fit the strips by pushing with hands 44 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy 3 8 HOW TO REPLACE THE RELAY BOARD Relay board is held by 6 plastic clips 4 at the corners and 2 in the middle Before removing the board disconnect the power supply and disconnect all the cables To remove the board squeeze the clips on the top and pull the board out To fit a new board re wire the cables according to the wiring diagram Ensure the correct parameter setting is on the memory 1 3 2 PLASTIC CLIPS 45 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 3 9 H
17. the compressor QUICK CONNECTIONS 4 1 3 Vacuum and charge recommendations Use vacuum pump at least 50 rated Pull the vacuum for 1 hour and at least Replace the filter drier whenever the circuit has been opened 49 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy H3 LS 9910555349 01515055949 6 of 28 015 2208 4146 Bb LN SOL Ode 7950 Po dt hana L AL OL 15 Lu TO ED Gy Pre AIO SA DE z 023018 IO STO Te TT SF ES STR AIO SA On p 7 721 8 esf 02 20118 IC 10 ST ST 105 YOLIN 00110110 4015 1012 8340 IU B OI O81113 D d3 13 2343 ONO adimi ases Z N A 18 495 TOES 27 LOS HSH3UH OJ 5390 DS KONO 5 SHO RYE Sp SLAY IN 94055554 quio 493204 gumuaasap Faas 695816 a parpas ouni m yutol qaa nd j FEJUOZUOY E3SE1 3JE U0ZZUID 010118 V 5 aac Ww ALPA o 8 77 58 2 92 Hev Date 2012 06 21 50 SCHEMES AND WIRING DIAGRAMS 5 Scheme of components 9 1 nep misi Blast chiller Service Manual Draft copy 5 2 Wiring diagram single phase units self contained
18. 1022 52 6093 64 21 2 3531 36 13 5698 1704 5 38 5828 59018 23 3376 345 3531 105 8 552 5 4691 572 248 3229 33 3373 1076 5354 5441_ 559 26 6 3089 3 6 524 1004 5173 5259 596 28 4 29526 3019 5089 11 2 4999 5094 5 77 30 2 2829 28 88 298 13 4832 14916 5 338 254 2648 269 7166 4517 4598 468 356 2485 2533 258 1184 4368 4 448 14529 _ 37 4 2381 2429 24 2 1202 4225 4 04 4 483 39 2 2282 234 2368 1722 24087 4465 443 41 2 8 17122277 2268 1238 3954 4031 4108 120 2 3505 3658 3 92 212 09247 09563 09886 6 131 3417 3543 366 2138 08998 0932 0966 1328 3362 3432 3504 215 6 08756 0909 09372 1346 5 256 3 225 3 396 136 4 3454 3222 3291 2192 08292 0 8584 1382 5 066 3423 3191 227 08071 108957 08653 1418 2869 294 3 2246 07647 10192 08207 1436 2781 2845 291 2254 07444 07715 0794 _ 0 7513 149 2 555 2 595 2657 2918 06872 07127 0730 1508 2459 2518 2578 232 6 06602 0 6943 07202 1526 2 205 2 43 2503 2354 06518 0 6764 1544 2313 2 371 2 429 2372 06349 0559 06889 7156 2 2245 2301 2358 239 06185 10649 06666 158 2178 2233 229 2408 06026 0828 0648 1598 2414 2468 2224 2426 05871 0809 0634 161 6 2052 2405 246 2444 05721 05945 0616 15 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 1995 1446 209 248 05435 0 566 058
19. 3 _ 1879 1429 1061 2498 05298 05509 0578 1778 1484 14117 2534 05097 0524 0541 7179 6 1535 1 8 1655 _ 1814 1492 1 56 158 1868 137 1411 1 453 1904 1294 1 34 1374 _ 194 1222 13 _ 194 1222 126 13 71958 1488 1 226 1264 7197 6 1455 1192 128 206 6 1 004 1 08 1072 0977 Ho 40440 2 DOOR SWITCH Each model is equipped with a magnetic door switch The door opening is detected by a magnetic sensor When the door is closed the sensor is activated from a magnet foamed in the bottom part of the door coming close to the sensor each door has two magnets inside one in the bottom side and an additional one in the upper side allowing the door to be reversed EE SENSOR EH p BRACKET MAGNET MAGNETIC SENSOR BEHIND FRONT PANEL 1 E MAGNETIC SENSOR 16 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy When the sensor is activated closed door the two wires circuit gets closed The two wires are connected to terminals 49 48 When the circuit gets opened open door an alarm occurs d r see Tab 1 2 2 1 Checking the door switch lt may happen that the magnetic sensor is faulty or the wires interrupted shorted In that case d r alarm is always on so the switch cables must be checked disconnect the cables from 49 48 and ohm out the switch If the switch works good check for rust loosen l
20. E VALVE z 48 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy 4 1 2 Remote units On the remote units pull the vacuum from compressor check pressure valve and liquid receiver valve as well The split evaporator unit is also equipped with one additional valve or more than one to be used for charge pressure check purpose Use this valve to pull the vacuum on the evaporator unit Two options can be chosen i Pull the vacuum in all the system with condensing and evaporating units connected trough pipes and recharge li Thanks to the membrane quick connections self closing used in the remote units another option can be chosen firstly pull the vacuum in the condensing unit separately and charge this unit with all the refrigerant refer to DATA CHART TABLE After that pull the vacuum in the evaporator unit NOTE connect both suction and liquid pipes to evaporator unit equipped with quick connections to provide vacuum into them also Once the vacuum has been created in the evaporator unit just connect the pipes to the condensing unit previously charged CONNECTING PIPE QUICK CONNECTIONS EVAPORATOR SIDE TOP OF THE CABINET QUICK CONNECTIONS m UNSCREWING Last mentioned option is very helpful when only one components must be replaced E g if the compressor needs to be replaced its not necessary to open the entire unit Just disconnect the pipes at sections Lc and Sc and operate on
21. ETL BLAST CHILLER SERIES SERVICE MANUAL 1 BASIC SERVICE INSTRUCTION 1 kis JABARNUVEAIEURE LIS uuu uum 1 12 ALARM EIST GHEGK uu u S 2 12 SERVICE MENU PARAMETER SETIINQ u uu uu y u unu 2 L3 Enter e parameter IS 2 9 2 Parameter Inst lac Oy 2 1 3 3 Temperature probes 00 000 nnn nnn nnns 2 TA MAGGP PRINTE R tele modi IN ton 7 kaet FINNO ST uM M S 9 124 2 5 ClO RT 10 TA SB FOW to replace ING rOl tutta ata Ra 11 2 TROUBLESHOOTING u L L u u uu 12 2d PROBE Ue o t E 12 SGHECKING PROBES 13 2 1 2 NTC 10 5 077 T DIAGRAM AND CHART TABLE 14 205 16 22T1 3Xheckng te GOOF SWIIC usun a u anaes 17 22 PRES OURE S 17 2 3 1 Pressure switch working principles 18 2 0 Pressure SWIC tactory qasusqa y ua ies d vy ideae dd d deis 18 24d DOORFRAME HEATER sse uu agn edad pn de
22. OW TO REPLACE THE KEYBOARD a Remove the front panel 3 1 and unscrew the faulty keyboard SCREW LOCKING WASHER WASHER _ SPACER 46 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy c Connect the keyboard to the RS485 1 port using the proper connector 47 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 4 VACUUM AND CHARGE PROCEDURE Always perform Vacuum and charge procedure whenever one or more of the following action have been done Replacement of compressor Replacement of a solenoid valve body Replacement of heat exchangers condenser or evaporator Replacement of a TX VALVE Replacement of a tank liquid receiver or oil separator Replacement of a filter Repair of a leakage Replacement of a pipe Any action which involves opening of the refrigeration system NOTE A BEFORE DOING VACUUM AND CHARGE MIND TO REPLACE THE FILTER DRIER B REFER TO DATA CHART TABLE TO CHARGE THE RIGHT AMOUNT OF REFRIGERANT C NO TOP OFF OF REFRIGERANT IS ALLOWED 4 1 Instruction for Vacuum and Charge Before doing the vacuum all the refrigerant must be recovered with a proper machine Best procedure is to pull the vacuum from more points 4 1 1 Self contained units One point to pull the vacuum is compressor check pressure valve The other one is the valve placed on the liquid receiver LIQUID RECEIVER VALVE 5 _ amp compressor
23. The problem may concern a the probe cables or bulb The probe alarms 0 Er1 Er3 are commonly due to an interruption open circuit in the cables Occasionally it may happen that a probe cable goes short to the chassis or the two probe wires go short each other To detect the alarm root disconnect the concerned probe and ohm out the two cables between each other If the reading is 0 Ohms it means the probe wires are shorted between each other Replace the probe If the reading is that means the probe circuit is opened Replace the probe If the reading matches with the chart table 3 then the probe works good jump to b or If the reading its not 0 neither gt and doesn t match with the chart table then the probe may be out of range very unusual Replace the probe If none out of 4 above options can be easily detected then Ohm out the probe wires one by one against chassis If the reading is 0 or anyway less than it means the probe is short to the chassis Replace the probe Alternatively and much more rapidly a spare probe can be used If the alarm keeps on buzzing go to pint b or c b the probe to board terminal connection Check for rust water humidity loosen lost connections on the probe terminal block PROBES TERMINAL BLOCK 13 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy c the main board internal circuits or the mother board processor If inst
24. asis plate at the condenser sides III Disconnect the keyboard Loosen or cut plastic ties in order to extend cables length and make possible to slide out compressor basis 30 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy IV Cut the ties which hold the draining duct V Fix the draining pipe in order to prevent interfering with the basis movement while sliding 3 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy VI Remove the caps from the corner s s angles INTERNAL EXTERNAL Once the caps have been removed unscrew as shown below Internal screws of the corner angle must be reached placing the screwdriver on a 45 direction with respect to the back panel They only need to be loosened 32 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy VIII The external screws must be completely removed After that the angle cover can be removed INSULATED 5 INTERNAL HOOK LOOSEN ONLY EXTERNAL MOTHERSCREW 33 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy Unscrew the right and left bolts from the compressor basis plate X On the front side lift up a little bit the basis panel that is linked to the underneath panel by holding the condenser and pushing it forward 34 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy The system is d
25. at the compressor is on with reference to the condenser probe see also P54 PRES A condenser switch off delay on switching off the compressor the presence of the condenser probe P61 1 see also P52 GROUP al ES MISCELLANEOUS pes chill and freeze cycle completion buzzer duration maximum buzzer duration during an alarm state elapsed time between switching on the compressor and pump down valve activation down in power up also elapsed time between deactivation of 10 the pump down valve and switching off the compressor pump down in power down Hev Date 2012 06 21 B Blast chiller Service Manual Draft copy defrost parameter units of measurement P58 0 P25 h P24 P26 P28 and P35 min 1 P25 min P24 P26 P28 and P35 s P59 0 reserved probe type 0 1 condenser probe enabling CONDENSER TEMPERATURE ALARMS the temperature above which the condenser temperature alarm is activated with reference to the condenser probe hee al P62 differential CABINET TEMPERATURE ALARMS temperature below which the minimum temperature alarm is activated during post chill storage with relation to P7 1 6 P7 P64 with reference to the cabinet probe 0 no alarm temperature above which the maximum temperature alarm is activated during post chill storage with relation to P7 i e P7 P65
26. e OR DA i Dn e 18 2 4 1 Heater cable TealllfOS u oussspashusnapanhunpapaqhuspatapbuanapanbunpapanhuanppanshanupuatpuanaanhuayhu 19 29s MAINBOARD 2 uu S 19 2 5 1 Checking relay outputs do vedi odes 19 26 1 tau uniri RH 21 2 62 Kepod TIOBUDICSIOOlFOsu 21 2 7 REFRIGERANT PRESSURES CEEQN oerte rtt toto ettet i pete 21 3 SERVICE AND REPAIR u uuu i uu u uuu uuu u uu uuu 23 3 1 23 SA UNITS FROM GBC305G TO GBF171 19285 2 uidi e it uti Ed redes 23 3 1 2 GBF15 11S smallest self contained unit 24 22 DOOR REVERSING ES etii doeet 25 3 39 HOW TO ACCESS TO THE CONDENSING UNIT 30 3 3 1 Units from GBC39S to GBF171 1329 esee seien nennen nna 30 WOM GBG50SG lo GBF44 209P Marr aaa duda 35 3 3 3 GBF15 11S smallest self contained unit 37 3 3 4 Remote units units GBF440 385R and GBF837 727R 38 3 4 HOW TO ACCESS EVAPORATOR ASS 38 3 4 1 Evaporator assy description 38 3 4 2 How to access to the evaporator
27. e cable path same as the probes one and fit the new cable by tying it to the old one cable From the electrical box pull the old motor cable and let the new one pass through the plastic duct Alternatively cut the old cable and connect to the new motor fan with a suitable waterproof connection 3 5 HOW TO REPLACE THE DOOR SWITCH 3 5 1 GBF15 11S smallest self contained unit remove the front panel Follow instruction at 3 1 2 Remove the screws that hold the switch on the panel Disconnect the switch cables from terminals 48 49 Take the cables out of the electrical box and fit a new switch 42 Rev Date 2012 06 21 b C d ETL Blast chiller Service Manual Draft copy 3 5 2 Units from GBC30SG to 171 1325 remove the front panel Follow instruction at 3 1 1 Unscrew the bolt nut that hold the switch on the bracket other info s at 2 2 Disconnect the switch cables from terminals 48 49 Take the cables out of the electrical box and fit a new switch BOLT NUT 3 6 HOW TO REPLACE THE PRESSURE SWITCH It m ay happen that the pressure switch is mechanically blocked or faulty giving an hp alarm even though pressures are good To replace it the capillary tubes must be disconnected High pressure capillary tube is generally connected on the liquid receiver upper tab SCHROEDER SAE FOR LOW PRESSURE CONNECTION 7 1 LIQUID RECEIVER Before removing connections the
28. e is set to 40 and the setpoint is going to be reached the actual evaporator temperature is approx 49 0 psig The Pr3 label seen after shutting down the controller may show temperature down to 42 indeed there is a limit in the NTC signal reading by the controller therefore temperature lower than 42 FT will be never shown any case when there is a suspect of starved evaporator a quick proof with the empty cabinet can be done Within maximum 40 50mins ambient temperature at 90 with compressor continuously running the cabinet temperature must be at 40f If not the evaporator temperature should be checked from the display Evaporator temperature not going under 22 f within 40 50mins may probably indicate a starved evaporator 1 4 HACCP PRINTER Detailed instruction on how to use install and trouble shoot the HACCP printer are worth mentioning in this manual Printer option can be ordered as a special option upon request for the blast chillers as well as installed as a retrofit device Printer has its own supply connector 110 VAC to 240 VAC 50 60 Hz Printer must be connected to the main board through the second RS 485 serial port Hev Date 2012 06 21 Blast chiller Service Manual Draft copy 451 46 47 PRINTER TERMINAL BLOCK MAIN BOARD TERMINAL BLOCK Rev Date 2012 06 21 Blast chiller Service Manual Draft copy The main controller must be set to enable printer main board communication
29. er Service Manual Draft copy g Cross the bottom hinge and upper plastic bush positioning Fit he small plastic caps on the screw holes that were previously holding the bottom hinge h Move the locking pin from the right to the left side by fitting it in the provided opposite hole on the frame panel Fit pins and nylon bushings as shown PIN LOCKING RING Rev Date 2012 06 21 28 Blast chiller Service Manual Draft copy NYLON BUSHINGS i Move the C shaped stirrup from the right side to the left one screw it on the housing without tightening Be careful that the stirrup is positioned with the square hole according to the angle below indicated The right angle will allow the hinge spring to be loaded when the door is closed therefore providing a better sealing pushing the gasket against the door frame LEFT SIDE FRAME BOTTOM PANEL UNDER THE DOOR Turn the door upside down fit the upper hinge fit the bottom hinge pin in the stirrup squared hole Tighten the screws to fix the C stirrup and the upper hinge Check the proper working of the door and sealing Fit back the front panel 29 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy 3 3 HOW ACCESS TO THE CONDENSING UNIT 3 3 1 Units from GBC39S to GBF171 132S Remove the rear grid by unscrewing corner screws Il Remove the front panel and unscrew the left and right bolts from the compressor b
30. esigned wit two flexible pipe lines to make the operation easier FLEXIBLE LINES 3 3 2 Units from GBC30SG to GBF44 26SP The above units do not come with any sliding panel to host the condensing units Everything is built in the basis panel of the body structure That s why procedure to access those components is different from the above described even though it is similar regarding some points Instruction i Follow instruction from to VIII from chapter 3 3 1 li Unscrew the 8 bolts from the bottom of the cabinet 4 each side ii On the front side lift up the cabinet and pull it in order to make the draining duct overcome the condenser coil without damages 35 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy E ms ui 2 m l BR LIFT THE CABINET UP IV While keeping in its place the cabinet basis push the cabinet body from the back towards the front side as much as needed to access to the concerned part 36 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 3 3 3 GBF15 11S smallest self contained unit Unscrew on the right side panel 3 screws Unscrew on the back right side 3 screws Il Remove the side panel to access the condensing unit 24 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy 3 3 4 Remote units units GBF440 385R and GBF837 727R
31. o replace the cabinet probe b Evaporator probe bulb is positioned on the evaporator output tube tighten by a plastic tie and wrapped by an aluminium tape Then everything is insulated When replacing the defrost probe be careful that the factory configuration is rebuilt DEFROST PROBE CABLE 40 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy c Needle probe cable firstly enters the evaporator assy trough a port and then goes together with the other probe cables in a common tube toward the electrical box NEEDLE PROBE ELEMENT NEEDLE PROBE CABLE PORT E a IT LASTIC DUCT When replacing one of the above probe remove the bubs and all the holding ties in the evaporator side Disconnect the probe wires from the controller terminal block see details at 2 1 1 picture the new probe end cable terminals to the old probe cable cut the old bulbs to avoid blocking From the electrical box side pull the old probe cable and let the new cable run through the plastic duct until reaching the terminal block on the controller THROUGH THE BODY SIDE WALL TOWARDS THE CNTRL TERMINAL BLOCK VIEW FROM THE BACK VIEW FROM INSIDE UNDER THE S S LEFT ANGLE COVER 41 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 3 4 4 How to replace evaporator motor fans a Unscrew the finger guard open the panel and unscrew the motor fan b Follow th
32. ost connections on the terminal block If the alarm keeps buzzing tray to replace the mother board 2 J PRESSURE SWITCH A pressure regulating switch is installed in all the units to prevent compressor failures or not proper running due to high discharge pressure or low suction pressure CAPILLARY W S REN PRESSURE SWITCH HIGH LOW CUT OUT PRESSURE DIFFERENTIAL 17 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 2 3 1 Pressure switch working principles The switch provides a free voltage normally closed output connected to pins 48 49 on the board s terminal block A common input on 48 is shared with the door switch connection When pressures reading is above below high low limits then the output gets opened and an hp alarm occurs See Tab1 for details Both high and low pressures events reach to same alarm code This happens because the switch output is made by two wires only and only the high pressure input on board s terminal block is used 8W2 74 SWITCH E CABLES Once the proper pressure re establish high or low pressure limits hysteresis then the switch provide an automatic reset 2 3 2 Pressure switch factory setting Nobody is allowed to modify factory setting fro pressure switch e High pressure limit 2420 psig ow pressure limit O psig e Differential 10 psi 2 4 DOOR FRAME HEATER
33. r checking low and high pressure values nothing can be said about the proper working of the unit by only measuring these pressures A more careful analysis must be done considering above listed conditions and measuring also temperature in some specific point see 1 3 3 for 21 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy more information about evaporator temperature checking For instance if from a low pressure checking the outcome is 0 1 psig this could be a correct pressure if in the cabinet the temperature is at the minimum 40 and if the evaporator temperature is 49 accordingly If not the evaporator could be starved and actual temperature could be much more higher than 49F In this last case even if the pressure may appear to be correct the unit is not working properly Although is not recommended to base a troubleshooting on two pressure measurements below there is some figure on refrigerant pressure values SUCTION PRESSURE 1 5 2 psig This pressure should be measured when the cabinet temperature is stable at 40 t and compressor running DISCHARGE PRESSURE 230 psig This value can vary extensively and reach up to 360 psig depending on ambient temperature and heat load inside the cabinet Higher value of condensing pressure may cause the pressure switch to trip 22 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy 3 SERVICE AND REPAIR This chapter deals with
34. repairing replacing instruction of both mechanical and electrical components 3 1 REMOVE THE FRONT PANEL 3 1 1 Units from GBC30SG to 171 1325 a Remove the two bottom screws by inserting the screwdriver through the squared holes LEER RC RETI hr CL E i EET 1 SCREW 2 4 SCREW gt b The front panel is fixed on the top by two pins left and right Just pull the pane the bottom side and let the pins exit the holes 23 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy 3 1 2 GBF15 11S smallest self contained unit a Unscrew on the side panel and on the front panel on the door frame side P scel med n p sl nd Latt aep m adipe e sd NW 24 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy 3 2 DOOR REVERSING Each door can be easily reversed from right to left hinged type Hinges stirrups bushes are assembled as per images below 25 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy Reversing instrruction a Remove the front panel and look for the C shaped stirrup under the right side of the door SQUARED HOLE UPPER HINGE 26 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy d Lift the door up pull it and take it away BOTTOM HINGE 21 Rev Date 2012 06 21 Blast chill
35. ruction as per points and b have been performed without any clear outcome and the alarm still occurs then try to replace the main board 2 1 2 NTC 10kOhms 77F Diagram and Chart Table low R kO mid R kO high 19971 2052 296 428 2098 2145 orrs 1863 1938 2016 446 2012 2047 2092 190477 4 amp 4 193 1963 19 1734 HS 176 181 190 173 1 157 5 1636 1491 158 1607 51 8 1707 174 1761 1412 145 15 536 1639 1664 1699 1337 1387 1438 154 1575 1598 1622 1535 1474 9 117 1158 115 1025 16 1097 64 1202 1006 9551 13 62 13 09 13 26 104 1662 1243 12 0 1274 9867 _ 168 11 96 1211 1225 8783 9040 9364 698 1151 1165 11708 2 8347 8615 8801 17 6 1108 1122 1133 7 131 3 136 1201 1244 1289 59 1454 14 74 14 Rev Date 2012 06 21 ETL Blast chiller Service Manual Draft 19 4 76 7547 7781 5802 752 1028 1038 1049 _ 58 7179 73 89 76 24 77 99 110 1 4 6832 70 37 17248 7848 9522 9632 9735 1 4 32 523 5786 5941 6 821 8309 47 878 704 802 _ 811 5111 5249 1539 896 763 777 7825 48 75 50044 15136 4 73588 74584 17551 10 4 122 4439 45 52 4 8 95 647 641 7 036 14 42388 434 4452 968 6606 67 674 158 4047 4144 4248 986 6 376 6468 6562 17 6 3866 39 59 405 171004 6155 6246 6 358 19 4 3 4 13781 357
36. series can only provide a single output closed or opened The high low pressure switch is connected among terminals 48 49 The circuit is normally opened it closes both when high low pressure limits are exceeded So the code failure HP could mean actually a high discharge pressure as well as a low suction pressure Deep troubleshooting on connection failure between keyboard and interface board look at RS 485 1 1 GND wire connection missing The display digits blink and grow dim 2 Wire connection missing display might work without giving any specific alarm 3 Wire connection missing Err is displayed 4 12V wire missing no light at all on the display Hev Date 2012 06 21 Blast chiller Service Manual Draft copy 1 2 ALARM LIST CHECK Thanks to the HACCP features the controller allows to check the occurred alarm It provides alarm codes date of alarm maximum minimum occurred temperature if dealing with a high low temperature alarm alarm duration To access the alarm log list only possible during OFF mode keep pressed the program key for 5 seconds 5 All the information concerning the alarm will be displayed To scroll through the alarms use the up down keys To exit press the program key 1 3 SERVICE MENU PARAMETER SETTING 1 3 1 Enter the parameter list The service menu can be accessed only during OFF mode Press the up down keys together for 5 seconds to enter the menu Label PA
37. ut just disconnect the input Line to the relay and the output wire e g to check K10 disconnect both wires on 19 and 20 terminals Ohm out the relay 19 Hev Date 2012 06 21 Blast chiller Service Manual Draft copy terminals and check if the contact is closed when the relay is activated A faulty relay may remain always opened or become shorted When this occurs replace the board 20 Rev Date 2012 06 21 Blast chiller Service Manual Draft copy 2 6 KEYBOARD The RS485 1 port on the relay board is used to connect the keyboard td 4 CONNECTION ON RELAY BOARD CONNECTION ON KEYBOARD 2 6 1 Keyboard Troubleshooting Main troubles that can occur on the keyboard are GND wire connection missing The display digits blink and grow dim wire connection missing display might work without giving any specific alarm wire connection missing Err is displayed 12V wire missing no light at all on the display Keyboard faulty all the cables are properly connected but the display do not work Ic 2 7 REFRIGERANT PRESSURES CHECK Refrigerant high and low pressure values are closely related to ambient temperature heat load in the cabinet full empty status of the cycle beginning with a lot of steam frozen food etc cabinet temperature TX valve regulation Evaporator coil airflow Condenser coil airflow Even if at least two pressures gauge ports are available on each unit fo
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